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At least 19 records

FedCSpc: A Cross-Silo Federated Learning System With Error-Bounded Lossy Parameter Compression

Cross-Silo federated learning is widely used for scaling deep neural network (DNN) training over data silos from different locations worldwide while guaranteeing data privacy. Communication has been identified as the main bottleneck when training large-scale models due to large-volume model parameters and gradient transmission across public networks with limited bandwidth. Most previous works focus on gradient compression, while limited work tries to compress parameters that can not be ignored and extremely affect communication performance during the training. Here, to bridge this gap, we propose FedCSpc: an efficient cross-silo federated learning system with an XAI-driven adaptive parameter compression strategy for large-scale model training. Our work substantially differs from existing gradient compression techniques due to the distinct data features of gradient and parameter. The key contributions of this paper are fourfold. (1) Our designed FedCSpc proposes to compress the parameter during the training using the state-of-the-art error-bounded lossy compressor – SZ3. (2) We develop an adaptive compression error bound adjustment algorithm to guarantee the model accuracy effectively. (3) We exploit an efficient approach to utilize the idle CPU resources of clients to compress the parameters. (4) We perform a comprehensive evaluation with a wide range of models and benchmarks on a GPU cluster with 65 GPUs. Results show that FedCSpc can achieve the same model accuracy as FedAvg while reducing the data volume of parameters and gradients in communication by up to 7.39× and 288×, respectively. With 32 clients on a 4 Gb size model, FedCSpc significantly outperforms FedAvg in wall-clock time in the emulated WAN environment (at the bandwidth of 1 Gbps or lower without loss of generality).

SZ3↗

An analysis of parameter compression and Full-Modeling techniques with Velocileptors for DESI 2024 and beyond

In anticipation of forthcoming data releases of current and future spectroscopic surveys, we present the validation tests and analysis of systematic effects within velocileptors modeling pipeline when fitting mock data from the AbacusSummit N-body simulations. We compare the constraints obtained from parameter compression methods to the direct fitting (Full-Modeling) approaches of modeling the galaxy power spectra, and show that the ShapeFit extension to the traditional template method is consistent with the Full-Modeling method within the standard ΛCDM parameter space. We show the dependence on scale cuts when fitting the different redshift bins using the ShapeFit and Full-Modeling methods. We test the ability to jointly fit data from multiple redshift bins as well as joint analysis of the pre-reconstruction power spectrum with the post-reconstruction BAO correlation function signal. We further demonstrate the behavior of the model when opening up the parameter space beyond ΛCDM and also when combining likelihoods with external datasets, namely the Planck CMB priors. Finally, we describe different parametrization options for the galaxy bias, counterterm, and stochastic parameters, and employ the halo model in order to physically motivate suitable priors that are necessary to ensure the stability of the perturbation theory.

79 ASTRONOMY AND ASTROPHYSICS↗

Full Modeling and parameter compression methods in configuration space for DESI 2024 and beyond

In the contemporary era of high-precision spectroscopic surveys, led by projects like DESI, there is an increasing demand for optimizing the extraction of cosmological information from clustering data. This work conducts a thorough comparison of various methodologies for modeling the full shape of the two-point statistics in configuration space. We investigate the performance of both direct fits (Full Modeling) and the parameter compression approaches (ShapeFit and Standard). We utilize the ABACUS-SUMMIT simulations, tailored to exceed DESI's precision requirements. Particularly, we fit the two-point statistics of three distinct tracers (LRG, ELG, and QSO), by employing a Gaussian Streaming Model in tandem with Convolution Lagrangian Perturbation Theory and Effective Field Theory. We explore methodological setup variations, including the range of scales, the set of galaxy bias parameters, the inclusion of the hexadecapole, as well as model extensions encompassing varying ns and allowing for w 0 w a CDM dark energy model. Throughout these varied explorations, while precision levels fluctuate and certain configurations exhibit tighter parameter constraints, our pipeline consistently recovers the parameter values of the mocks within 1σ in all cases for a 1-year DESI volume. Additionally, we compare the performance of configuration space analysis with its Fourier space counterpart using three models: PyBird, FOLPS and velocileptors, presented in companion papers. We find good agreement with the results from all these models.

79 ASTRONOMY AND ASTROPHYSICS↗

Full-Shape analysis of the power spectrum and bispectrum of DESI DR1 LRG and QSO samples

We present the first joint analysis of the power spectrum and bispectrum using the Data Release 1 (DR1) of the Dark Energy Spectroscopic Instrument (DESI), focusing on Luminous Red Galaxies (LRGs) and quasars (QSOs) across a redshift range of 0.4 ≤ z ≤ 2.1. By combining the two- and three-point statistics, we are able to partially break the degeneracy between the logarithmic growth rate, f(z), and the amplitude of dark matter fluctuations, σ s8 (z), which cannot be measured separately in analyses that only involve the power spectrum. In comparison with the (fiducial) Planck ΛCDM cosmology we obtain f/f fid = {0.888 -0.089 +0.186 ,0.977 -0.220 +0.182 ,1.030 -0.085 +0.368 }, σ s8 /σ fid s8 = {1.224 -0.133 +0.091 ,1.071 -0.163 +0.278 ,1.00 0 -0.223 +0.088 } respectively for the three LRG redshift bins, corresponding to a cumulative 10.1% constraint on f, and of 8.4% on σ s8 , including the systematic error budget. Additionally, we obtain constraints for the ShapeFit compressed parameters describing the isotropic scaling parameter, α iso (z), the Alcock-Paczyński parameter, α AP (z), the combined growth of structure parameter fσ s8 (z), and the combined shape parameter m(z)+n(z). Their cumulative constraints from our joint power spectrum-bispectrum analysis are respectively σ αiso = 0.9% (9% improvement with respect to our power spectrum-only analysis); σ α AP = 2.3% (no improvement with respect to power spectrum-only analysis, which is expected given that the bispectrum monopole has no significant anisotropic signal); σ fσs8 = 5.1% (9% improvement); σ m+n = 2.3% (11% improvement). These results are fully consistent with the main DESI power spectrum analysis, demonstrating the robustness of the DESI cosmological constraints, and compatible with Planck ΛCDM cosmology.

79 ASTRONOMY AND ASTROPHYSICS↗

Fiducial-cosmology-dependent systematics for the DESI 2024 full-shape analysis

We assess the impact of the fiducial cosmology choice on cosmological inference from full-shape (FS) fits of the galaxy power spectrum in the DESI 2024 Data Release 1 (DR1). Using a suite of AbacusSummit DR1 mock catalogues based on the Planck 2018 best-fit cosmology, we quantify potential systematic shifts introduced by analysing the data under five secondary cosmologies — featuring variations in matter density, thawing dark energy, higher effective number of neutrino species, reduced clustering amplitude, and the DESI DR1 BAO best-fit w 0 w a CDM cosmology — relative to DESI's baseline Planck 2018 cosmology. We investigate two complementary FS analysis approaches: full-modelling (FM) and ShapeFit (SF), each with distinct sensitivities to the assumed fiducial model. Across all tracers, we find for FM that systematic shifts induced by fiducial cosmology mismatches remain well below the DESI DR1 statistical uncertainties, with maximum deviations of 0.22σ DR1 in ΛCDM scenarios and 0.12σ DR1+SN when including SN Ia mock data in extended w 0 w a CDM fits. For SF, the shifts in the compressed parameters remain below 0.45σ DR1 for all tracers and cosmologies.

dark energy experiments↗

Peridynamic modeling of cementitious materials for nuclear waste management

Radioactive and hazardous waste generated from fuel processing plants, nuclear reactors, and hospitals, requires effective management strategies. Cementitious materials are widely applied for these needs, serving as structural materials, reactive barriers, or waste forms. In these applications cracking poses a significant risk to performance, driven by inconsistent shrinkage of the components and the varying strength and permeability of their interfaces. Traditional modeling approaches face challenges in representing the complex fracture behavior of cementitious materials due to the reliance on spatial derivatives and difficulties with mesh generation. Here, to overcome these limitations, we employ peridynamics, a novel continuum mechanics formulation that uses integrals to describe mechanical equilibrium, avoiding discontinuities associated with traditional methods. Through incorporation of a bi-linear softening model and quasistatics, an experimentally validated model for Portland cement concrete samples was created. Mechanical parameters, including compressive strength and elastic modulus were validated and variation due to aggregate packing was evaluated. Additionally, sensitivity analysis of the peridynamic parameters to the bulk material properties was established. The results lay the groundwork for evaluating the impact of unique conditions of cementitious waste forms that can be assessed to improve the reliability of waste management strategies.

Aggregates↗

Sound speed and Grüneisen parameter up to three terapascal in shock-compressed iron

This paper presents the first sound speed and Grüneisen parameter data for fluid iron compressed to 3 TPa (30 million atmospheres) and 20 g/cm 3 on the Hugoniot. Both the sound speed and Grüneisen parameter are derivatives of the equation of state (EOS), and thus tightly constrain the contours of the EOS surface. The sound speed data are systematically lower than expected from a simple extrapolation of previous data. The Grüneisen parameter shows a 30% drop at pressures and temperatures above the melt transition. Furthermore, while some models compare well with either the sound speed or Grüneisen parameter, none of today’s state-of-the-art models can explain both sets of data. Furthermore these new data will provide pivotal benchmarks for both future theoretical EOSs of warm dense iron and modeling planetary states and processes.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Dark Energy Survey Year 3 results: Simulation-based 𝑤CDM inference from weak lensing and galaxy clustering maps with deep learning: Analysis design

Data-driven approaches using deep learning are emerging as powerful techniques to extract non-Gaussian information from cosmological large-scale structure. Here, this work presents the first simulation-based inference (SBI) pipeline that combines weak lensing and galaxy clustering maps in a realistic Dark Energy Survey Year 3 (DES Y3) configuration and serves as preparation for a forthcoming analysis of the survey data. We develop a scalable forward model based on the CosmoGridV1 suite of N-body simulations to generate over one million self-consistent mock realizations of DES Y3 at the map level. Leveraging this large dataset, we train deep graph convolutional neural networks on the full survey footprint in spherical geometry to learn low-dimensional features that approximately maximize mutual information with target parameters. These learned compressions enable neural density estimation of the implicit likelihood via normalizing flows in a ten-dimensional parameter space spanning cosmological 𝑤CDM, intrinsic alignment, and linear galaxy bias parameters, while marginalizing over baryonic, photometric redshift, and shear bias nuisances. To ensure robustness, we extensively validate our inference pipeline using synthetic observations derived from both systematic contaminations in our forward model and independent Buzzard galaxy catalogs. Our forecasts yield significant improvements in cosmological parameter constraints, achieving 2−3× higher figures of merit in the 𝛺 𝑚 − 𝑆 8 plane relative to our implementation of baseline two-point statistics and effectively breaking parameter degeneracies through probe combination. These results demonstrate the potential of SBI analyses powered by deep learning for upcoming Stage-IV wide-field imaging surveys.

Thomsen, A. [Zurich, ETH] (ORCID:0000000203099021)↗

Structure-property relationships and recyclability of natural fiber insulation

Thermal insulation can significantly decrease the energy required to maintain internal temperatures within buildings, saving money and decreasing environmental impacts. Many industrially available insulation options utilize petroleum-derived materials, such as polyurethane, fiberglass, and polystyrene, which can be detrimental to the environment by emitting greenhouse gases during production. A sustainable alternative to these synthetic insulations is the use of renewable feedstocks to produce comparable insulation products. In this work, natural fibers such as flax and banana were bound with an epoxy system to produce natural-fiber insulation. Key experimental parameters for this study included evaluating the fiber lengths and processing methods while varying the viscosity of the epoxy binder solvent dissolution. Insulation performance was determined by comparing density, thermal conductivity, resilience, and compressive strength; these parameters were tested to further understand and investigate the structure- property relationships within the system and to understand how these composites compare to current commercial materials. Furthermore, from this characterization and optimization, a natural fiber sample with an R/in. >5 was achieved, making these materials competitive with commercial alternatives.

Compressive strength↗

Lossy Compression: An Online Multi-Stage Technology for High-Fidelity Synchro- Waveform Measurements

Effective real-time monitoring and analysis of distributed grids necessitate the use of synchro-waveform measurements, which capture almost all high-frequency disturbances and transient phenomena. However, due to limitations in high-speed measurements and network bandwidth, it is challenging to transfer all high-fidelity synchro-waveforms losslessly and successfully. To cope with these challenges, a hybrid-based online multi-stage compression algorithm is proposed to significantly improve the compression efficiency for synchro-waveform measurements. Initially, the multiple discrete Wavelet transformation is deployed to deconstruct the waveform components. The delta encoding is further developed to decrease the magnitude. In conjunction with the Lempel-Ziv-Markov chain, the hybrid compression algorithm is implemented to achieve real-time compression for the synchro-waveform measurements. Moreover, an innovative error index that synergizes the time and frequency domain error and correlation is formulated to evaluate the waveform distortion. By integrating compression ratio, suitable parameters can be optimally selected. Finally, the simulation, laboratory experiments, as well as field tests across a spectrum of sampling frequencies and time intervals are conducted to substantiate the efficacy of the proposed method. Here, the outcomes demonstrated that a compression ratio of approximately 15.5 and 17.83 can be reached for 0.5 s and 1 s data under both offline and online scenarios, which equates to a substantial 93.5% to 94.39% reduction in data storage requirements.

High-fidelity synchro-waveform measurements↗

Can classical DEM simultaneously capture compressibility and flowability of milled biomass?

Accurate prediction of the rheological behavior of biomass is essential for the design and operation of hoppers, feeders, and storage systems in biorefineries. This study examines whether the classical, coarse-grained discrete element method (DEM) formulation can simultaneously reproduce the compressibility and flowability of milled herbaceous biomass, using Miscanthus × giganteus as a representative material. The model represents particles as rigid spheres interacting through Hertz-Mindlin elastic-frictional contacts augmented with an area-dependent cohesion term. Laboratory cyclic compression and wedge-shaped hopper discharge experiments were used as calibration benchmarks. Although the model can independently reproduce each behavior by appropriately tuning particle Young's modulus E and cohesion energy density k, an extensive parametric investigation comprising more than 600 simulations reveals that the optimal parameter regions for compression and hopper flow are distinct and non-overlapping in (E, k) space. Surrogate surface analysis further shows that the corresponding objective-function valleys exhibit similar trends but are approximately parallel and spatially offset, precluding a unified calibration within the explored domain. Sensitivity analysis indicates that compressibility is governed predominantly by stiffness and cohesion, whereas the slope of the mass flow rate-opening relation in hopper discharge is primarily controlled by tangential friction. Extensions incorporating particle size distribution and clumped-sphere representations do not eliminate the incompatibility. These results systematically reveal, for the first time, the structural limitation of simplified DEM formulations in representing biomass rheological behavior, underscoring the necessity for models incorporating additional physical mechanisms, such as particle deformability or enhanced interlocking, to achieve unified predictive capability for biomass handling behavior.

09 BIOMASS FUELS↗

Examining the possibility that normal nuclear matter is quarkyonic

The possibility that nuclear matter might be quarkyonic is considered. Quarkyonic matter is high baryon density matter that is confined but can be approximately thought of as a filled Fermi sea of quarks surrounded by a shell of nucleons. Here, nuclear matter is described by the IdylliQ sigma model for quarkyonic matter, generalizing the noninteracting IdylliQ model [Y. Fujimoto et al., Phys. Rev. Lett. 132, 112701 (2024)] to include interactions with a σ meson and a pion. When such interactions are included, we find that isospin-symmetric nuclear matter binds with acceptable values of the compressibility and other parameters for nuclear matter at saturation. The energy per nucleon and sound velocity of such matter is computed, and the isospin dependence is determined. Nuclear matter is formed at a density close to but slightly above the density at which quarkyonic matter forms. Quarkyonic matter predicts a strong depletion of nucleons in normal nuclear matter at low momentum. Finally, such a depletion for nucleon momenta k ≲ 120 MeV is shown to be consistent with electron scattering data.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Recovery of Natural Gas Equipment Emissions into Gas Compression Engines for the Reduction of Potential Greenhouse Gas Emissions

Since the turn of the millennium, the United States (U.S.) oil and natural gas (ONG) industry has nearly doubled its natural gas production rate. As a result, the ONG industry has recently come under increasing scrutiny for its contributions to greenhouse gas (GHG) emissions. Consequently, various solutions to this problem have been proposed and formulated to reduce the impacts of GHG emissions on the environment. West Virginia University (WVU) have found it important to research the impacts of recovering vented gas streams into prime-mover engines. The U.S. Department of Energy (DOE) and National Energy Technology Laboratory (NETL) have granted WVU funding to research and develop a “Methane Mitigator” (M2) - a “Scalable Vent Mitigation Strategy to Simultaneously Reduce Methane Emissions and Fuel Consumption from the Compression Industry.” One of the main areas of interest for this research was the collection of emissions from natural gas equipment into a Caterpillar G3508J natural gas compression engine. The parameters being analyzed from the engine were brake-specific emissions and power output. The emissions sources considered for this research were pneumatic controllers (PCs), reciprocating compressor vents, and the engine’s open crankcase breather. The compressor vent and PC emissions were simulated using a mass flow controller (MFC) and flowed into the engine using two separate methods: (1) directly into the air intake, and (2) through a retrofitted closed crankcase ventilation system (CCV), serving as a buffer volume. The crankcase emissions were quantified without the CCV, and the impact on exhaust emissions from circulating the crankcase gases into the intake was measured. The simulated compressor vent and PC flows from the MFC had limited effect on the steady state operation of the engine and resulting performance. When the simulated flows were fed directly into the engine’s air intake, the changes within the engine’s continuous performance and emission parameters were larger but lasted for shorter durations. Conversely, when the simulated flows were fed into the CCV before entering the air intake, the changes in the engine’s performance and emission parameters were less pronounced for continuous analysis but lasted for longer durations. In either case, the continuous emission changes in both emissions and performance varied in size depending on the test scenario being run, but the cycle average changes in emissions and performance showed little impact overall compared to the engine’s baseline operation. As a result, the inclusion of a CCV shows a decrease in baseline carbon dioxide equivalent (CO2-eq.) engine emissions (from combined exhaust and open crankcase) of almost 4%. Likewise, the CCV inclusion reduced baseline total methane (CH4) from combined exhaust and open crankcase by upwards of 16%. These atmospheric emissions only decreased further with the inclusions of collected PC and compressor vent flows. The resulting changes in time-averaged rated exhaust behavior (or lack thereof) prove that the proposed M2 system could likely be deployed at sites with modern lean-burn natural gas engines as a viable option for reducing and eliminating potential GHG sources that would have otherwise been unutilized as energy sources.

03 NATURAL GAS↗

Development of a near-isothermal transcritical CO 2 compression system with a liquid piston compressor

Compressors are critical components in vapor compression cycle systems, significantly contributing to energy consumption. As global demand for HVAC&R systems rises, enhancing compressor efficiency becomes increasingly vital. This paper introduces a novel liquid piston compressor integrated with a gas cooler for the transcritical CO 2 refrigeration cycle. The liquid piston enables CO 2 refrigerant compression within various types of heat exchangers, facilitating the transfer of compression heat to the heat transfer fluid. By releasing significant heat, this compressor allows for removing or downsizing the traditional gas cooler in the refrigeration system. This paper presents the experimental performance of the first near-isothermal compressor utilizing a liquid piston in a vapor compression cycle. The critical parameters affecting heat transfer are analyzed by using a 1-D simulation model to achieve a near-isothermal compression process. The results show that the developed prototype successfully reduced the compression temperature increase from 95 K to 10 K, achieving 90 % isothermal efficiency. Furthermore, the 1-D simulation results suggest the smaller internal diameter tubes benefit the isothermal efficiency the most.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Modulated Thermomechanical Analysis of Compression-Molded High-Density Polyethylene

Thermomechanical analysis (TMA) experiments conducted on high-density polyethylene (HDPE) show both reversible and irreversible dimensional changes. To further explore these reversible and irreversible processes, modulated thermomechanical analysis (MTMA) was used. Before reliable data on compression-molded HDPE was collected, a parameter optimization was performed to obtain a suitable MTMA method. Once a suitable method was obtained, several MTMA experiments were conducted on compression-molded HDPE. This work highlights the steps taken during the MTMA parameter optimization and the results obtained from MTMA experiments conducted on pristine compression-molded HDPE samples.

36 MATERIALS SCIENCE↗

SHOCK TUBE IGNITION STUDIES OF RENEWABLE DIESEL FUELS FOR MEDIUM AND HEAVY-DUTY TRANSPORTATION

Currently extensive research on alternative fuels is being conducted due to their increasing demand to reduce greenhouse emissions. One renewable fuel studied in this work is dimethyl ether (DME) blended with propane(C3H8) as a potential mixture for heavy-duty engines used in semi-trucks. The blend has the potential to drastically reduce particulate and greenhouse gas emissions compared to a conventional diesel engine operating under similar conditions. To develop the use of mixture, one must conduct detailed conceptual and simulation studies before progressing to detail studies in CFD, engine modifications, and live testing. For simulations, accurate high-fidelity chemical kinetic models are necessary. However, the validity of the chemical kinetic mechanism for operating conditions of a heavy-duty mixing-controlled compression (MCCI) engine was widely unknown until recent work presented here and published. In this work, we studied the ignition of DME and propane blends in a shock tube under MCCI engine conditions. Ignition delay time (IDT) gathered behind the reflected shock for DME-propane mixtures for heavy-duty compression ignition (CI) engine parameters. Testing was conducted for undiluted varieties spanning from temperatures of 700 to 1100 K at pressures ranging from 55 to 84 bar for various blends (100% CH3OCH3, 100% C3H8, 60% CH3OCH3/ 40% C3H8) of DME and propane were combusted in synthetic air (21% O2/ 79% N2). Several experiments were conducted at higher pressures (90-120 bar) to improve the model performance and accuracy. The ignition delay times (IDTs) were compared to recent mechanisms, including Aramco3.0, NUIG, and Dames et al. A common trend among the mechanisms was overpredicted experimental IDTs. Further studies were conducted by a sensitivity analysis using the Dames et al. model, and critical reactions sensitive to IDTs of DME-propane mixture near 60 bar are outlined. Chemical analysis was conducted on the NTC region to explain chemical kinetics which is critical for developing MCCI heavy duty engines.

Mohammed, Zuhayr Pasha↗

Dark Energy Survey Year 3 results: Simulation-based cosmological inference with wavelet harmonics, scattering transforms, and moments of weak lensing mass maps. II. cosmological results

Here, we present a simulation-based cosmological analysis using a combination of Gaussian and non-Gaussian statistics of the weak lensing mass (convergence) maps from the first three years of the Dark Energy Survey. We implement the following: (1) second and third moments; (2) wavelet phase harmonics; (3) the scattering transform. Our analysis is fully based on simulations, spans a space of seven 𝑤 Cold Dark Matter (𝑤⁢ CDM) cosmological parameters, and forward models the most relevant sources of systematics inherent in the data: masks, noise variations, clustering of the sources, intrinsic alignments, and shear and redshift calibration. We implement a neural network compression of the summary statistics, and we estimate the parameter posteriors using a simulation-based inference approach. Including and combining different non-Gaussian statistics is a powerful tool that strongly improves constraints over Gaussian statistics (in our case, the second moments); in particular, the figure of merit (𝑆 8 , Ω m ) is improved by 70% (Λ ⁢CDM) and 90% (𝑤 ⁢CDM). When all the summary statistics are combined, we achieve a 2% constraint on the amplitude of fluctuations parameter 𝑆 8 ≡ 𝜎 8 ⁢(Ω m /0.3) 0.5 , obtaining 𝑆 8 = 0.794 ±0.017 (Λ⁢ CDM) and 𝑆 8 = 0.817 ±0.021 (𝑤 ⁢CDM), and a ∼10% constraint on Ω m , obtaining Ω m =0.259 ±0.025 (Λ ⁢CDM) and Ω m = 0.273 ±0.029 (𝑤⁢ CDM). In the context of the 𝑤⁢ CDM scenario, these statistics also strengthen the constraints on the parameter 𝑤, obtaining 𝑤 <−0.72. The constraints from different statistics are shown to be internally consistent (with a 𝑝-value>0.1 for all combinations of statistics examined). We compare our results to other weak lensing results from the first three years of the Dark Energy Survey data, finding good consistency; we also compare with results from external datasets, such as planck constraints from the cosmic microwave background, finding statistical agreement, with discrepancies no greater than <2.2⁢𝜎.

79 ASTRONOMY AND ASTROPHYSICS↗

Numerical framework for integrated additive manufacturing-compression molding (AM-CM) of thermoplastic composites

Additive manufacturing-compression molding (AM-CM) has emerged as a transformative technology in advanced composite manufacturing. Additive manufacturing (AM) offers high design flexibility and the ability to produce complex geometries with precisely aligned fibers in the preferred orientation. Compression molding (CM) enhances composite materials by providing excellent dimensional stability, reduced porosity, high production rates, and a smooth surface finish. Despite these advantages, extensive integrated analysis is required to optimize processing conditions for improved fiber orientation distribution (FOD) and porosity control. Here, this study develops a comprehensive numerical model to simulate the AM-CM manufacturing process. The model isolates the effects of both the AM and CM phases while also capturing their integration. Additionally, it accounts for heat transfer, temperature-dependent viscosity, and fiber orientation in the extruded fiber-filled polymer, accurately representing material behavior during processing. This approach enables the analysis of interactions between deposited beads of complex strand shapes and their interface regions after full compression. Moreover, the model predicts key parameters such as polymer flowability, fiber orientation, and temperature evolution in AM-CM parts. By optimizing processing conditions, it facilitates a controlled and predictable microstructure.

36 MATERIALS SCIENCE↗