Reduced Order Modeling of a MOOSE-based Advanced Manufacturing Model with Operator Learning

Advanced Manufacturing (AM) has gained significant interest in the nuclear community for its potential application on nuclear materials. One challenge is to obtain desired material properties via controlling the manufacturing process during runtime. Intelligent AM based on deep reinforcement learning (DRL) relies on an automated process-level control mechanism to generate optimal design variables and adaptive system settings for improved end-product properties. A high-fidelity thermo-mechanical model for direct energy deposition has recently been developed within the MOOSE framework at the Idaho National Laboratory (INL). The goal of this work is to develop an accurate and fast-running reduced order model (ROM) for this MOOSE-based AM model that can be used in a DRL-based process control and optimization method. Operator learning (OL)-based methods will be employed due to their capability to learn a family of differential equations, in this work, produced by changing process variables in the Gaussian point heat source for the laser. We will develop OL-based ROM using Fourier neural operator, and perform a benchmark comparison of its performance with a conventional deep neural network-based ROM.

Fast and Accurate Reduced-Order Modeling of a MOOSE-based Additive Manufacturing Model with Operator Learning

One predominant challenge in additive manufacturing (AM) is to achieve specific material properties by manipulating manufacturing process parameters during the runtime. Such manipulation tends to increase the computational load imposed on existing simulation tools employed in AM. The goal of the present work is to construct a fast and accurate reduced-order model (ROM) for an AM model developed within the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, ultimately reducing the time/cost of AM control and optimization processes. Our adoption of the operator learning (OL) approach enabled us to learn a family of differential equations produced by altering process variables in the laser's Gaussian point heat source. More specifically, we used the Fourier neural operator (FNO) and deep operator network (DeepONet) to develop ROMs for time-dependent responses. Furthermore, we benchmarked the performance of these OL methods against a conventional deep neural network (DNN)-based ROM. Ultimately, we found that OL methods offer comparable performance and, in terms of accuracy and generalizability, even outperform DNN at predicting scalar model responses. The DNN-based ROM afforded the fastest training time. Furthermore, all the ROMs were faster than the original MOOSE model yet still provided accurate predictions. FNO had a smaller mean prediction error than DeepONet, with a larger variance for time-dependent responses. Unlike DNN, both FNO and DeepONet were able to simulate time series data without the need for dimensionality reduction techniques. The present work can help facilitate the AM optimization process by enabling faster execution of simulation tools while still preserving evaluation accuracy.