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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Deployment of Digital Twins and Advanced Instrumentation to Identify Looseness Between Rotor Spider Arms and Rim Attachment in Hydro Turbines

The project aimed to develop a Virtual Sensor Digital Twin (VS-DT) to monitor rotor rim float displacement (RRFD) in legacy hydropower turbines. RRFD, if undetected, can cause rotor and stator damage, leading to costly repairs and safety concerns. The purpose of the VS-DT was to predict RRFD signals using existing conventional sensors instead of installing dedicated, costly physical sensors, thereby reducing operational costs and enhancing safety.

13 HYDRO ENERGY↗
DOE OSTI2024

Thermo-Fluid Modeling Framework for Supercomputer Digital Twins: Part 1, Demonstration at Exascale

A thermo-fluid modeling framework is being developed for ExaDigiT---an open-source framework for developing comprehensive digital twins of liquid-cooled supercomputers. The work is being conducted in two parts, and discussion is divided into two companion papers. The work documented in this paper focuses on the development of a cooling system library in Dymola for the Frontier supercomputer at Oak Ridge National Laboratory. The second part, outlined in a companion paper, focuses on a templating structure called Auto-CSM for easily creating model-agnostic, physics-based thermo-fluid cooling system models for liquid-cooled supercomputers using a text-based schema. The cooling model is being developed using primarily the open-source Transient Simulation Framework of Reconfigurable Models (TRANSFORM) library. The library follows the templating architecture developed within the TRANSFORM library for modeling subsystems. A full-system validation was performed to validate a very simple model that is integrated with the system controls, and the results are presented herein.

Kumar, Vineet↗
DOE OSTI2023

Defects in MX2 Phases (DMX) Dataset: STEM Digital Twins

DFT is used to optimize defects in monolayer MX2 phases. We calculate ~600 optimized defect structures, then use multislice simulations in abTEM to generate STEM digital twins, which can be used to train experimental ML. The reference paper for procedures and demonstration of their utility is https://arxiv.org/abs/2305.02917, and the images here correspond with the discussed Messy dataset.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Defects in MX2 (DMX) 2.0: STEM Digital Twins

DFT is used to optimize defects in monolayer MX2 phases. We calculate ~600 optimized defect structures, then use multislice simulations in abTEM to generate STEM digital twins, which can be used to train experimental ML. The reference paper for procedures and demonstration of their utility is https://arxiv.org/abs/2305.02917, and the images here correspond with the discussed Messy dataset. Version 2 includes an auxiliary dataset matched with experiment.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Novel Observing Strategies (NOS) and Earth System Digital Twins (ESDT) for Disaster Resilience

"Earth systems have now been observed continuously for more than 50 years, not only from space but also from airplanes, balloons and in-situ sensors. With the addition of commercial remote sensing providers, many more Internet-of-Things sensors and new NASA and international observatories being planned, these incredible amounts of data will soon be augmented by even larger amounts of diverse data and therefore will become more and more difficult to access, integrate, understand and utilize. At the same time, because of climate change and its impacts, in order to predict, manage, and mitigate the effects of extreme science events and disasters, the information produced by all of this data needs to be optimized, organized and analyzed in such a way that it can be utilized by traditional as well as many new non-traditional users. This calls for the development of observing systems that are agile, coordinated and responsive to events of interest, and for information systems to be dynamic, interactive and fast. With these objectives in mind, the Advanced Information Systems Technology (AIST) Program has been developing technologies that will allow for the development of Novel Observing Strategies (NOS) in a distributed, coordinated fashion (i.e., similar to an “Internet-of-Earth-Things”), as well as for the development of novel information systems or Earth System Digital Twins (ESDT) that will build a digital replica of the past and current states of the Earth systems, will derive forecasts of future states under nominal assumptions and will also offer the capability to investigate many hypothetical evolution scenarios under varying impact assumptions. Both NOS and ESDT will be facilitated by the unprecedented advances of Artificial Intelligence technologies, especially Machine Learning (ML), for extracting relevant information from these large amounts of data, for fusing and assimilating diverse data together and for running complex models faster. Together NOS and ESDT will help build the capabilities needed to anticipate, predict and mitigate the effects of future disasters."

Earth Science Remote Sensing; Information Systems↗
NASA NTRS2017

Structural Health Management of Damaged Aircraft Structures Using the Digital Twin Concept

The development of multidisciplinary integrated Structural Health Management (SHM) tools will enable accurate detection, and prognosis of damaged aircraft under normal and adverse conditions during flight. As part of the digital twin concept, methodologies are developed by using integrated multiphysics models, sensor information and input data from an in-service vehicle to mirror and predict the life of its corresponding physical twin. SHM tools are necessary for both damage diagnostics and prognostics for continued safe operation of damaged aircraft structures. The adverse conditions include loss of control caused by environmental factors, actuator and sensor faults or failures, and structural damage conditions. A major concern in these structures is the growth of undetected damage/cracks due to fatigue and low velocity foreign object impact that can reach a critical size during flight, resulting in loss of control of the aircraft. To avoid unstable, catastrophic propagation of damage during a flight, load levels must be maintained that are below a reduced load-carrying capacity for continued safe operation of an aircraft. Hence, a capability is needed for accurate real-time predictions of damage size and safe load carrying capacity for structures with complex damage configurations. In the present work, a procedure is developed that uses guided wave responses to interrogate damage. As the guided wave interacts with damage, the signal attenuates in some directions and reflects in others. This results in a difference in signal magnitude as well as phase shifts between signal responses for damaged and undamaged structures. Accurate estimation of damage size, location, and orientation is made by evaluating the cumulative signal responses at various pre-selected sensor locations using a genetic algorithm (GA) based optimization procedure. The damage size, location, and orientation is obtained by minimizing the difference between the reference responses and the responses obtained by wave propagation finite element analysis of different representative cracks, geometries, and sizes.

Seshadri, Banavara R.↗
DOE OSTI2025

Artificial Intelligence–Enabled Digital Twin for U.S. Cities

Over 50 participants—including national laboratory researchers, academic scholars, industry representatives, and stakeholders from the City of Chicago—convened in person and online to assess the readiness and potential of an Artificial Intelligence–Enabled Digital Twin (AIDT) for urban systems, with the Greater Chicago area serving as the benchmark location. The workshop underscored that the Chicago Urban Integrated Field Laboratory provides an unparalleled testbed for developing and validating urban DTs—combining dense, multiscale observations, advanced physics-based and AI modeling capabilities, and strong stakeholder and industry engagement. Discussions highlighted available datasets, AI architectures for high resolution, multipurpose urban DTs, key applications, and near- and long-term priorities for scaling this framework within Chicago and to other U.S. and global cities.

AIDT↗
DOE OSTI2025

Digital Twin for Chemical Science: a case study on water interactions on the Ag(111) surface

Directly visualizing chemical trajectories offers insights into catalysis, gas-phase reactions and photoinduced dynamics. Tracking the transformation of chemical species is best achieved by coupling theory and experiment. Here we developed Digital Twin for Chemical Science (DTCS) v.01, which integrates theory, experiment and their bidirectional feedback loops into a unified platform for chemical characterization. DTCS addresses a core question: given a set of experimental conditions, what is the expected outcome and why? It consists of a forward solver that takes a chemical reaction network and predicts spectra under experimental conditions, and an inverse solver that infers kinetics from measured spectra. We applied DTCS to ambient-pressure X-ray photoelectron spectroscopy measurements of the Ag–H2O interface as an example. This approach enables real-time knowledge extraction and guides experiments until a stopping condition is met based on accuracy and degeneracy. As a step toward autonomous chemical characterization, DTCS provides mechanistic knowledge in a verified, standardized manner.

Chemistry↗
DOE OSTI2024

Image-Based Digital Twin for Assessing the Coupled Electro-Chemo-Mechanical Behavior of Li-Ion Batteries

In energy storage materials, strong electrochemical-mechanical coupling and highly anisotropic material properties contribute to the formation and propagation of micro-cracking during charge/discharge cycling, resulting in reduced performance and service life. In this work, a digital twin is created to investigate the performance of a Li-ion battery cathode and simulate degradation accumulation. Pixel-based model construction is used to represent the complex material geometries from microstructural images supplied by the National Renewable Energy Laboratory (NREL). Because of the expected large deformation and crack opening, the reproducing kernel particle method (RKPM), a meshfree method with discretization at the image pixels, is used to approximate the field variables: electrostatic potential, concentration, and displacement. An interface modified reproducing kernel (IM-RK) is constructed by scaling a smooth kernel function with an interface-distance function to achieve strategic discontinuity types (i.e. weak discontinuities for strain discontinuities and strong discontinuities for cracks) and alleviate Gibbs oscillations near these transition zones. The discrete nature of the images' pixel points is employed throughout the model and approximation construction. The mechanical model is verified using an image-based microstructure under tensile loading. A transient electro-chemo-mechanical coupled simulation is performed to evaluate the potential micro-cracking induced degradation of the battery cathode material subjected to charge/discharge cycling.

battery degradation↗
DOE OSTI2025

Digital Twin Framework for PIP-II Linac: AI-Driven Multi-Scale Modeling from Ion Source to 800 MeV

The PIP-II linac will enable >1.2 MW beam power for DUNE, requiring unprecedented operational reliability across its warm front-end (RFQ, MEBT) and five distinct SRF sections operating at 162.5/325/650 MHz. We present a comprehensive digital twin framework uniquely combining a fully differentiable fast beam transport code with neural network surrogates trained on high-fidelity PIC simulations, capturing space charge and nonlinear dynamics beyond traditional envelope codes while achieving 10⁴ speedup at <1% accuracy. End-to-end differentiability enables gradient-based optimization across 500+ parameters simultaneously previously impossible with conventional tools while the model incorporates static/dynamic errors and serves as a virtual commissioning platform for diverse hardware integration. The framework facilitates reinforcement learning for pulsed/CW mode transitions, predictive maintenance through anomaly detection, and autonomous tuning algorithm development with real-time execution capability. Validation against physics simulations shows excellent agreement for the front-end, with initial results demonstrating potential for 30% commissioning time reduction and proactive fault mitigation, providing a scalable blueprint for operating next-generation high-intensity accelerators.

Pathak, Abhishek [Fermilab] (ORCID:000000021704208↗
DOE OSTI2025

Digital Twin Framework for PIP-II Linac: AI-Driven Multi-Scale Modeling from Ion Source to 800 MeV

The PIP-II linac will enable >1.2 MW beam power for DUNE, requiring unprecedented operational reliability across its warm front-end (RFQ, MEBT) and five distinct SRF sections operating at 162.5/325/650 MHz. We present a comprehensive digital twin framework uniquely combining a fully differentiable fast beam transport code with neural network surrogates trained on high-fidelity PIC simulations, capturing space charge and nonlinear dynamics beyond traditional envelope codes while achieving 10⁴× speedup at <1% accuracy. End-to-end differentiability enables gradient-based optimization across 500+ parameters simultaneously—previously impossible with conventional tools—while the model incorporates static/dynamic errors and serves as a virtual commissioning platform for diverse hardware integration. The framework facilitates reinforcement learning for pulsed/CW mode transitions, predictive maintenance through anomaly detection, and autonomous tuning algorithm development with real-time execution capability. Validation against physics simulations shows excellent agreement for the front-end, with initial results demonstrating potential for 30% commissioning time reduction and proactive fault mitigation, providing a scalable blueprint for operating next-generation high-intensity accelerators.

Pathak, Abhishek [Fermilab] (ORCID:000000021704208↗
DOE OSTI2025

Unified differentiable digital twin for the IOTA/FAST facility

As the design complexity of modern accelerators grows, there is more interest in using advanced simulations that have fast execution time or produce insights about accelerator state. One notable example of additional information are gradients of physical observables with respect to design parameters produced by differentiable simulations. The IOTA/FAST facility has recently begun a program to implement and experimentally validate a unified start-to-end differentiable digital twin to serve as a virtual accelerator test stand, allowing for rapid prototyping of new software and experiments with minimal beam time costs. In this contribution we will discuss our plans and progress. Specifically, we will cover the selection and benchmarking of both physics and ML codes, the development of generic interfaces between device models and surrogate or physics-based sections, and the export of the parameters through either a deterministic event loop or a fully asynchronous EPICS soft input/output controller. We will also discuss challenges in model calibration and uncertainty quantification, as well as future plans to support larger proton accelerators like PIPII and Booster.

Kuklev, Nikita [Fermilab]↗
DOE OSTI2025

End-to-end differentiable digital twin for the IOTA/FAST facility

As the design complexity of modern accelerators grows, there is more interest in using controllable-fidelity simulations that have fast execution time or can yield additional insights about accelerator state. One notable example of additional information are gradients of physical observables with respect to design parameters produced by differentiable simulations. The IOTA/FAST facility has recently begun a program to implement and experimentally validate an end-to-end digital twin to serve as a virtual accelerator test stand, allowing for rapid prototyping of new software and experiments with minimal beam time costs. In this contribution we will discuss our plans and progress. Specifically, we will cover the selection and benchmarking of both physics and ML codes for linac and ring simulation, the development of generic interfaces between surrogate and physics-based sections, and presenting the control interface as either a deterministic event loop or a fully asynchronous EPICS soft input/output controller. We will also discuss challenges in model calibration and uncertainty quantification, as well as future plans to implement larger proton accelerators like PIPII and Booster.

Kuklev, N. [Fermilab]↗
NASA NTRSDate not supplied

NASA's Advanced Information Systems Technology (AIST): Combining New Observing Strategies and Analytics Frameworks to Build Earth System Digital Twins

NASA's Advanced Information Systems Technology (AIST) Program is one of several Technology programs managed by the Earth Science Technology Office (ESTO) in the Earth Science Division (ESD). The AIST Program focuses on advanced information systems and novel computer science technologies that will be needed by NASA Earth Science in the next 5 to 10 years. The three main thrusts of the AIST Program deal with New Observing Strategies, Analytic Collaborative Frameworks and Earth System Digital Twins. This paper describes these three thrusts and how they work together to create future Earth Science information systems.

Jacqueline Le Moigne↗
NASA NTRSDate not supplied

Artificial Intelligence for Future Earth Science Information Systems and Earth System Digital Twins

NASA's Advanced Information Systems Technology (AIST) Program is one of several Technology programs managed by the Earth Science Technology Office (ESTO) in the Earth Science Division (ESD). The AIST Program focuses on advanced information systems and novel computer science technologies that will be needed by NASA Earth Science in the next 5 to 10 years. The three main thrusts of the AIST Program deal with Novel Observing Strategies (NOS), Analytic Collaborative Frameworks (ACF) and Earth System Digital Twins (ESDT). This presentation summarizes the AIST Program with a special focus on the Artificial Intelligence (AI) and Machine Learning (ML) technologies included in its funded projects.

Earth Science Remote Sensing; Information Systems↗
DOE OSTI2020

Augmented Kalman filter with a reduced mechanical model to estimate tower loads on a land-based wind turbine: a step towards digital-twin simulations

This article presents an application of the Kalman filtering technique to estimate loads on a wind turbine. The approach combines a mechanical model and a set of measurements to estimate signals that are not available in the measurements, such as wind speed, thrust, tower position, and tower loads. The model is severalfold faster than real time and is intended to be run online, for instance, to evaluate real-time fatigue life consumption of a field turbine using a digital twin, perform condition monitoring, or assess loads for dedicated control strategies. The mechanical model is built using a Rayleigh–Ritz approach and a set of joint coordinates. We present a general method and illustrate it using a 2-degrees-of-freedom (DOF) model of a wind turbine and using rotor speed, generator torque, pitch, and tower-top acceleration as measurement signals. The different components of the model are tested individually. The overall method is evaluated by computing the errors in estimated tower-bottom-equivalent moment from a set of simulations. From this preliminary study, it appears that the tower-bottom-equivalent moment is obtained with about 10 % accuracy. The limitation of the model and the required steps forward are discussed.

17 WIND ENERGY↗
DOE OSTI2026

Virtual Inspection of Advanced Manufacturing via Process-Scale Digital Twins (Abbreviated Report)

Inspection and certification comprise the most significant bottlenecks in advanced manufacturing for NNSA applications, often requiring far more time and resources than the fabrication of the parts themselves. Traditional methods, such as manual review and X-ray computed tomography, are not only slow and costly, but also struggle to provide a clear connection between manufacturing instructions and the final performance of critical components. This gap limits both the agility and assurance needed to support the modernization and safety of the United States nuclear stockpile. In response, our Strategic Initiative established a digital twin framework that integrates realtime process monitoring, automated data analysis, and immersive virtual reality collaboration into a unified inspection pipeline. By leveraging data from sensors, machine instructions, and imaging, we created high-fidelity virtual models of manufactured parts that could be rapidly analyzed and certified. This approach was first demonstrated with Direct Ink Write, and then extended to other manufacturing settings, including conventional (or “subtractive”) manufacturing and to predict the end of life performance of parts per the aging and lifetimes programs. The result is a transformational capability: inspection times have been reduced by a factor of 120,000 without loss of accuracy and while simultaneously improving traceability and confidence in part quality. This framework not only streamlines certification for critical applications, but also positions the national security enterprise to respond more flexibly to emerging challenges, supporting agile manufacturing and digital engineering practices across a broad range of mission-relevant domains.

42 ENGINEERING↗