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DOE OSTI2026

Cross-domain digital twin architecture for predictive maintenance via machine learning and Large Language Models

This research introduces a comprehensive framework for creating and deploying a digital twin platform for continuous monitoring and predictive maintenance within industrial settings. Through utilizing advanced technologies, including Unreal Engine 5, Unity 3D, the Message Queue Telemetry Transport protocol, Random Forest machine learning algorithms, and Large Language Models (LLMs), we establish a platform that digitally reproduces physical equipment and translates digital controls into real-world actions. This facilitates preventive maintenance approaches and improves operational effectiveness. The digital twin platform gathers sensor data from operational equipment, analyzes it using machine learning, and delivers practical insights to prevent potential malfunctions and enhance equipment performance. Furthermore, the incorporation of a web portal enables efficient monitoring and access to historical data, educational materials, and equipment status information. Preliminary findings indicate that digital twins can transform industrial equipment management and maintenance methodologies.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Semi-supervised permutation invariant particle-level anomaly detection

The development of analysis methods to distinguish potential beyond the Standard Model phenomena in a model-agnostic way can significantly enhance the discovery reach in collider experiments. However, the typical machine learning (ML) algorithms employed for this task require fixed length and ordered inputs that break the natural permutation invariance in collision events. To address this, a semi-supervised anomaly detection tool is presented that takes a variable number of particle-level inputs and leverages a signal model to encode this information into a permutation invariant, event-level representation via supervised training with a Particle Flow Network (PFN). Data events are then encoded into this representation and given as input to an autoencoder for unsupervised ANomaly deTEction on particLe flOw latent sPacE (ANTELOPE), classifying anomalous events based on a low-level and permutation invariant input modeling. Performance of the ANTELOPE architecture is evaluated on simulated samples of hadronic processes in a high energy collider experiment, showing good capability to distinguish disparate models of new physics.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Uncovering obscured phonon dynamics from powder inelastic neutron scattering using machine learning

The study of phonon dynamics is pivotal for understanding material properties, yet it faces challenges due to the irreversible information loss inherent in powder inelastic neutron scattering spectra and the limitations of traditional analysis methods. In this study, we present a machine learning framework designed to reveal obscured phonon dynamics from powder spectra. Using a variational autoencoder, we obtain a disentangled latent representation of spectra and successfully extract force constants for reconstructing phonon dispersions. Notably, our model demonstrates effective applicability to experimental data even when trained exclusively on physics-based simulations. The fine-tuning with experimental spectra further mitigates issues arising from domain shift. Analysis of latent space underscores the model’s versatility and generalizability, affirming its suitability for complex system applications. Furthermore, our framework’s two-stage design is promising for developing a universal pre-trained feature extractor. This approach has the potential to revolutionize neutron measurements of phonon dynamics, offering researchers a potent tool to decipher intricate spectra and gain valuable insights into the intrinsic physics of materials.

domain adaptation↗

DOE OSTI2025

Machine Learning to Select Experiments Driven by Fundamental Science and Applications for Targeted Nuclear Data Improvement

This work describes a blueprint for a process that accelerates progress in science by quantitatively answering the following question: What is the optimal combination of fundamental-science and application-driven experiments to maximally reduce pertinent data uncertainties? Answering this question entails solving a high-dimensional and complex optimization problem that is best solved with advanced statistic techniques often classified as machine learning. We apply this process within the framework of nuclear data with the aim to select an experiment combination that will reduce uncertainties in 239 Pu nuclear data for neutron energies between 1 and 600 keV. In this field, fundamental-physics driven data, called differential, look at one nuclear physics observable at a time. They are contrasted to application-driven, integral, data where one or few resulting values inform a broad set of nuclear data across several nuclides and energies. The candidates for integral experiments are criticality measurements that were refined by a genetic algorithm to be maximally sensitive to 239 Pu fission cross sections in the desired energy range. Twenty-three candidate differential experiments were investigated and span multiple nuclear physics observables (e.g., total, capture cross sections) for isotopes appearing in the integral experiments. The optimal combination among these candidate experiments was investigated via generalized least squares fitting, augmented with Gaussian processes to ameliorate statistical irregularities in data, and the D-optimality criterion. The latter evaluates for each pair of candidates the joint reduction in uncertainties of all 12200 nuclear data appearing in the integral experiments compared to the knowledge we have from 168 past experiments, theory, and nuclear data. We chose as differential measurements those that investigate 63 Cu and 239 Pu total cross sections, based on D-optimality rank and feasibility constraints. Two integral (criticality) experiments were selected: An experiment with Al 2 ⁢O 3 and graphite interleaved with Pu and a thick Cu reflector explores 1–30 keV, while we target the 30–600 keV range with an experiment that swaps boron in place of graphite with a different geometry.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS2018

Serious Gaming for Building a Basis of Certification via Trust and Trustworthiness of Autonomous Systems

Autonomous systems governed by a variety of adaptive and nondeterministic algorithms are being planned for inclusion into safety-critical environments, such as unmanned aircraft and space systems in both civilian and military applications. However, until autonomous systems are proven and perceived to be capable and resilient in the face of unanticipated conditions, humans will be reluctant or unable to delegate authority, remaining in control aided by machine-based information and decision support. Proving capability, or trustworthiness, is a necessary component of certification. Perceived capability is a component of trust. Trustworthiness is an attribute of a cyber-physical system that requires context-driven metrics to prove and certify. Trust is an attribute of the agents participating in the system and is gained over time and multiple interactions through trustworthy behavior and transparency. Historically, artificial intelligence and machine learning systems provide answers without explanation - without a rationale or insight into the machine “thinking”. In order to function as trusted teammates, machines must be able to explain their decisions and actions. This transparency is a product of both content and communication. NASA’s Autonomy Teaming & TRAjectories for Complex Trusted Operational Reliability (ATTRACTOR) project seeks to build a basis for certification of autonomous systems via establishing metrics for trustworthiness and trust in multi-agent team interactions, using AI (Artificial Intelligence) explainability and persistent modeling and simulation, in the context of mission planning and execution, with analyzable trajectories. Inspired by Massively Multiplayer Online Role Playing Games (MMORPG) and Serious Gaming, the proposed ATTRACTOR modeling and simulation environment is similar to online gaming environments in which player (aka agent) participants interact with each other, affect their environment, and expect the simulation to persist and change regardless of any individual agent’s active participation. This persistent simulation environment will accommodate individual agents, groups of self-organizing agents, and large-scale infrastructure behavior. The effects of the emerging adaptation and coevolution can be observed and measured to building a basis of measurable trustworthiness and trust, toward certification of safety-critical autonomous systems.

Allen, B. Danette↗

DOE OSTI2025

Co-optimization of fuel properties, combustion system geometry, and injection strategy for conventional diesel fuel

Here, studies have shown that fuel properties can impact an engine’s operation in several ways, including ignition delay, sooting tendency, mixture formation, and combustion temperature. In mixing-controlled compression ignition (MCCI) engines, the fuel system design and piston bowl geometry significantly affect combustion performance and emissions. Based on current information, it is difficult to draw conclusions about fuel property effects and sensitivities. The central fuel hypothesis approach used in the US Department of Energy Co-Optima program has worked well for spark ignition fuels: identifying critical fuel property ranges is sufficient to screen fuel blends that are expected to maximize efficiency and reduce pollutant emissions. However, for MCCI-relevant fuels, the information gained from past studies is not sufficient to build such a merit function or to allow for performing a similar screening of fuel blends. It is hypothesized that a co-optimization of a fuel’s physical and chemical properties, combustion system geometry, and injection strategy could leverage synergies between the effects of the fuel properties and geometries, resulting in improved performance over state-of-the-art. A machine learning–assisted unconstrained global optimization algorithm was used to explore a design space comprising 23 independent variables. The results show that physical property effects were minimal even for large variations in fuel properties, and the only interaction effect that was observed was the effect of varied fuel density parameters on fuel/air mixture formation. Nevertheless, these interactions were not sufficient in magnitude to significantly affect optimization results. Therefore, analysis of the results suggests that fuel physical properties cannot be leveraged in a co-optimization context to increase engine efficiency.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2019

Application of Machine Learning Techniques to Aviation Operations: Promises and Challenges

There is an increasing interest in applying methods based on Machine Learning Techniques (MLT) to problems in aviation operations. The current interest is based on developments in Cloud Computing, the availability of open software and the success of MLT in automation, consumer behavior and finance involving large database. This paper reviews the current-state-of-the art in applying MLT to aviation operations, its promises and challenges. Historically aviation operations have been analyzed using physics-based models and provide information for making operational decisions. This paper compares the methodology used in and issues to be addressed in applying either model-driven or data-driven methods. Some aviation operations involving many decision makers, multiple objectives, poor or unavailable physics-based models and a rich historical database are prime candidates for data-driven methods. The application of MLT to aviation operations falls into three categories: (a) based on the lack of a physics-based model, MLT is the favored approach, (b) marginal difference between regression methods using physics-based models and MLT and (c) better results using a blend of physics-based methods combined with MLT. As always, the best approach depends on the task, the physical understanding of the problem and the quality and quantity of the available data.

Sridhar, Banavar↗

NASA NTRS2020

Convolutional Neural Network for Transition Modeling Based on Linear Stability Theory

Transition prediction is an important aspect of aerodynamic design because of its impact on skin friction and potential coupling with flow separation characteristics. Traditionally, the modeling of transition has relied on correlation-based empirical formulas based on integral quantities such as the shape factor of the boundary layer. However, in many applications of computational fluid dynamics, the shape factor is not straightforwardly available or not well-defined. We propose using the complete velocity profile along with other quantities (e.g., frequency, Reynolds number) to predict the perturbation amplification factor. While this can be achieved with regression models based on a classical fully connected neural network, such a model can be computationally more demanding. We propose a novel convolutional neural network inspired by the underlying physics as described by the stability equations. Specifically, convolutional layers are first used to extract integral quantities from the velocity profiles, and then fully connected layers are used to map the extracted integral quantities, along with frequency and Reynolds number, to the output (amplification ratio). Numerical tests on classical boundary layers clearly demonstrate the merits of the proposed method. More importantly, we demonstrate that, for Tollmien-Schlichting instabilities in two-dimensional, low-speed boundary layers, the proposed network encodes information in the boundary layer profiles into an integral quantity that is strongly correlated to a well-known, physically defined parameter – the shape factor.

Laminar-turbulent transition↗

NASA NTRSDate not supplied

Hybrid Model Based Approaches for Systems Health Management and Prognostics

To facilitate and solve the prediction problem, awareness of the current health state of the system is key, since it is necessary to perform condition-based predictions. To accurately predict the future state of any system, it is required to possess knowledge of its current health state and future operational conditions. Latest achievements of data-driven algorithms in regression of complex nonlinear functions and classification tasks have generated a growing interest in artificial intelligence for industrial applications. Complex multi-physics models as well as digital twins, once purely built on physics and corresponding simplified lumped parameter iterations, can now benefit from machine learning algorithms to mitigate the lack of understanding of some complex behavior. Given models of the current and future system behavior, a general approach of model-based prognostics can solve the prediction problem and further decision making. In principle, data driven approaches can replace expensive experimental test-setups as well as reduce the number of simulations needed to explore, e.g., the parametric space of a multi-parameter model. Nonetheless, the limitations of pure data-driven methods came to light rather quickly, at least for some industries. In many industrial applications, data acquisition is costly, and the volume of data that can be collected does not satisfy the requirements for an effective model training and cross-validation. Therefore, some recent works in the area of machine learning is focusing on blending physics with data-driven algorithms, thus mitigating the drawbacks of the two approaches and emphasizing respective advantages. Partial physical knowledge of the problem can aid the learning process by “guiding” the algorithm towards efficient solutions that satisfy the physics driving the system behavior. The result is a hybrid modeling approach combining physical knowledge as well data driven methods to develop a unified hybrid approach. A hybrid framework for fusing information from physics-based performance models along with deep learning algorithms for prognostics of complex safety critical systems is presented. In this framework, physics-based performance models infer unobservable model parameters related to the system's components health solving a calibration problem in the deep learning approach.

Hybrid Modeling↗

NASA NTRSDate not supplied

Hybrid Approaches to Systems Health Management and Prognostics

Systems Health Management↗

NASA NTRSDate not supplied

Space-Based Lidar Observations of the 3D Structure of the Earth System

Lidar provides precise measurements of the three-dimensional structure of the clouds, aerosols, ocean/land/snow/ice surfaces, as well as ocean subsurface. Lidar also provides unique information about physical propertiesof particulates in the atmosphere for both radiative transfer and air quality applications.In this talk, I will present an overview of our recent studies of aerosols, clouds, ocean and snow using space-based lidar measurements (e.g., LITE, CALIPSO and ICESat-2), such as classifications of aerosols and thermodynamics phase of clouds, cloud microphysical properties, snow depths and phytoplankton biomass. I will also introduce a new concept of 3D Earth system observations with data fusion though combined active/passive remote sensing and machine learning. The new concept aims to reveal vertical structure of the aerosols/clouds/surfaces/subsurface from passive sensors by taking advantage of lidar measurements to effectively resolve the vertical structureby unscrambling the highly convoluted multi-angle, spectral and polarization information from passive sensors and apply the knowledge to a large swath where lidar measurements are not available.

Ali Omar↗

NASA NTRS2020

Prognostics for Systems Health Management - Model and Hybrid Based Approaches. Where are We Heading?

To facilitate and solve the prediction problem, awareness of the current state and health of the system is key, since it is necessary to perform condition-based system health predictions. To accurately predict the future state of any system, it is required to possess knowledge of its current health state and future operational conditional. In case of next generation electric aircrafts, computing remaining flying time is safety-critical, since an aircraft that runs out of power (battery charge) while in the air will eventually lose control leading to catastrophe. In order to tackle and solve the prediction problem, it is essential to have awareness of the current health state of the system, especially since it is necessary to perform condition-based predictions. To be able to predict the future state of the system, it is also required to possess knowledge of the current and future operational conditions and flight profiles for accurate estimation of end-of-discharge (EOD) for the batteries. Similar framework can be implemented to other complex systems and subsystems. Our research approach is to develop a system level health monitoring safety indicator which runs estimation and prediction algorithms to estimate remaining useful life predictions at system, subsystem swell as component levels. Given models of the current and future system behavior, a general approach of model-based prognostics is discussed as a solution to the prediction problem and further for decision making. Data driven prognostics approaches have been equally used with good results in the past, where respective approaches have their own challenges to tackle. This limits their applicability to complex real-world domains: (a) high complexity or incompleteness of physics-based models and (b) limited representativeness of the training dataset for data-driven models. With the advent of internet of things for data collection and increased use of ML algorithms, hybrid approaches are the next avenue to reduce the challenges and achieve better results. An hybrid framework for fusing information from physics-based performance models along with deep learning algorithms for prognostics of complex safety critical systems is presented. In this framework, we use physics-based performance models to infer unobservable model parameters related to the system's components health solving a calibration problem.

Prognostics↗

DOE OSTI2025

Synergistic learning with multi-task DeepONet for efficient PDE problem solving

Multi-task learning (MTL) is an inductive transfer mechanism designed to leverage useful information from multiple tasks to improve generalization performance compared to single-task learning. It has been extensively explored in traditional machine learning to address issues such as data sparsity and overfitting in neural networks. In this work, we apply MTL to problems in science and engineering governed by partial differential equations (PDEs). However, implementing MTL in this context is complex, as it requires task-specific modifications to accommodate various scenarios representing different physical processes. To this end, we present a multi-task deep operator network (MT-DeepONet) to learn solutions across various functional forms of source terms in a PDE and multiple geometries in a single concurrent training session. We introduce modifications in the branch network of the vanilla DeepONet to account for various functional forms of a parameterized coefficient in a PDE. Additionally, we handle parameterized geometries by introducing a binary mask in the branch network and incorporating it into the loss term to improve convergence and generalization to new geometry tasks. Our approach is demonstrated on three benchmark problems: (1) learning different functional forms of the source term in the Fisher equation; (2) learning multiple geometries in a 2D Darcy Flow problem and showcasing better transfer learning capabilities to new geometries; and (3) learning 3D parameterized geometries for a heat transfer problem and demonstrate the ability to predict on new but similar geometries. Finally, our MT-DeepONet framework offers a novel approach to solving PDE problems in engineering and science under a unified umbrella based on synergistic learning that reduces the overall training cost for neural operators.

42 ENGINEERING↗

NASA NTRS2022

Hybrid Model Based Approaches for Systems Health Management and Prognostics

This is a previously approved and published presentation. To accurately predict the future state of any system, it is required to possess knowledge of its current health state and future operational conditions. Present achievements of data-driven algorithms in regression of complex nonlinear functions and classification tasks have generated a growing interest in artificial intelligence for industrial applications. Complex multi-physics models as well as digital twins, once purely built on physics and corresponding simplified lumped parameter iterations, can now benefit from machine learning algorithms to mitigate the lack of understanding of some complex behavior. Given models of the current and future system behavior, a general approach of model-based prognostics can solve the prediction problem and further decision-making. In principle, data-driven approaches can replace expensive experimental test-setups as well as reduce the number of simulations needed to explore, e.g., the parametric space of a multi-parameter model. Nonetheless, the limitations of pure data-driven methods came to light rather quickly, at least for some industries. In many industrial applications, data acquisition is costly, and the volume of data that can be collected does not satisfy the requirements for effective model training and cross-validation. Therefore, some recent works in the area of machine learning is focusing on blending physics with data-driven algorithms, thus mitigating the drawbacks of the two approaches and emphasizing respective advantages. Partial physical knowledge of the problem can aid the learning process by “guiding” the algorithm towards efficient solutions that satisfy the physics driving the system behavior. The result is a hybrid modeling approach combining physical knowledge as well data-driven methods to develop a unified hybrid approach. A hybrid framework for fusing information from physics-based performance models along with deep learning algorithms for prognostics of complex safety-critical systems is presented. In this framework, physics-based performance models infer unobservable model parameters related to the system's components health solving a calibration problem in the deep learning approach.

Prognostics↗

DOE OSTI2025

Optimizing Facility Operations by Applying Machine Learning to the Army Reserve Enterprise Building Control System (Final Report)

Thousands of U.S. Department of Defense (DoD) buildings have building automation systems (BASs) and/or advanced meters. Although these systems have a wealth of data, performance optimization requires time and expertise to review and act on that information. Machine learning (ML) can provide automated and actionable insights to controls operators. This demonstration implemented proven ML methods on the Army Reserve Enterprise Building Control System. ML refers to algorithms that “learn” from data and improve their performance on a given task over time. In the buildings domain these tasks range from predicting future energy consumption, to identifying operational issues before faults occur, to optimizing control decisions. To learn, ML requires input data, which – for buildings – typically consists of instrument data such as energy consumption data and subsystem controls information such as set-point temperatures, and context data consisting of information such as the physical location of the building, the area of the building, and the weather. ML models use the relationships learned from the input data to make predictions with new, previously unseen, data. The team was able to investigate and successfully implement the following ML use cases: labeling consumption data as anomalous or non-anomalous; baseline whole-building load prediction (unknown fault status); fault detection (validation not possible); and site prioritization for energy-related projects. Due to the constraints of the project, interventions were not able to be implemented during the demonstration; therefore, assessments of operational cost savings and maintenance avoided could not be performed. The project has been presented at two leading national building conferences and two additional publications to peer-reviewed journals are currently in preparation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Comparison of tungsten versus molybdenum for double shell capsules using machine learning design optimization

Double shell targets are an alternative ignition platform for inertial confinement fusion. One design consideration for double shell targets is the choice of inner shell material to help trap radiation emitted by the hot fuel to aid ignition. Materials such as molybdenum and tungsten are of interest for the inner shell layer of the targets. While molybdenum has a lower density that could inhibit instability growth and allow for radiography and code benchmarking, tungsten has a higher density that could provide more compression and confinement. These tradeoffs have been explored using optimized designs for each material. Our previous work [Vazirani et al., “Coupling 1D xRAGE simulations with machine learning for graded inner shell design optimization in double shell capsules,” Phys. Plasmas 28, 122709 (2021); Vazirani et al., “Coupling multi-fidelity xRAGE with machine learning for graded inner shell design optimization in double shell capsules,” Phys. Plasmas 30, 062704 (2023); and Vazirani et al., “Bayesian batch optimization for molybdenum versus tungsten inertial confinement fusion double shell target design,” Stat. Anal. Data Min. 17, e11698 (2024)] resulted in a multi-fidelity Bayesian optimization framework to find yield-optimized double shell target geometries. By leveraging simulations of varying fidelities (one-dimensional and two-dimensional) to inform one another, the multi-fidelity optimization was able to optimize a design in the highest fidelity with significantly fewer simulations than would be used in a systematic parameter scan. In this work, we apply the multi-fidelity Bayesian optimization to explore the optimized designs of double shell targets with molybdenum and tungsten inner shells as well as the physics producing the high performing implosions. A physics exploration of all the simulations used in this study shows trends in designs that contribute to high yields, ion temperatures, and fuel areal densities. Comparison of molybdenum and tungsten simulations shows that they can produce similar implosion conditions with different geometries, which would be important to study in experiments. Graded density layers produce varying performances with the two materials but continue to be of interest for future studies along with studies of doped inner shell materials and applied surface roughness.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS2022

Lunar Simulant Deposition Technique for Dust Tolerance Studies

A renewed interest in lunar exploration has spawned an array of development efforts for lunar surface assets. These systems depend on the reliable operation of mechanisms and components that may be susceptible to performance degradations or failure due to dust. The Uniform Dust Deposition System was developed at the NASA Glenn Research Center to provide repeatable, uniform, and automated deposition of simulants on surfaces of interest for dust mitigation testing. The system is capable of depositing simulants on test articles up to 60 cm in diameter and 15 cm high in a dry air environment with less than 1 percent relative humidity while keeping users safe from aerosolized dust. The automation of the system allows for high testing throughput while not sacrificing test quality and allows the user to reduce data in parallel. The additional development of a simulant preparation technique complements the repeatability of the deposition physics during testing. The system includes an imaging subsystem that leverages the power of machine learning to count simulant particles and measure their size, thereby allowing for accurate predictions of surface deposition densities (coefficient of determination R^(2) = 0.93) from images alone. The coverage of dust on a surface was shown to be uniform (coefficient of variation CV < 0.11), allowing developers to accurately evaluate the performance of their technology with a prescribed amount of lunar simulant, information that can be used to develop and refine models. The accuracy of the system is currently less than desired for a single deposition run, with a standard deviation (SD) ranging from 18 to 24 mg, or 0.839 to 1.184 mg/sq. cm , for a 5-cm-diameter area. However, the accuracy can be improved by performing multiple deposition runs to build dust to a desired level. Testing has shown that a SD of 0.2 to 0.6 mg, or 0.076 to 0.227 mg/sq. cm, can be achieved for a 5-cm-diameter area using this technique.

Stephen Gerdts↗

DOE OSTI2025

Variational autoencoders for at-source data reduction and anomaly detection in high energy particle detectors

Detectors in next-generation high-energy physics experiments face several daunting requirements, such as high data rates, damaging radiation exposure, and stringent constraints on power, space, and latency. To address these challenges, machine learning in readout electronics can be leveraged for smart detector designs, enabling intelligent inference and data reduction at-source. Variational autoencoders (VAEs) offer a variety of benefits for front-end readout; an on-sensor encoder can perform efficient lossy data compression while simultaneously providing a latent space representation that can be used for anomaly detection. Results are presented from low-latency and resource-efficient VAEs for front-end data processing in a futuristic silicon pixel detector. Encoder-based data compression is found to preserve good performance of off-detector analysis while significantly reducing the off-detector data rate as compared to a similarly sized data filtering approach. Furthermore, the latent space information is found to be a useful discriminator in the context of real-time sensor defect monitoring. Together, these results highlight the multifaceted utility of autoencoder-based front-end readout schemes and motivate their consideration in future detector designs.

47 OTHER INSTRUMENTATION↗