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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

High Fidelity Digital Twins for BWRX-300 Critical Systems

This project developed and demonstrated digital-twin technology for advanced nuclear systems under the ARPA-E GEMINA program, with a focus on the BWRX-300 small modular reactor. The primary objective was to reduce operation and maintenance (O&M) costs through predictive health monitoring and model-based fault detection. The project combined MIT’s high-fidelity physics models and machine-learning and digital-twin algorithms, and GE Hitachi’s digital-twin algorithms and operational expertise to build physics-based digital twins capable of real-time system monitoring and maintenance scheduling.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Semicoherent symmetric quantum processes: Theory and applications

Discovering pragmatic and efficient approaches to construct ε-approximations of quantum operators such as real (imaginary) time-evolution propagators in terms of the basic quantum operations (gates) is challenging. Prior ε-approximations are invaluable, in that they enable the compilation of classical and quantum algorithm modeling of, e.g., dynamical and thermodynamic quantum properties. In parallel, symmetries are powerful tools concisely describing the fundamental laws of nature; the symmetric underpinnings of physical laws have consistently provided profound insights and substantially increased predictive power. In this work, we consider the interplay between the ε-approximate processes and the exact symmetries in a semicoherent context—where measurements occur at each logical clock cycle. Here we draw inspiration from Pascual Jordan's groundbreaking formulation of nonassociative, but commutative, symmetric algebraic form. Our symmetrized formalism is then applied in various domains such as quantum random walks, real-time evolutions, variational algorithm ansatzes, and efficient entanglement verification. Our work paves the way for a deeper understanding and greater appreciation of how symmetries can be used to control quantum dynamics in settings where coherence is a limited resource.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

Machine Learning (ML) Classifier to Assist Metadata Creation

The Atmospheric Radiation Measurement (ARM) Data Center is responsible for the timely collection, archival, and curation of science data products. These products are freely available through an online data repository. Metadata creation is paramount for scientific users to find and access over seven petabytes of atmospheric science data. The hierarchical metadata structure allows users to search for information at both broad and narrow levels. This project aims to leverage 30 years’ worth of manually created metadata to enable machine predictions of broad-term classifications from narrow-term descriptions. These classification predictions would assist metadata coordinators with their term selections. This paper discusses the cleaning and preprocessing of the training data, the pipeline developed to determine the best model for this task, and the creation of an API metadata classifier for ARM measurement metadata. Our results show that the Linear Support Vector Classification (LinearSVC) algorithm, along with the Term Frequency – Inverse Document Frequency (TF-IDF) vectorizer, is well-suited for our multi-class classification task. Lengthier input training data led to better results, and artificial balancing was unnecessary for this particular use case. This predictive classifier enhances efficiency in metadata creation, as well as supports greater consistency and accuracy in metadata tagging.

Collier, Hannah [ORNL] (ORCID:0000000341284292)↗

DOE OSTI2024

Computationally efficient and error aware surrogate construction for numerical solutions of subsurface flow through porous media

Limiting the injection rate to restrict the pressure below a threshold at a critical location can be an important goal of simulations that model the subsurface pressure between injection and extraction wells. The pressure is approximated by the solution of Darcy’s partial differential equation for a given permeability field. The subsurface permeability is modeled as a random field since it is known only up to statistical properties. This induces uncertainty in the computed pressure. Solving the partial differential equation for an ensemble of random permeability simulations enables estimating a probability distribution for the pressure at the critical location. These simulations are computationally expensive, and practitioners often need rapid online guidance for real-time pressure management. An ensemble of numerical partial differential equation solutions is used to construct a Gaussian process regression model that can quickly predict the pressure at the critical location as a function of the extraction rate and permeability realization. The Gaussian process surrogate analyzes the ensemble of numerical pressure solutions at the critical location as noisy observations of the true pressure solution, enabling robust inference using the conditional Gaussian process distribution. Our first novel contribution is to identify a sampling methodology for the random environment and matching kernel technology for which fitting the Gaussian process regression model scales as O ( n log n ) instead of the typical O ( n 3 ) rate in the number of samples n used to fit the surrogate. The surrogate model allows almost instantaneous predictions for the pressure at the critical location as a function of the extraction rate and permeability realization. Our second contribution is a novel algorithm to calibrate the uncertainty in the surrogate model to the discrepancy between the true pressure solution of Darcy’s equation and the numerical solution. Finally, although our method is derived for building a surrogate for the solution of Darcy’s equation with a random permeability field, the framework broadly applies to solutions of other partial differential equations with random coefficients.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Understanding and Estimating Error Propagation in Neural Networks for Scientific Data Analysis

Neural networks are increasingly integrated into scientific discovery, where input data reduction and model quantization play a key role in accelerating inference. However, understanding and mitigating the impact of these techniques on output error is critical for ensuring reliable results, particularly in tasks demanding high numerical precision. This paper introduces a comprehensive framework for optimizing neural network inference in scientific computing by combining data reduction and weight quantization while maintaining error-controlled outcomes. We develop theoretical analyses to bound error propagation under these reductions and propose a framework that balances computational performance with error constraints. Evaluation on real-world learning-based combustion simulations and satellite image classification demonstrates that our derived error bounds accurately predict observed errors while enabling significant computational speedup under our framework. This work highlights the potential for further leveraging advancements in modern lossy compression algorithms and hardware accelerators that support lower-precision formats.

He, Weiming [New Jersey Institute of Technology]↗

DOE OSTI2026

Scalable multiplexed machine learning gas sensor chips for food classification

Multiplexed gas sensor arrays combined with machine learning have unlocked previously inaccessible applications for scent-based sensing. Current platforms are limited by overlapping sensing materials with similar compositions, leading to highly correlated responses, or multistep deposition processes that hinder scalability. In this work, we developed a 16-element monolithic chip with fully distinct sensing layers, enabling a truly heterogeneous array. The system consists of highly sensitive carbon nanotube field effect transistors that are functionalized through a single-step microdispensing method compatible with automated pipetting systems. The resulting chip produces characteristic signal patterns in response to object-specific scent profiles and, when combined with machine learning algorithms, can perform automated object identification. We demonstrate the classification of 16 different objects, including food spoilage and nut allergens, with a 92.6% overall prediction accuracy.

Bassil, Carla [University of California, Berkeley,↗

DOE OSTI2024

Predicting ptychography probe positions using single-shot phase retrieval neural network

Ptychography is a powerful imaging technique that is used in a variety of fields, including materials science, biology, and nanotechnology. However, the accuracy of the reconstructed ptychography image is highly dependent on the accuracy of the recorded probe positions which often contain errors. These errors are typically corrected jointly with phase retrieval through numerical optimization approaches. When the error accumulates along the scan path or when the error magnitude is large, these approaches may not converge with satisfactory result. We propose a fundamentally new approach for ptychography probe position prediction for data with large position errors, where a neural network is used to make single-shot phase retrieval on individual diffraction patterns, yielding the object image at each scan point. The pairwise offsets among these images are then found using a robust image registration method, and the results are combined to yield the complete scan path by constructing and solving a linear equation. We show that our method can achieve good position prediction accuracy for data with large and accumulating errors on the order of 10 2 pixels, a magnitude that often makes optimization-based algorithms fail to converge. For ptychography instruments without sophisticated position control equipment such as interferometers, our method is of significant practical potential.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

A Methodology for Simulating Supercritical CO2 Heat Transfer Experiments Using Machine Learning Models

To support the growth of supercritical carbon dioxide (sCO2) power cycles in the energy industry, this study seeks to train a machine learning model to mirror experimental data to predict new heat transfer data. To do this experimental data was amassed, one preliminary set comprised of 16 test results, and an expanded version comprised of 38 test results. With the goal of predicting experimental apparatus temperatures and pressures, several iterations of models were tested investigating the impact of model hyper-parameters, data inclusion, and data pre-processing on model performance. A total of 15 variations cumulatively of Gaussian Process Regressors, Gradient Boosting Regressors, and Multi-Layer Perceptrons were trained and validated on the preliminary set, and the best algorithm of each class was re-trained on the expanded set. These were compared based on test/train R^2 , test/train mean absolute error (MAE), and validation MAE, to identify the successfulness of these models. It was shown temperatures could be predicted within just a few degrees, showing the potential of this approach. Future research has been identified with approaches to improve pressure and temperature predictions going forward.

Grabowski, Owen↗

DOE OSTI2025

Genetic algorithm optimization of nuclear criticality experiment for reduction of intermediate-energy 239 Pu nuclear data uncertainties

Nuclear criticality experiments are conducted to investigate specific nuclear data important for safe handling and storage of fissile materials, reactor design and operation, and the validation of radiation transport codes. Incorrect or uncertain nuclear data can prohibitively impact operational safety limits, reactor licensing, and predictive simulation capability; therefore, integral measurements from criticality experiments are necessary and should be performed frequently. To maximize the impact of the integral measurements, it is important to consider experiment geometry, material selection, and component dimensions. When taking these considerations into account, the experiment design process becomes iterative and very time intensive. This work utilizes a genetic algorithm to efficiently explore potential nuclear criticality experiment designs for the Laboratory Directed Research & Development project PARADIGM (PARallel Approach of Differential and InteGral Measurements) at Los Alamos National Laboratory. In this paper, the building blocks of the genetic algorithm are discussed in detail, the genetic algorithm methodology is verified, and the genetic algorithm is used to produce three candidate experiment models for the final PARADIGM design. The three candidate models produced by the genetic algorithm consist of copper-reflected assemblies containing 14 repeating units of alumina, graphite, boron, and plutonium plates. Furthermore, in addition to the optimization results, final design considerations are also discussed for designs with a height and/or weight very close to or slightly above assembly machine operational limits.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

A robust approach to Gaussian process implementation

Abstract. Gaussian process (GP) regression is a flexible modeling technique used to predict outputs and to capture uncertainty in the predictions. However, the GP regression process becomes computationally intensive when the training spatial dataset has a large number of observations. To address this challenge, we introduce a scalable GP algorithm, termed MuyGPs, which incorporates nearest-neighbor and leave-one-out cross-validation during training. This approach enables the evaluation of large spatial datasets with state-of-the-art accuracy and speed in certain spatial problems. Despite these advantages, conventional quadratic loss functions used in the MuyGPs optimization, such as root mean squared error (RMSE), are highly influenced by outliers. We explore the behavior of MuyGPs in cases involving outlying observations and, subsequently, develop a robust approach to handle and mitigate their impact. Specifically, we introduce a novel leave-one-out loss function based on the pseudo-Huber function (LOOPH) that effectively accounts for outliers in large spatial datasets within the MuyGPs framework. Our simulation study shows that the LOOPH loss method maintains accuracy despite outlying observations, establishing MuyGPs as a powerful tool for mitigating unusual observation impacts in the large data regime. In the analysis of US ozone data, MuyGPs provides accurate predictions and uncertainty quantification, demonstrating its utility in managing data anomalies. Through these efforts, we advance the understanding of GP regression in spatial contexts.

Mukangango, Juliette↗

DOE OSTI2025

Computational toolkit for predicting thickness of 2D materials using machine learning and autogenerated dataset by large language model

The thickness of 2D materials not only plays a crucial role in determining the performance of nanoelectronic and optoelectronic devices but also introduces complexities in predicting volume-dependent properties, such as energy storage capacity, due to the intrinsic vacuum within these materials. Although a plethora of experimental techniques, including but not limited to optical contrast, Raman spectroscopy, nonlinear optical spectroscopy, near-field optical imaging, and hyperspectral imaging, facilitate the measurement of 2D material thickness, comprehensive data for many materials remain elusive. Over the past decade, the exponential proliferation of 2D materials and their heterostructures has outstripped the capabilities of conventional experimental and computational approaches. In this evolving landscape, machine learning (ML) has emerged as an indispensable tool, offering a scalable approach to augment these traditional methodologies. Addressing the critical gap, we introduce THICK2D—Thickness Hierarchy Inference and Calculation Kit for 2D Materials. This Python-based computational framework harnesses an autogenerated thickness database, developed using large language models, and advanced ML algorithms to facilitate the rapid and scalable estimation of material thickness, relying solely on crystallographic data. To demonstrate the utility and robustness of THICK2D, we successfully used the toolkit to predict the thickness of more than 8000 2D-based materials, sourced from two extensive 2D materials databases. THICK2D is disseminated as an open-source utility, accessible on GitHub at https://github.com/gmp007/THICK2D, and archived on Zenodo at https://10.5281/zenodo.11216648.

Ekuma, Chinedu E. (ORCID:0000000258527556)↗

DOE OSTI2024

Improving the National Solar Radiation Database (NSRDB) Using a Physics-Based Direct Normal Irradiance (DNI) Model

The National Solar Radiation Database (NSRDB) is a widely used resource providing satellite-derived solar data across the United States and globally. While the NSRDB employs a physical model for computing global horizontal irradiance (GHI), its current method for estimating cloudy-sky direct normal irradiance (DNI) relies on surface observations and empirical models. Recently, a novel physics-based approach, the Fast All-Sky Radiation Model for Solar applications with DNI (FARMS-DNI), was developed to enhance the DNI forecasting. FARMS-DNI incorporates both direct and scattered solar radiation within the circumsolar region, resulting in improved day-ahead DNI predictions when integrated into the Weather Research and Forecasting model with Solar extensions (WRF-Solar). This study integrates FARMS-DNI into the NSRDB algorithm to generate high-resolution DNI data from satellite resources. Our findings reveal that FARMS-DNI effectively mitigates the substantial DNI overestimation present in the conventional NSRDB across surface sites, particularly in conditions categorized as cloudy overcast. Consequently, this innovative model substantially enhances the overall accuracy of the NSRDB.

Xie, Yu↗

DOE OSTI2024

Improving the National Solar Radiation Database (NSRDB) Using a Physics-Based Direct Normal Irradiance (DNI) Model: Preprint

DNI↗

DOE OSTI2024

Error and Correction Analysis for the FFA@CEBAF Energy Upgrade

An energy upgrade design for the Continuous Electron Beam Accelerator Facility (CEBAF) is under development, using fixed field alternating gradient (FFA) return arcs to recirculate electron beam up to an additional five times through the accelerating structures at CEBAF. A necessary component of any large accelerator is a beam steering and optical correction system. Small environmental changes and system errors can lower beam quality or even shut down the machine; and in pursuit of the scientific mission of JLab, high quality electron beams must be delivered to the experimental halls on a predictable schedule. Correction in the novel FFA arcs of the current upgrade design is complicated by several factors. These complexities inform the choice of correction algorithm structure and parameter values. A baseline algorithm in addition to diagnostic and correction hardware configuration is presented. The effect of this correction protocol is shown with respect to estimated errors, and several possible extensions of the algorithm are discussed. This work presents an important proof of concept for the FFA@CEBAF design effort, and provides a functional correction strategy which may be simply adjusted and optimized for future design changes.

Coxe, Alex [Old Dominion Univ., Norfolk, VA (Unite↗

DOE OSTI2024

Deep-Learning-Based Multi-Timescale Load Forecasting in Buildings: Opportunities and Challenges from Research to Deployment

Electricity load forecasting for buildings and campuses is becoming increasingly important as the penetration of distributed energy resources (DERs) grows. Efficient operation and dispatch of DERs require reasonably accurate predictions of future energy consumption in order to conduct near-real-time optimized dispatch of on-site generation and storage assets. Electric utilities have traditionally performed load forecasting for load pockets spanning large geographic areas, and therefore, forecasting has not been a common practice by buildings and campus operators. Given the growing trends of research and prototyping in the grid-interactive efficient buildings domain, characteristics beyond simple algorithm forecast accuracy are important in determining the algorithm's true utility for smart buildings. Other characteristics include the overall design of the deployed architecture and the operational efficiency of the forecasting system. In this work, we present a deep-learning-based load forecasting system that predicts the building load at 1-hour intervals for 18 hours in the future. We also discuss challenges associated with the real-time deployment of such systems as well as the research opportunities presented by a fully functional forecasting system that has been developed within the National Renewable Energy Laboratory's Intelligent Campus program.

building load forecasting↗

DOE OSTI2025

Predictive modeling of Néel temperature in austenitic alloys using CALPHAD and data analytics

The Néel temperature is a crucial yet often overlooked parameter in calculating the stacking fault energy (SFE) of austenitic alloys. Several empirical equations have been proposed to estimate the Néel temperature of austenitic alloys, which are then used to calculate the SFE and explain deformation mechanisms. However, these empirical equations, typically derived using linear regression algorithms, are often simplistic and may fail to capture the complex interactions among multiple alloying elements that influence the Néel temperature. Moreover, their applicability is usually limited to specific compositional ranges. In this study, we propose a CALPHAD based approach and develop a surrogate decision tree based regression model capable of capturing the interactions among multiple alloying elements to predict the Néel temperature. Predictions from both the CALPHAD approach and the regression model show close agreement with experimental measurements reported in the literature. In conclusion, the implications of accurate Néel temperature predictions on the calculated SFE and deformation mechanisms are also discussed.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Physics-Informed Neural Network (PINN) Prediction of Mixed Mass-Heat-Crystallization Limited Methane Hydrate Formation and Dissociation in Micro-Confinement

The creation and use of Physics-Informed Neural Networks (PINNs) for simulating the dynamics of methane hydrate formation and dissociation will be presented. The PINN framework's main benefit is its capacity to impose physical consistency with only a partial comprehension of the governing equations. This makes the algorithm especially useful for systems with little experimental evidence or a lack of theoretical knowledge. A strong basis for forecasting methane hydrate behavior over the verified operating ranges of 30.0-80.9 bar pressure and 1.0-4.0 K sub-cooling conditions is provided by the combination of conductive heat transfer equations and mixed mass-transfer–crystallization kinetics. PINNs were more accurate at predicting the mixed mass-heat-crystallization limited kinetics than conventional Artificial Neural Networks (ANNs), demonstrating remarkable predictive accuracy for methane hydrate production over the ANN model. The efficiency of incorporating physical limitations from first principles into machine learning frameworks for methane hydrate crystallizations is reinforced by these findings. For hydrate-related applications in energy generation, carbon sequestration, and climate modelling, our study establishes PINNs as a computational tool that is both scalable and efficient. The proven capacity to close the gap between conventional physics-based simulations and solely data-driven models creates new opportunities for expedited hydrate research and practical applications.

Hartman, Ryan L [NYU Tandon School of Engineering]↗