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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Fermilab's controls development with virtual accelerator

Control Systems development is often the last thing considered when designing and building new equipment, e.g. a new detector or superconducting RF LINAC; however when the new equipment is installed, it is the first thing desired to be operational for testing. Due to frequent delays in building new equipment and project deadlines, control system development and testing is often curtailed. A way to alleviate this problem is to simulate the control system, though this will be challenging for complex systems.The Fermilab PIP-II (proton improvement plan - II) project is being constructed at Fermilab to deliver $800\,MeV$ protons of $>1\,MW$ beam power to replace the present LINAC for the remainder of the existing accelerator complex. The new LINAC consists of a warm front end (WFE), 23 superconducting RF cryomodules (of 5 types), and a beam transfer line (BTL) to the existing complex.The accelerator physics group has a parallel project to create a digital twin (DT) of the PIP-II accelerator. We have coupled the EPICS controls to this DT and are developing both the DT and EPICS software in parallel. This will allow us to develop the EPICS software framework, the HMIs, sequences, high level physics applications, and other services for use in a fully functional control system.This presentation will detail the work that we have performed to date and show demonstrations of controlling and monitoring the status of the accelerator, as well as future plans for this work.

Hanlet, Pierrick [Fermilab]↗
DOE OSTI2025

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Review of low-cost self-driving laboratories in chemistry and materials science: the “frugal twin” concept

This review proposes the concept of a “frugal twin,” similar to a digital twin, but for physical experiments. Frugal twins range from simple toy examples to low-cost surrogates of high-cost research systems. For example, a color-mixing self-driving laboratory (SDL) can serve as a low-cost version of a costly multi-step chemical discovery SDL. Frugal twins already provide hands-on experience for SDLs with low costs and low risks. They can also offer as test beds for software prototyping (e.g., optimization, data infrastructure), and a low barrier to entry for democratizing SDLs. However, there is room for improvement. The true value of frugal twins can be realized in three core areas. Firstly, hardware and software modularity; secondly, purpose-built design (human-inspired vs. hardware-centric vs. human-in-the-loop); and thirdly state-of-the-art (SOTA) software (e.g., multi-fidelity optimization). We also describe the ethical benefits and risks that come with the democratization of science through frugal twins. For future work, we suggest ideas for new frugal twins, SDL educational course outcomes, and a classification scheme for autonomy levels.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Latent Twins

Over the past decade, scientific machine learning has transformed the development of mathematical and computational frameworks for analyzing, modeling, and predicting complex systems. From inverse problems to numerical partial differential equations (PDEs), dynamical systems, and model reduction, these advances have pushed the boundaries of what can be simulated. Yet they have often progressed in parallel, with representation learning and algorithmic solution methods evolving largely as separate pipelines. With Latent Twins, we propose a unifying mathematical framework that creates a hidden surrogate in latent space for the underlying equations. Whereas digital twins mirror physical systems in the digital world, Latent Twins mirror mathematical systems in a learned latent space governed by operators. Through this lens, classical modeling, inversion, model reduction, and operator approximation all emerge as special cases of a single principle. We establish the fundamental approximation properties of Latent Twins for both ordinary differential equations (ODEs) and PDEs and demonstrate the framework across three representative settings: (i) canonical ODEs, capturing diverse dynamical regimes; (ii) a PDE benchmark using the shallow-water equations, contrasting Latent Twin simulations with deep operator network and forecasts with a four-dimensional variational method baseline; and (iii) a challenging real-data geopotential reanalysis dataset, reconstructing and forecasting from sparse, noisy observations. Latent Twins provide a compact, interpretable surrogate for solution operators that evaluate across arbitrary time gaps in a single-shot, while remaining compatible with scientific pipelines such as assimilation, control, and uncertainty quantification. Looking forward, this framework offers scalable, theory-grounded surrogates that bridge data-driven representation learning and classical scientific modeling across disciplines.

Latent Twins↗
DOE OSTI2021

Virtual Framework for Science Federations with Instruments Access and Control

Experimental science workflows require federations of geographically dispersed science instruments and computing systems connected over a wide-area network. We develop a Virtual Infrastructure Twin (VIT) framework, which is a digital twin of the physical infrastructure that utilizes network virtualization and containerization technologies to support the development and testing of science workflow codes. Using VIT, we illustrate the access to instruments via EPICS system and the orchestration of containerized computations across federation computing systems. We also present a machine learning method to convert VIT throughput measurements to closely match the corresponding physical testbed measurements.

Rao, Nageswara↗
DOE OSTI2021

Cyber Protection of Grid-Connected Devices Through Embedded Online Security

Cybersecurity research regarding the electric power grid has primarily been focused on protecting the communication layer of grid-connected devices against cyber-attack threats. Although many developed methods have greatly reduced the effects of a cyber-attack on the vulnerabilities of grid-connected devices, discovering new vulnerabilities is inevitable and a constant threat. As a result, the overall reliability and security of network communications with regard to grid-connected devices is a concern. Here, this paper proposes a method that further secures a system by focusing on the control and hardware layer of grid-connected devices. The device’s controller firmware will be validated and authenticated using integrated device emulation resources prior to being activated to control the grid-connected device. This verification process is performed while the controller is online and actively controlling power flows related to the device. Therefore, an attack to the system through a malicious firmware patch would be detected by the online security and rejected while safely maintaining continuous and stable control of the device. This method integrates the concepts of firmware hot-patching, digital twins, and active monitoring into an overall cybersecurity protection system.

cybersecurity↗
DOE OSTI2025

BCTC LDRD - 2023 Slides for HQ

This presentation presents an overview of the LDRD project developing a digital twin for the solvent extraction laboratory at Idaho National Lab.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

A Graph Dynamical neural network approach for decoding dynamical states in ferroelectrics.

Ferroelectric materials such as BaTiO 3 show tremendous potential for emerging advances in memory devices, particular neuromorphic type devices. High density of memory can be obtained by stabilising polar domain walls at the nanoscale, regions of discontinuity between the well-defined polarization order parameter, but little is known about what controls their structure and dynamics in real nanoscale materials. Indeed, chiral polar domain walls have been observed in heterogeneous ferroelectrics, such as oxygen-deficient BaTiO 3 , but very little is known about how such polar-domains walls interact with defects. Indeed, a critical understanding of how dynamics of domain-walls depend on point-defects is crucial to create engineered ferroelectric memory devices. For this work, we perform large-scale simulations of nansocale domain-wall dynamics in pristine and defective BaTiO 3 using reactive force-field developed by us earlier (Phys. Chem. Chem. Phys., 2019, 21, 18240–18249), and capture their dynamical dependence on point defects using a graph dynamical neural-network approach, which we adapted to interrogate solids with well-defined order-parameters, and implemented using Pytorch based libraries. Our machine learning (ML) approach goes beyond the traditional post-processing methods to capture both spatial and temporal heterogeneities of large-scale molecular dynamics simulations of complex defective ferroelectric oxide materials. We crucially find that isolated oxygen vacancies introduce very localized spatial regions (~1–2 unit-cell in length) that show slow dipole relaxation due to formation of defect-dipoles, and that these defect-dipoles in turn slow the intrinsic dynamics of domain walls. Further, the roughness of domain walls, also influenced by vacancies, introduce dynamic heterogeneity along the domain-wall. As such we find a novel mechanism by which quenched disorder due to defects introduce dynamic heterogeneity thereby influencing response to external fields (particularly time varying fields) in a ferroelectric. Our study also emphasizes the need for creating digital twins of dynamical quantities to achieve autonomous in operando control of nanoscale switching.

42 ENGINEERING↗
DOE OSTI2021

Digital Engineering Sensor Architectures for Future Microreactor Builds

The development of new nuclear reactors continues to be high risk during the construction phase, with many programs exceeding their budget by 2–3×. This work entails an investigation of sensors that can be utilized during the construction of microreactors and their incorporation into a digital twin supporting the construction process. These sensors can be used to monitor construction progress, inform of variances from the expected design, and verify that the reactor is being built to the planned building information management model. This will ensure reactor equipment and components accurately interact through welding or additive manufacturing technologies. This study illustrates the importance of the digital engineering architecture for microreactor deployment.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Analysis of Automated Transit Network Systems with Battery-Electric Vehicles in Automated Mobility Districts: Preprint

The paper provides an overview of the insights and findings of the National Renewable Energy Laboratory's (NREL) ongoing research on the implementation of automated mobility districts (AMDs). AMD is a term coined by NREL to describe a geographically defined district or major activity center located in a dense urban setting with mobility applications provided by automated/autonomous vehicle (AV) systems spanning internal circulation and first-mile/last-mile connections to regional transportation hubs. Research over the past five years has focused on understanding the evolution of AMDs, beginning with demonstrations of automated shuttles prior to the pandemic, to more integrated on-demand mobility systems currently in initial stages of deployment. Initial insights and findings from earlier studies include the need for designation of a "jurisdiction having authority," a clear vision of a complete system to provide end-to-end mobility services, and the requisite intelligent infrastructure to complement AV technology. NREL's most recent Phase III research investigates station boarding/alighting (curb) issues, the full electrification of fleets, and the need for a systems engineering methodology (SEM) to properly analyze the complexities resulting from the convergence of automation, on-demand mobility, and electrification of the transit systems within the AMD. The paper reviews the findings of AMD research conducted during Phase I, II, and III, with special emphasis on Phase III results with respect to a descriptive example of the proposed SEM when a "digital twin" analytical model is used to simulate the transport fleet's battery-electric vehicle miles of travel and associated duty cycles through a rigorous analytical assessment with a comprehensive modeling process.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Added value of site load measurements in probabilistic lifetime extension: a Lillgrund case study

Site-specific fatigue estimation is an essential part of wind turbine lifetime extension, with various methods depending on data availability. The present study compares probabilistic lifetime extension assessment results for rotor blades with and without load measurements. It also addresses two key questions in such assessments: the applicability of the Frandsen model for estimating waked turbulence under complex and mixed wake conditions and the extrapolation of mid-term data over longer time periods. The case study wind turbine is SWT-2.3-93, located at the edge of the Lillgrund wind farm, situated in the Øresund Strait between Denmark and Sweden. The turbine is extensively instrumented, with 5 years of data available from its supervisory control and data acquisition (SCADA) system. Although the Frandsen turbulence estimates deviate in a different manner from measurements at below- and above-rated mean wind speeds, the model remains a conservative approach for fatigue load prediction and reliability. In the current case study, the site-specific assessment using strain gauge measurements yields a 33 % higher annual fatigue reliability index after 35 years compared to a scenario based on the Frandsen estimation combined with ambient environmental data and a generic aeroelastic model. The results also demonstrate that the sensitivity of fatigue reliability to load uncertainty is negligible when load measurements are used directly but relatively high when relying on the Frandsen model in combination with a generic aeroelastic model. Overall, the high variability of the lifetime extension in different scenarios of data availability and accuracy shows the importance and added value of high-quality measurements combined with wind-farm-level SCADA and a model updated in real time (digital twins).

17 WIND ENERGY↗
DOE OSTI2022

Development of a nearly autonomous management and control system for advanced reactors

This presentation discusses the development of a Nearly Autonomous Management and Control (NAMAC) system for advanced reactors. This presentation first introduces the NAMAC-enabled plant control. Next, this presentation introduces major technologies of implementing NAMAC, including operational workflow, digital twin, and advanced machine learning algorithms. To demonstrate the capability of the NAMAC system, NAMAC is connected with a simulator of the Experimental Breeder Reactor II, where NAMAC is activated to provide recommendations during a single loss of flow accident.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

A general Bayesian algorithm for the autonomous alignment of beamlines

Autonomous methods to align beamlines can decrease the amount of time spent on diagnostics, and also uncover better global optima leading to better beam quality. The alignment of these beamlines is a high-dimensional expensive-to-sample optimization problem involving the simultaneous treatment of many optical elements with correlated and nonlinear dynamics. Bayesian optimization is a strategy of efficient global optimization that has proved successful in similar regimes in a wide variety of beamline alignment applications, though it has typically been implemented for particular beamlines and optimization tasks. In this paper, we present a basic formulation of Bayesian inference and Gaussian process models as they relate to multi-objective Bayesian optimization, as well as the practical challenges presented by beamline alignment. We show that the same general implementation of Bayesian optimization with special consideration for beamline alignment can quickly learn the dynamics of particular beamlines in an online fashion through hyperparameter fitting with no prior information. We present the implementation of a concise software framework for beamline alignment and test it on four different optimization problems for experiments on X-ray beamlines at the National Synchrotron Light Source II and the Advanced Light Source, and an electron beam at the Accelerator Test Facility, along with benchmarking on a simulated digital twin. We discuss new applications of the framework, and the potential for a unified approach to beamline alignment at synchrotron facilities.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Cybersecurity Enhancement in Digital Substations: Hidden Markov Model-Based Smart Cyber Switching and Threat Response

The rising incidence of cyber-attacks on critical infrastructure and power grids poses significant threats to the stability and reliability of electrical substations, with potentially devastating consequences such as extended blackouts. This paper introduces an advanced cybersecurity framework aimed at safeguarding IEC 61850-based substations through the integration of software-defined networking (SDN) and digital twin (DT) technologies. The proposed DT-based framework employs smart cyber switching (SCS) for proactive threat mitigation and concurrent intelligent electronic device (CIED) for swift system restoration, thereby maintaining continuous operational integrity and robust cybersecurity defenses. Central to this framework is the adaptive port controller (APC), which enables dynamic port management to adapt to evolving threats, and an intrusion detection system (IDS) designed to detect and neutralize malicious attacks on IEC 61850-based sampled value (SV) and generic object-oriented substation event (GOOSE) messages within the substation’s communication network. Further, novel predictive intrusion detection and response (PIDR) algorithm is implemented on a digital substation (DS) to predict the best route to be taken by the attacker. The efficacy of these comprehensive cybersecurity frameworks is validated through rigorous simulations and a hardware-in-the-loop (HIL) testbed, showcasing the system’s ability to sustain substation operations amidst cyber-attacks.

Digital substation↗
DOE OSTI2024

Challenges and Technology-Driven Opportunities for Safeguarding Microreactors

Nuclear microreactors (MRs) represent a new class of reactors characterized by their compactness, portability, and low power output. These features enable MRs to supply electricity and process heat to remote areas like military bases; inaccessible locations; small grids, such as on islands; or disaster impacted areas. Compared to traditional light water reactors, MRs have a unique set of attributes that need to be considered for the implementation of safeguard strategies. Current safeguard methodologies are reactor technology specific and are employed on large, stationary reactors where there is easy access by safeguards inspectors and where safeguard equipment can be easily installed and retrofitted. While there are numerous benefits to MRs, their compact size, portability, scalability, and operational lifetime create challenges to the traditional safeguard approaches, thus needing novel safeguard strategies. Here, this paper addresses the unique challenges posed by MRs to the international nuclear safeguards regime, including limited human resources, and explores how technology advancements can help mitigate these challenges. Specifically, it examines novel technologies that could contribute to establishing a comprehensive safeguards framework for MRs. These safeguards-enabling technologies encompass safeguards by design, remote sensing and monitoring technologies, applications of artificial intelligence and machine learning algorithms, utilization of digital twins, and system of systems assessments. While each of these safeguards-enabling technologies offers partial solutions to the challenges posed by MRs for the international safeguards regime, none of them alone can entirely address these challenges. Consequently, a combination of the safeguards-enabling technologies outlined in this paper is recommended to establish a robust safeguards regime for MRs.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2026

Technical Report for Bayesian Optimization and Reinforcement Learning for Beam Polarization Increase in the BNL Hadron Injectors

This project developed and evaluated physics-informed Bayesian learning and machine learning (ML)-based optimization methods for improving beam polarization preservation in the BNL hadron injector chain. The work focused on uncertainty-aware digital twin modeling, Bayesian calibration of accelerator simulations using beam measurements, and data-efficient optimization strategies including Bayesian optimization and reinforcement learning. These methods were applied to injector tuning and RF control problems in realistic accelerator settings to support improved operational robustness and readiness for RHIC operations and future Electron–Ion Collider facilities. No subject inventions were disclosed under this award.

43 PARTICLE ACCELERATORS↗