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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

A Theoretical Open Architecture Framework and Technology Stack for Digital Twins in Energy Sector Applications

Digital twin is often viewed as a technology that can assist engineers and researchers make data-driven system and network-level decisions. Across the scientific literature, digital twins have been consistently theorized as a strong solution to facilitate proactive discovery of system failures, system and network efficiency improvement, system and network operation optimization, among others. With their strong affinity to the industrial metaverse concept, digital twins have the potential to offer high-value propositions that are unique to the energy sector stakeholders to realize the true potential of physical and digital convergence and pertinent sustainability goals. Although the technology has been known for a long time in theory, its practical real-world applications have been so far limited, nevertheless with tremendous growth projections. In the energy sector, there have been theoretical and lab-level experimental analysis of digital twins but few of those experiments resulted in real-world deployments. There may be many contributing factors to any friction associated with real-world scalable deployment in the energy sector such as cost, regulatory, and compliance requirements, and measurable and comparable methods to evaluate performance and return on investment. Those factors can be potentially addressed if the digital twin applications are built on the foundations of a scalable and interoperable framework that can drive a digital twin application across the project lifecycle: from ideation to theoretical deep dive to proof of concept to large-scale experiment to real-world deployment at scale. This paper is an attempt to define a digital twin open architecture framework that comprises a digital twin technology stack (D-Arc) coupled with information flow, sequence, and object diagrams. Those artifacts can be used by energy sector engineers and researchers to use any digital twin platform to drive research and engineering. This paper also provides critical details related to cybersecurity aspects, data management processes, and relevant energy sector use cases.

Gourisetti, Sri, Nikhil Gupta (ORCID:0000000188778↗
DOE OSTI2020

Safety-Related Instrumentation and Control Pilot Upgrade (Initial Scoping Phase Implementation Report)

This research report (1) describes the process followed and products developed during the SR I&C Pilot Project Initial Scoping Phase, and (2) captures lessons learned. Exelon Generation and LWRS collaborated to develop a Digital Transformation Strategy as part of a larger Advanced Concept of Operations. The proposed SR I&C Pilot Upgrade provides a foundation stone for this Digital Transformation that will improve plant safety, reliability, and operational performance while lowering plant Total Cost of Ownership (TCO). Initial Scoping Phase activities for this Pilot Project have been performed in accordance with industry processes that have been adapted to better support digital upgrades. These processes include IP-ENG-001, Standard Design Process (SDP), NISP-EN-04, Standard Digital Engineering Process (SDEP), and Electric Power Research Institute (EPRI) Report 3002011816, Digital Engineering Guide (DEG). Completing Initial Scoping Phase Engineering and Operations, Licensing, and Project Management Activities was necessary to sufficiently bound the scope, schedule, and estimated cost of the Project to enable utility management to authorize moving into the Conceptual Design Phase. A significant finding of the Business Case Analysis (BCA) methodology developed and applied as part of this effort was that the growth rate of material costs for sustaining the operation of obsolete SR I&C equipment is accelerating. This directly contributed to the Project Economic Analysis created to justify continuing the Project. Project Initial Scoping Phase lessons learned have also been captured to assist the larger industry in understanding the Digital Transformation Strategy and SR I&C Pilot Project Initial Scoping Phase efforts. This is in keeping with the public/private partnership that has been established between the Department of Energy (DOE) and Exelon for this effort with engagement from the NRC. By addressing first-of-a-kind (FOAK) risks and capturing lessons learned, the SR I&C Pilot Upgrade Project addresses technical, regulatory, and business risks to enable subsequent implementers of similar upgrade.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Safety-Related Instrumentation & Control Pilot Upgrade Initiation Phase Implementation Report

This research report (1) describes the process followed and products developed during the SR I&C Pilot Project Initial Scoping Phase, and (2) captures lessons learned. Exelon Generation and LWRS collaborated to develop a Digital Transformation Strategy as part of a larger Advanced Concept of Operations. The proposed SR I&C Pilot Upgrade provides a foundation stone for this Digital Transformation that will improve plant safety, reliability, and operational performance while lowering plant Total Cost of Ownership (TCO). Initial Scoping Phase activities for this Pilot Project have been performed in accordance with industry processes that have been adapted to better support digital upgrades. These processes include IP-ENG-001, Standard Design Process (SDP) [Reference 2], NISP-EN-04, Standard Digital Engineering Process (SDEP) [Reference 3], and Electric Power Research Institute (EPRI) Report 3002011816, Digital Engineering Guide (DEG). Completing Initial Scoping Phase Engineering and Operations, Licensing, and Project Management Activities was necessary to sufficiently bound the scope, schedule, and estimated cost of the Project to enable utility management to authorize moving into the Conceptual Design Phase. A significant finding of the Business Case Analysis (BCA) methodology developed and applied as part of this effort was that the growth rate of material costs for sustaining the operation of obsolete SR I&C equipment is accelerating. This directly contributed to the Project Economic Analysis created to justify continuing the Project. Project Initial Scoping Phase lessons learned have also been captured to assist the larger industry in understanding the Digital Transformation Strategy and SR I&C Pilot Project Initial Scoping Phase efforts. This is in keeping with the public/private partnership that has been established between the Department of Energy (DOE) and Exelon for this effort with engagement from the NRC. By addressing first-of-a-kind (FOAK) risks and capturing lessons learned, the SR I&C Pilot Upgrade Project addresses technical, regulatory, and business risks to enable subsequent implementers of similar upgrades.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

A Real2Sim Digital Twin Pipeline for Photorealistic Robot Simulation: Evaluating VLA Policy Deployment on a Bimanual Mobile Robot

Digital twins that are automatically constructed from robot sensor data offer a promising pathway for scalable Real2Sim and Sim2Real transfer. However, it remains an open question whether photorealistic reconstruction alone is sufficient to support reliable deployment of vision-language-action (VLA) policies. We present a generative-AI-assisted Real2Sim pipeline that generates simulation-ready digital twins from real-world RGB observations with minimal manual intervention. The pipeline uses prompted segmentation to isolate scene components and a generative 3D model to directly produce simulation assets, eliminating the need for traditional multi-view reconstruction or manual 3D modeling.\r\nTo evaluate simulation fidelity, we deploy and compare policies from two VLA models in both the real robot and the reconstructed\r\nsimulation under identical tasks and initial conditions. We compare joint-level action trajectories and analyze how divergence evolves over time in closed-loop execution. Although the reconstructed environments are visually accurate, we observe increasing trajectory divergence during closedloop operation. These results indicate that photorealistic reconstruction alone is insufficient to preserve closed-loop control behavior\r\nin VLA policies, particularly in contact-rich manipulation settings where small perceptual errors compound over time.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Human-System Interface Style Guide for ACORN Digital Control System

The purpose of this style guide is to assist developers in designing effective and consistent-looking user interfaces for accelerator control rooms. A similar purpose is to help developers avoid the creation of user interfaces that needlessly stray from the accepted standard set forth in this document. This way, all interfaces combined will look congruous. This is especially beneficial for development that spans multiple years by many different contributors. This document is intended as a ready reference source for all user interface design for the Fermilab accelerator complex.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

DeepLynx Ecosystem 2025

Poor data integration and governance continue to plague complex engineering projects, resulting in missed cost, schedule, and performance targets. Departments operate in isolated systems with manual data exchange, creating fragmented information that compounds errors and leads to significant delays and cost overruns. The DeepLynx ecosystem addresses these challenges through an open-source, modular data management platform that transforms fragmented project data into an integrated digital thread. Built on a federated microservice architecture, the ecosystem comprises seven specialized tools centered around DeepLynx Nexus, a unified data catalog with hierarchical organization and graph-based navigation capabilities. The ecosystem includes: DeepLynx Stream for real-time timeseries data ingestion from industrial sources; DeepLynx Ingest for governed data uploads with formal review workflows; DeepLynx Lattice for ontology-based entity and relationship extraction; DeepLynx Run for workflow orchestration and secure AI/ML compute; DeepLynx Visualize for 3D digital twin visualization; and DeepLynx Insight for AI-assisted document analysis with traceable, grounded responses. Deployable in cloud, on-premise, or hybrid environments using containerized Docker applications and Helm charts, the DeepLynx ecosystem provides flexible infrastructure that adapts to organizational requirements. By consolidating project data into a unified data lake with role-based access controls and OAuth2 authentication, DeepLynx enables digital thread and digital twin capabilities that improve decision-making, reduce risk, and support complex engineering workflows throughout the project lifecycle.

42 - ENGINEERING↗
DOE OSTI2020

Reconfigurable Real-Time Power Grid Emulator for Systems With High Penetration of Renewables

Novel power system control and new utility devices need to be tested before their actual deployment to the power grid. To assist with such a testing need, real-time digital emulators such as RTDS and Opal-RT can be used to connect to the physical world and form a hardware in the loop (HIL) emulation. However, due to the limitations of today's computational resources, the accuracy and fidelity suffer from different levels of model reductions in purely digital simulations. CURENT has developed a reconfigurable electric grid hardware testbed (HTB) to overcome the limitations of digital emulators. The HTB has been used to develop measurement, control, modeling, and actuation techniques for a national grid with a high penetration of renewables. The power electronic-based system includes emulators for synchronous generators; photovoltaics with grid-interfacing inverter; wind turbines; induction motor loads, ZIP loads, power electronic loads; batteries; ac and dc transmission lines; short circuit faults and grid relay protection; and a multiterminal HVDC overlay including power electronics interfaces. The system contains real elements of power flow, measurement, communication, protection, and control that mimic what would be seen in an actual electric grid. This paper presents an overview of the HTB and several scenarios that have been run to determine control and actions needed for the future power grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Adaptive Dynamic Digital Twin for Test Scenario Generation

Vehicle testing has been an important part in the development of both highly automated vehicles (HAV) and advanced driving assistant systems (ADAS). Obtaining a good representation of the Vehicle Under Test (VUT) is crucial for test scenario library generation (TSLG). Current vehicle testing methods often involve calibrating car-following models using vehicle trajectory data to create static representations that cannot be dynamically updated. For instance, when multiple vehicle trajectories are collected, it is difficult to automatically determine whether a new trajectory improves the model's representativeness or degrades its accuracy. In this paper, we introduce a dynamically updated digital twin modeling framework featuring an adaptive mechanism that evaluates new trajectory data. This mechanism can decide whether to incorporate newly collected data into the current model or create a separate digital twin model when the trajectory significantly differs from prior data. Vehicle location, speed, and acceleration extracted from the newly collected trajectory data are used to support the dynamic update decision. By integrating this digital twin model into the test library generation process, we demonstrate its ability to assist in generating test libraries while effectively handling newly collected data.

Chen, Hanlin [ORNL] (ORCID:0000000165087715)↗
DOE OSTI2026

Data for Autonomous Transportation Awareness: Data Exchange Use Cases, Standards, and Barriers

This report examines the critical data exchanges between automated vehicle (AV) service providers and the cities and municipalities they serve. It assists municipal authorities in navigating the often complex and real-time digital data exchanges needed to support AV mobility services, with emphasis in three areas: (1) critical safety data for broad-area situational awareness of hazards typically associated emergency dispatch or roadway work zones; (2) performance metrics of AV services that inform the quantity, quality, spatial extents, and impact on the roadway network; and (3) regulatory and policy information, particularly dynamic information that governs how AV services interact with the roadway network, with emphasis on curb space. The report reviews existing practices and emerging protocols and standards and identifies key gaps to address moving forward.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Clarification of creep deformation mechanism in heat-affected zone of 9Cr steels with In Situ experiments

This work quantified nonuniform creep deformation across the heterogeneous heat-affected zone (HAZ) of Grade 91 steel with sophisticated experiments, including an electric-thermal finite element model–assisted Gleeble thermomechanical simulation and a high-temperature creep testing with in situ digital image correlation (DIC). High temperature creep properties of HAZ sub-zones were quantitatively measured by the DIC. Furthermore, by utilizing peak temperature, hardness, local creep strain, and underlying microstructures, creep deformation mechanisms in HAZ were further understood. DIC measurements reveal a creep-vulnerable zone (CVZ) exposed to a peak temperature of 932°C (close to A C3 ) in the intercritical HAZ experienced the fastest creep strength degradation instead of the soft zone with the lowest hardness prior to creep. The significantly reduced precipitation strengthening from misplacement of undissolved and coarsened M 23 C 6 carbides led to a faster recrystallization of tempered martensite in the CVZ. Weak untransformed tempered martensite (ferrite grains) stabilized by local Cr enrichment from dissolved M 23 C 6 also harmed the CVZ's creep resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Investigating the Vulnerabilities of the Direct Transfer Trip Scheme for Network Protector Units in the Secondary Networks of Electric Power Distribution Grids

Network protector units (NPUs) are crucial parts of the protection of secondary networks to effectively isolate faults occurring on the primary feeders. When a fault occurs on the primary feeder, there is a path of the fault current going through the service transformers that causes a negative flow of current on the NPU connected to the faulted feeder. Conventionally, NPUs rely on the direction of current with respect to the voltage to detect faults and make a correct trip decision. However, the conventional NPU logic does not allow the reverse power flow caused by distributed energy resources installed on secondary networks. The communication-assisted direct transfer trip logic for NPUs can be used to address this challenge. However, the communication-assisted scheme is exposed to some vulnerabilities arising from the disruption or corruption of the communicated data that can endanger the reliable operation of NPUs. This paper evaluates the impact of the malfunction of the communication system on the operation of communication-assisted NPU logic. To this end, the impact of packet modification and denial-of-service cyberattacks on the communication-assisted scheme are evaluated. The evaluation was performed using a hardware-in-the-loop (HIL) co-simulation testbed that includes both real-time power system and communication network digital simulators. This paper evaluates the impact of the cyberattacks for different fault scenarios and provides a list of recommendations to improve the reliability of communication-assisted NPU protection.

direct transfer trip↗
DOE OSTI2021

Digital-twin-based improvements to diagnosis, prognosis, strategy assessment, and discrepancy checking in a nearly autonomous management and control system

We report the Nearly Autonomous Management And Control System (NAMAC) is a comprehensive control system to assist plant operations by furnishing control recommendations to operators in a broad class of situations. This study refines a NAMAC system for making reasonable recommendations during complex loss of flow (LOF) scenarios with a validated EBR-II simulator, digital twins improved by machine-learning algorithms, a multi-attribute decision-making scheme, and a discrepancy checker for identifying unexpected recommendation effects. The performance of each NAMAC component is assessed, while the capability of NAMAC is demonstrated and evaluated in a class of LOF scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

NPP Simulators for Coupled Thermal and Electric Power Dispatch

The Light Water Reactor Sustainability (LWRS) program within the United States Department of Energy supports extending the operation of the U.S. commercial nuclear power plant (NPP) fleet. Within the LWRS program, the Flexible Plant Operation and Generation (FPOG) Pathway works to diversify the revenue streams of light water reactors (LWRs) by opening opportunities for the co-generation of non-electric products in addition to supplying electrical power to the grid. Recent events have added greater motivation to these efforts. For example, the recent Inflation Reduction Act (IRA) passed by the U.S. federal government offers substantial tax incentives for producing clean hydrogen, the technology readiness level of dispatchable and high-efficiency hydrogen production has dramatically increased in a short time, and societal response to world climate change is driving a transition away from fossil fuels. Producing hydrogen with maximum efficiency using nuclear power requires dispatching both electrical and thermal power from the nuclear plant to the hydrogen plant, so testing concepts of operations for combined electrical and thermal power dispatch (TPD) from an NNP to a hydrogen plant is of interest. This report documents achievement of the Light Water Reactor Sustainability (LWRS) program milestone “Install and demonstrate a vendor-developed simulator on the Human Systems Simulation Laboratory (HSS) for dispatch of LWR electrical power to a close-coupled electrolysis plant” with a due date of Dec. 22, 2022. Several factors provide motivation for this effort. Coupling the power generation deck of a nuclear power plant to a hydrogen production facility introduces new possibilities for operational transients that must be addressed. In particular, the performance of the integrated system during startup and shutdown of the hydrogen production facility, as well as offnormal conditions, need to be evaluated to ensure there are no adverse effects on the operation of the existing NPP. The concept of operations involving the NPP, the hydrogen plant, and the electric power grid must be tested using NPP simulators and operating procedures that have been modified for TPD operations. These tests must also include dynamic simulations of the coupled tertiary thermal and electric loads as well as coordinated activities with NPP operators, tertiary load operators and grid power coordinators. The report summarizes progress in developing and testing full-scope NPP simulators at the HSSL, including a generic BWR simulator from GSE Systems, Inc. and generic PWR simulator from Westinghouse. In the case of the TPD-GBWR Simulator from GSE Systems, Inc., a BWR is thermally coupled to a high temperature electrolysis (HTE) plant that produces hydrogen and oxygen from de-ionized water. The hydrogen plant is not explicitly simulated but only included as a transient heat sink. A thermal power dispatch (TPD) system transfers heat between the steam systems at the BWR and the hydrogen plant. Operational results from two versions of the modified simulator are presented. The first version uses synthetic oil as a heat transfer fluid in a closed delivery heat loop (DHL) that generates steam at the hydrogen plant. The second version uses steam as the heat transfer fluid in a delivery steam line (DSL) to provide steam to the hydrogen plant. For both versions, the estimated thermal power delivery distance is approximately one kilometer. The amount of thermal power dispatched in the simulators is 15% of the total reactor thermal power such that the simulators provide a tool to study the feasibility of coupling a BWR to industrial processes that benefit from a combination electrical and thermal power dispatch. Ongoing work within a CRADA is also developing a full-scope PWR simulator provided by Westinghouse for both thermal and electric power coupling. This simulator is based on a PWR plant with two three-loop Westinghouse reactors. Westinghouse PWRs are sufficiently similar that a simulator of a three-loop reactor is an appropriate representation for two-loop and four-loop PWR reactors. The three-loop simulator will initially be modified for close-coupling to a 100 MW HTE hydrogen production plant that will require approximately 25 MW of thermal power while operating at its maximum rated capacity. The simulator testing will include full coupling to dynamic simulations of a hydrogen production plant and a representative bulk electric grid. The simulator provided by Westinghouse is similar to the GPWR simulator that INL has already obtained from GSE Systems but has a few important added benefits. First, the Westinghouse simulator is based on digital controls and has additional screens that can be called up to show parameter trends to assist operators in decision-making. The Westinghouse simulator also has upgrades to the controls and hardware representations, such as valve actuators, that make it more realistic and flexible in terms of accurately sim

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

On the efficacy of post-build thermomechanical treatments to improve properties of Zirconium fabricated using ultrasonic additive manufacturing

Here, hot-isostatic pressing has been applied to Zirconium plate fabricated using the ultrasonic additive manufacturing (UAM) technique to enhance interfacial bond quality. Specimens heated to 800 C for 1 h at 100 MPa pressure showed grain growth across many prior foil-to-foil interfaces, thereby increasing foil adhesion. In addition to the material softening induced by a loss of Hall-Petch strengthening, premature failure of specimens loaded parallel to the build direction was observed. Premature specimen failure was attributed to the local delamination at prior foil-to-foil boundaries where grain growth was pinned by Ti impurities introduced during the UAM process via the interaction between a Ti-alloy buffer foil and the welded Zr-foils underneath. In addition, the presence of Ti along select foil interfaces resulted in the nucleation and growth of secondary (Zr,Ti)(Fe,Cr) laves phases during higher-temperature thermomechanical processing. Using a combination of micro-scale X-ray computed tomography, fractography, and in-situ digital image correlation, the effect of defects along prior foil-to-foil boundaries was revealed as delamination-assisted plasticity accelerated specimen failure in preferred tensile orientations. These findings underscore the importance of impurity control when optimizing weld quality of higher-strength material systems using ultrasonic welding.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Hahn-Echo Assisted Deconvolution (HEAD)

This repository contains the Bruker pulse program for acquire 2D HEAD data in addition to the C++ program used for data processing. Data must be acquired with identical digital resolution in both dimensions. The resulting 2D spectrum is converted to a ASCII file using the Topspin 'totxt' command. This file can be handled by the HEAD_processing program.

Perras, Frederic [Ames National Laboratory; Ames N↗
DOE OSTI2024

Achieving Cyber-Resilience for Power Systems using a Learning, Model-Assisted Blockchain Framework

The secure integration and management of distributed energy resources (DER) and power aggregators in the electric grid requires secure communications and a physics-aware Command and Control (C2) strategy. A Blockchain (BC)-based overlay network was developed to provide a security layer for the existing power grid network that mitigates risks in current and legacy network and C2 protocols. By integrating a Model-Assisted Machine Learning (MAML) framework with a Secure Blockchain Overlay Network (SBON) a defense-in-depth strategy was achieved. In our approach, the MAML framework leveraged a smart contract framework to gather network data and learn the dynamics of DER to develop detection strategies for attacks targeting sensors and actuators used by DER. The MAML framework learned dynamical systems models for individual DERs to detect sensor attacks. For DER we utilized a Digital Twin (DT) to accelerate the learning process for a model resistant to stealthy attacks. The project created DT for PV inverters and BESS. The DTs were coupled with a model-assisted, data-driven learning of DER behavior. Specifically, we evaluated architectures for model-based learning with model-free fine-tuning. Additionally, differential privacy techniques were used to obfuscate data, while still allowing the computation of attack detection results based on obfuscated data. The SBON developed leverages a private permissioned blockchain network orchestrated with the Hyperledger Fabric framework. To connect the cyber world, which orchestrates the blockchain fabric, and the physical world where the power network resides, we developed a system implementation to enable the secure interaction of the physical world and the abstracted blockchain.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Role of slip in hydrogen-assisted crack initiation in Ni-based alloy 725

We conduct in situ tensile straining experiments to investigate the role of hydrogen and slip in crack initiation in nickel-based alloy 725. Our experiments reveal no tendency for hydrogen to enhance localized slip and no necessity of slip for crack initiation. We use electrochemical charging to introduce hydrogen into samples, melt extraction to measure hydrogen content, and digital image correlation to analyze localized plastic strains during in situ tensile tests in a scanning electron microscope. Cracks initiate both in regions with and without nearby localized slip. Moreover, the fraction of cracks initiating with no nearby slip is greater at higher hydrogen content. Slip-assisted crack initiation generally occurs at locations where intergranular slip is arrested, especially at intersections of slipping coherent twin boundaries with thin twin lamellae. Cracks that initiate without nearby slip occur at a wider variety of microstructural features, including inclusions, triple junctions, and surface flaws.

36 MATERIALS SCIENCE↗
DOE OSTI2024

AutoCSM

A template system-of-systems modeling approach for automating the development, deployment, and integration of cooling system models (CSMs) for supercomputing facilities within the ExaDigiT framework. AutoCSM is a Python-based framework to assist in CSM developers in accelerating the creation and deployment of system-level thermal-hydraulic CSMs. The intention is for this tool specifically to help standardize digital twin workflows for ExaDigiT. However, this tool can be used independent of ExaDigiT (and even other systems besides CSMs).

Greenwood, MichaelScott [Oak Ridge National Labora↗