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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

An implementation of the phase-field model based on coupled thermomechanical finite element solvers for large-strain twinning, explicit dynamic fracture and the classical Stefan problem

The implementation of a phase-field model in finite elements usually requires significant expertise and involves the development of a user element with additional degrees of freedom. An alternative implementation of the phase-field model within a thermo-mechanical finite element simulation package was presented in (Cho et al 2012 Int. J. Solids Struct. 49 1973–1992), where the phase-field variable is treated as the temperature degree of freedom. However, this approach has only been used for small strain phase-field modelling of martensitic transformations and quasistatic phase-field modelling of fracture. Here, we present a phase-field finite element implementation via the temperature degree of freedom for several additional cases from the literature: (i) the large-strain phase-field description of deformation twinning presented in (Clayton and Knap 2011 Physica D 240 841–858), (ii) phase-field description of brittle fracture with inertial effects based on the theory from (Molnár and Gravouil 2017, Finite Elem. Anal. Des. 130 27–38) and (Miehe et al 2010 Int. J. Numer. Methods Eng. 83 1273–1311) and (iii) the classical Stefan problem of solidification presented in (Mackenzie and Robertson 2002 J. Comput. Phys. 181 526–544). The last problem involves the temperature and phase-field variables as unknowns.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A digital twin based on OpenFAST linearizations for real-time load and fatigue estimation of land-based turbines

Monitoring a wind turbine requires intensive instrumentation, which would be too cost-prohibitive to deploy to an entire wind plant. This work presents a technique that uses readily available measurements to estimate signals that would otherwise require additional instrumentation. This study presents a digital twin concept with a focus on estimating wind speed, thrust, torque, tower-top position, and loads in the tower using supervisory control and data acquisition (SCADA) measurements. The model combines a linear state-space model obtained using OpenFAST linearizations, a wind speed estimator, and a Kalman filter algorithm that integrates measurements with the state model to perform state estimations. The measurements are: top acceleration, generator torque, pitch, and rotational speed. The article extends previous work that derived the linear state-space model using a different method. The new implementation, based on OpenFAST linearization capability, allows for a systematic extension of the method to more states, inputs, outputs, and to the offshore environment. Results from the two methods are compared, and the validation is made with additional measurements using the GE 1.5-MW turbine located at the National Renewable Energy Laboratory test site. Real-time damage equivalent loads of the tower bottom moment are estimated with an average accuracy of approximately 10%. Overall, the results from this proof of concept are encouraging, and further application of the model will be considered.

17 WIND ENERGY↗
DOE OSTI2021

A mesoscopic digital twin that bridges length and time scales for control of additively manufactured metal microstructures

We present our recent development of an integrated mesoscale digital twin (DT) framework for relating processing conditions, microstructures, and mechanical responses of additively manufactured (AM) metals. In particular, focusing on the laser powder bed fusion technique, we describe how individual modeling and simulation capabilities are coupled to investigate and control AM microstructural features at multiple length and time scales. We review our prior case studies that demonstrate the integrated modeling schemes, in which high-fidelity melt pool dynamics simulations provide accurate local thermal profiles and histories to subsequent AM microstructure simulations. We also report our new mechanical response modeling results for predicted AM microstructures. In addition, we illustrate how our DT framework has been validated through modeling–experiment integration, as well as how it has been practically utilized to guide and analyze AM experiments. Finally, we share our perspectives on future directions of further development of the DT framework for more efficient, accurate predictions and wider ranges of applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The structures of mcgovernite and carlfrancisite reconsidered: static disorder or ordered defects and twinning?

Here, the minerals mcgovernite and carlfrancisite possess an extraordinary rhombohedral unit cell [mcgovernite: a = b = 8.206 Å and c = 204.118 Å, with the complex formula unit M 2+ 19 Zn 3 (OH) 21 (AsO 3 )(AsO 4 ) 3 (SiO 4 ) 3 (M = Mn, Mg, Zn); carlfrancisite similar]. Hawthorne [(2018), Mineral. Mag. 82, 1101–1118] reported a single-crystal study using a centrosymmetric model ($R\bar{3}c$) containing disorder on three cationic sites and an AsIII lone-pair site for both mcgovernite and carlfrancisite. A solution of the structure of mcgovernite from high-resolution synchrotron powder diffraction data suggests a reinterpretation of the crystal structures of mcgovernite and carlfrancisite as noncentrosymmetric R3c with ordered planar defects which allows for merohedral twinning.

carlfrancisite↗
DOE OSTI2022

Digital Twin of an ANPC inverter with integrated Design-For-Trust

Reducing costs and increasing manufacturing output while creating reliable products are three essential components needed to keep a business competitive. In the past, having an asset that could address these three challenges at the same time would be challenging. However, recent advances in computer processing capabilities coupled with increases to network speeds allowed such a system to become possible; and this is known as a Digital Twin (DT), which represents a virtual copy of a production system or a product. Here, this work exhibits a DT application of an Active Neutral Point Clamped (ANPC) inverter using a controller. The controller emulates the ANPC responses of a new Digital Signal Processing (DSP) firmware and validates this new firmware by using Design-For-Trust (DFTr) characteristics. If the new firmware is malicious, then it should be rejected, thus adding preemptive protection measures for inverter based distributed energy resources.

cybersecurity↗
DOE OSTI2024

Data-Driven Digital Twin for Reliability Assessment of DC/DC Buck Converter

In commercial applications, the operation of DC/DC converters significantly impacts overall system performance and long-term reliability. This study introduces a data-driven digital twin (DT) approach for estimating critical degradation parameters of DC/DC BUCK converter under steady-state condition. Initially, a circuit-level MATLAB/Simulink digital model (DM C ) is refined against a hardware prototype’s switching model dataset using offline particle swarm optimization. The optimized digital model’s steady-state response is then verified with its average model response while varying the duty and load. Subsequently, degradation profiles are imposed on the inductor, capacitor, MOSFET in the DMC. A large dataset is generated from this model, allowing training, validation, and testing of machine learning (ML) models for component health regression tasks. The proposed method employs random forest ML models, achieving impressive regression results with a squared R value as high as 0.99978 and a root mean square error of 4.2× 10 –6 . The method is further validated on a medium power level DC/DC BUCK prototype with varying load conditions, and includes the analysis of MOSFET’s on-resistance under degradation conditions. This data-driven DT method shows promise for identifying parasitic degradation and ohmic loss parameters, enhancing converter reliability assessments in a non-invasive, generalized, and computationally efficient manner.

14 SOLAR ENERGY↗
DOE OSTI2020

A Digital Twin Approach to Study Additive Manufacturing Processing Using Embedded Optical Fiber Sensors and Numerical Modeling

One of the major challenges for metal-powder-based additive manufacturing is measuring and mitigating residual strain induced during the manufacturing processes. This article reports distributed fiber optic sensors embedded in Inconel alloy components as experimental means to validate numerical models of additive manufacturing process. Electroplating was used to deposit a metal protective jacket onto standard telecom single-mode fibers for strain measurements, Fiber sensors were embedded in an Inconel alloy substrate using the laser engineered net shaping (LENS) process. Here by using a Rayleigh-scattering optical frequency domain reflectometer (OFDR), temperature changes, and residual strain in the metal substrate were monitored with 5 mm spatial resolution during the LENS process. Using finite element analysis, temperature and strain profiles induced by the LENS deposition processes were also numerically studied. Discrepancies between the simulated temperature and strain profiles and those measured directly were less than 10%. Results presented in this article demonstrates a digital twin approach to fuse modeling results with distributed fiber sensor measurement data to study additive manufacturing process toward design and fabrication process optimization.

36 MATERIALS SCIENCE↗
DOE OSTI2024

On Quantum Rainbows: Density Operator in the Frequency-Bin Representation for Entangled Twin-Photons Generated With Sub-Threshold Microcombs

Kerr optical frequency combs are generated by pumping a high-Q integrated microresonator with a resonant laser. Below threshold, the pump laser field mediates the phenomenon of spontaneous four-wave mixing, where two pump photons are symmetrically up- and down-converted as twin photons that can be entangled across up to tens of eigenmodes in the spectral domain. While these room-temperature integrated photonic circuits are expected to play a central role in quantum technology, their high dimensionality and dissipative nature are a challenge for their theoretical description, therefore hindering the understanding of their properties and potential of performance. In this article, we develop a framework that permits to obtain an explicit solution for the density operator of quantum microcombs below threshold. Furthermore, this self-consistent theoretical description allows for their complete characterization, as well as for the analytical determination of various performance metrics such as fidelity, purity, and entropy.

42 ENGINEERING↗
DOE OSTI2025

Real-Time Bayesian Inference at Extreme Scale: A Digital Twin for Tsunami Early Warning Applied to the Cascadia Subduction Zone

We present a Bayesian inversion-based digital twin that employs acoustic pressure data from seafloor sensors, along with 3D coupled acoustic–gravity wave equations, to infer earthquake-induced spatiotemporal seafloor motion in real time and forecast tsunami propagation toward coastlines for early warning with quantified uncertainties. Our target is the Cascadia subduction zone, with one billion parameters. Computing the posterior mean alone would require 50 years on a 512 GPU machine. Instead, exploiting the shift invariance of the parameter-to-observable map and devising novel parallel algorithms, we induce a fast offline–online decomposition. The offline component requires just one adjoint wave propagation per sensor; using MFEM, we scale this part of the computation to the full El Capitan system (43,520 GPUs) with 92% weak parallel efficiency. Moreover, given real-time data, the online component exactly solves the Bayesian inverse and forecasting problems in 0.2 seconds on a modest GPU system, a ten-billion-fold speedup.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Integrating Control Methods and Digital Twins for Advanced Nuclear Reactors

Advanced nuclear reactors offer new capabilities such as the ability to adapt to variable energy demand, operate autonomously with remote supervision, be deployable in rural locations, be compact in size, afford lower power ratings, and rely on novel techniques for increased operational safety. However, realizing these capabilities requires intelligent control systems that can track changing power demands and make autonomous decisions based on these demands. The unique aspects of advanced reactors (e.g., strict regulatory requirements, harsh operating environments, high consequences, highly coupled dynamics, evolving knowledge, and limited operating histories) directly impact the design and deployment of control systems for these reactors. The present work identifies and evaluates these aspects so as to develop a set of control system requirements to guide future research and development. To meet these requirements, a layered control system approach is proposed that integrates digital twins with different control paradigms. This work aims to demonstrate how different methods interface with enabling solutions, and to identify any gaps that need to be researched.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Digital-Twin-Enabling Technologies for Online Condition Monitoring of Nuclear Power Plant Components

Online condition monitoring is an area of active research that may enable optimized scheduling, maintenance, and safety of nuclear power plant components, reducing unnecessary derates while simultaneously improving operational capacity. Digital twins (DTs) are one avenue to conduct online condition monitoring and are currently being explored by national laboratories and universities alike. DTs for online condition monitoring are, in essence, state concurrent models that emulate a physical process which predicts a parameter and compares it against a measured value. A DT’s goal is to provide additional insights by combining and interpreting various sources of information for preventative maintenance scheduling optimization or early fault detection. DTs for condition monitoring are projected to be valuable for meeting requirements under 10 CFR 50.55a, “Codes and Standards,” and 10 CFR 50.65, “Requirements for Monitoring the Effectiveness of Maintenance at Nuclear Power Plants”. However, DT technologies are still under significant development, and the process for developing a DT for condition monitoring has not been formalized. Therefore, in this work, we present an initial framework for developing a DT, discuss and review the various challenges and considerations for DT deployment, and identify the opportunities that a DT can improve. The presented framework is intended to help developers formulate a strategy when approaching DT development for condition monitoring. In conclusion, a DT use case for a reactor coolant pump is presented to demonstrate the proposed framework.

advanced sensor instrumentation↗
DOE OSTI2021

Physics-Infused AI/ML Based Digital-Twin Framework for Flow-Induced-Vibration Damage Prediction in a Nuclear Reactor Heat Exchanger

This report summarizes some of the ongoing work related to the development of an expert-elicitation-digital-twin framework for real time damage state prediction in heat exchanger components of a nuclear reactor. The framework is targeted towards predicting damage associated with coupled low cycle fatigue (associated with regular heat-up, cool-down and power operation transients) and high cycle fatigue (associated with flow induced vibration transients). The overall framework will be based on a NoSQL based database, physics-infused-geometry-dependent virtual-sensor data, different AI/ML techniques-based data-driven-predictive-model applications (Apps) and real-time plant sensor measurements available through few existing sensors. Towards this overall goal, this report updates some of the ongoing work, such as on implementation of a NoSQL Database (such as MongoDB), FE based heat transfer analysis of a heat exchanger (e.g. of a PWR steam generator) for generating geometry-dependent virtual sensor data and evaluation of various AI/ML models such as based on multivariate linear regression, ensembled decision-tree based Random-Forest and Gradient-Boosting regression and high-dimensional-kernel-function-transformation based Support-Vector-Machine regression models. The AI/ML models were evaluated for predicting multi-time-series thermal states at thousands of 3D point-clouds

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Enhancing the Operational Resilience of Advanced Reactors with Digital Twins by Recurrent Neural Networks

Because of a lack of operational data and uncertainty in evaluation model for abnormal and accident scenarios, the established operating procedures can be biased in characterizing the reactor states and ensuring operational resilience. To reduce uncertainty associated with actual plant conditions, digital twin (DT) technology is suggested to support operator’s decision-making by effectively extracting and using knowledge of the current and future plant states from the knowledge base. This study first builds a knowledge base based on the characterization of issue space and the simulation tool. Next, this study discusses diagnosis and prognosis DTs for enhancing operational resilience by recovering the complete states of reactors and by predicting the future reactor behaviors. Finally, the decision-making module of the control system can determine the optimal control strategy that meets operational goals during loss-of-flow scenarios. To demonstrate and evaluate the DTs capability for supporting the operations of nuclear reactors, this study develops and assesses both the diagnosis and prognosis DTs in a nearly autonomous management and control system for an Experimental Breeder Reactor-II simulator during different loss-of-flow scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Digital Twin Model for Advanced Manufacture of a Rotating Detonation Engine Injector

A digital twin material model (DTMM) of an additive manufacturing (AM) process was created to advance the state of the art in rotating detonation engine (RDE) injector design. Current RDE injectors are designed with large pressure drops, enabling a stable and repeatable combustion process. However, this comes at the cost of system efficiency. For the technology to transition to commercial fossil-based power generation, it is important to develop injectors with reduced flow losses. Low-loss injectors are difficult to design and manufacture with conventional manufacturing techniques. AM enables new design options, but the AM manufacturing process must be thoroughly understood to result in a robust design. A DTMM provides the necessary insight by defining the cause-effect relationships between process parameters, microstructure features, and properties. Therefore, a DTMM to support the design and manufacturing process was developed and applied to the design of a new additively manufactured low-loss injector. The injector combustion behavior was characterized through hot-fire tests, and mechanical performance was compared to the DTMM predictions. The two project goals were the successful development of the DTMM and the demonstration of an improved RDE injector design. The RDE injector design and DTMM developments occurred on parallel but dependent paths. The injector was designed to reduce pressure drop by increasing the cross-sectional flow area ratio between the injector air passages and the combustor annulus. This resulted in less structural material, raising the concern that thin members would be susceptible to high-cycle fatigue (HCF) under the periodic loading inherent to an RDE. It was most important for the DTMM to predict behavior in these features; therefore, the injector design concept guided the material thicknesses used in fatigue tests. The DTMM development started by manufacturing a series of coupons over the range of possible AM process variations. A design-of-experiment approach was used to select which process variable combinations gave the most efficient coverage relevant to the injector design space. The microstructure in each of these coupons was characterized, and then computational methods were used to create a numerical model of the correlation between process variables and microstructure. Next, a set of HCF samples were tested to calibrate existing models that map microstructure to HCF performance. Together, these two links formed the DTMM that calculates HCF behavior from AM process variables. Two injector prototypes were additively manufactured. The first injector design strategy aggressively pursued low-loss performance by substantially increasing the oxidizer flow area. The combination of manufacturing lead times and the fatigue testing schedule meant that the DTMM was not available when building this first prototype. Therefore, its process parameters were chosen based on a manual review of the available coupon data. This prototype was built successfully and evaluated in 58 combustion tests. Sustained detonation was achieved with remarkably reduced pressure loss, and some tests even displayed pressure loss characteristics similar to conventional gas turbine combustors. This achieved the project goal of improving RDE injector design. The second injector was manufactured according to the optimized parameters predicted by the DTMM. The flow area modifications of this injector were less aggressive than the first injector since demonstrating low pressure loss was not an objective of the second hot-fire test series. Rather, the test objective was to cause high cycle fatigue failure in the part due to periodic loading from the rotating detonation wave. The observed number of cycles to failure was to be compared to the number predicted by the DTMM and thereby assess the utility of the DTMM in component design. However, the required level of vibration was not obtained during combustion. Therefore, high cycle fatigue was not experienced in the hot-fire tests of the second injector. Fatigue data was obtained by further testing the second injector in a conventional HCF test apparatus. The injector demonstrated HCF strength above the DTMM prediction. In fact, it did not fail and testing was only discontinued due to reaching the end of the period of performance. This points to some success in the project’s primary goal of successfully developing and applying the DTMM to a component design. Implementing the DTMM recommendations for optimal processing parameters led to a part with acceptable properties. The DTMM was also shown to be an efficient correlator of data and to provide insight into the relationship between process settings, microstructure, and property performance. However, the failure of the DTMM prediction to match the experimental result of the injector fatigue test also points to the need to include significantly more data in the model development. In this project, coupons made with identical processing parameters exhibited drastically different properties from each other and from the injector part, which clearly influences the accuracy of a model that predicts performance based on parameters. Uncertainties in the build process must be quantified to develop more robust models. A denser and broader matrix of coupon process and geometry variations, several repeated builds of every point, more in-situ build process measurements, and direct observation of tensile and HCF sample microstructure (as opposed to separate microstructure specimens) are recommendations to improve future AM modeling efforts.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Hybrid AI-ML and FE-based Digital Twin Predictive Modeling Framework for a PWR Coolant System Components: Updates on Multi-Time-Series-3D-Location Dependent Usages Factor Prediction

The long-term operation (LTO) of nuclear power plants (NPP) beyond their original design life of 40 years can lead to more material damage associated with cyclic fatigue under thermal-mechanical loading cycles and associated long-term exposure of reactor material to the deleterious reactor-coolant environments. However, under this LTO condition, the reactor components can still safely operate but may require more frequent Nondestructive Evaluation (NDE) of reactor components. Requiring frequent NDE inspections may lead to frequent NPP shutdowns which can lead to power outages and additional NDE inspection cost-related economic loss. The economic loss can be minimized by reducing uncertainty in life estimation of safety-critical pressure boundary components and by implementing a more digital approach such as using upcoming digital-twin (DT) technology for predicting the structural states (e.g., time and location dependent inside/outside thickness temperature, stress, strain, plastic deformation, etc.) and associated fatigue life of a component in real time. The DT framework is based on limited experimental data, Artificial-intelligence (AI)-Machine-Learning (ML) and multiphysics-computationalmechanics such as finite element- (FE) based models. Given the real-time thermal-hydraulic process measurements from several existing plant sensors, the overall goal of the DT framework is to predict the cumulative usages factors or equivalent fatigue lives in real time and at any random 3D location of the components. This includes inaccessible locations such as inside the thickness or location of a component. This prediction can be at thousands to millions of 3D point clouds or locations like conventional FE-based models, but without running an FE model in real time.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

PMDT: AI-Enabled Predictive Maintenance Digital Twins for Advanced Nuclear Reactors

Our team made substantial technical progress on various fronts during the course of the program. Multiple milestones were geared towards demonstrating the feasibility of machine learning based predictive maintenance digital twins towards reducing O&M costs, whereas some other milestones actually focused on identifying technical gaps and developing technologies such as humble AI to provide necessary robustness to the ML-based models. We were able to demonstrate in many cases that Machine learning-based methods can be successfully adapted for Nuclear plant environments especially for remote monitoring applications. Detailed analyses were carried out with plant and full scope simulation data along with capabilities of enhanced analytics to assess and set realistic expectations on cost reductions in O&M. These assessments are paving the way for investments towards reactor design improvements as well project planning for SMR projects as they develop and mature in the next few years. Technology developed under this program got direct visibility to GE Hitachi and their utility customers and resulted in positive intents to deploy some of the elements from design phase. The project additionally resulted in several reports, publications, software and data generation that will be useful in deployment and O&M services for BWRX300 fleets.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Technical Assessment of the Application of Digital Twin and Prognostic Tools for Condition Monitoring

This report was prepared for the U.S. Nuclear Regulatory Commission (NRC) to present use cases of the application of advanced technologies toward meeting the current and future regulatory requirements for maintenance and condition monitoring of structures, systems, and components (SSCs). The advanced technologies considered in this work, collectively referred to as digital twin (DT) technologies, are advanced sensors and instrumentation, data analytics, machine learning and artificial intelligence (ML/AI), and physics-based models. The report presents two use cases of reactor coolant pumps (RCPs) and heat pipes in nuclear power plants (NPPs) with technical and regulatory considerations and opportunities in using advanced technologies for conditional monitoring. Key findings from the exploration of these considerations are as follows: - Uncertainties in sensor data and model predictions must be rigorously addressed through validation and verification processes - Regulatory compliance is paramount, necessitating data driven models to be developed in line with existing codes and standards, as well as considering potential future guidelines for advanced reactors - Explainability and transparency in ML/AI models are essential for developing operator trust and regulatory review, including methods that enhance the interpretability of complex data-driven predictions - Condition monitoring programs must be evaluated for their effectiveness in reducing maintenance-preventable function failures (MPFF) and aligning with plant performance criteria - The deployment of advanced technologies for condition monitoring could lead to a transition from periodic to continuous monitoring, thereby optimizing maintenance schedules - Collaborative efforts between industry stakeholders, regulatory bodies, and technology developers are crucial for the successful adoption of advanced technologies for condition monitoring systems in nuclear facilities In summary, the introduction of advanced technologies into condition monitoring programs represents a significant leap forward in the domain of NPP maintenance. By harnessing the capabilities of advanced sensors, data analytics, and ML/AI, NPP operators can transition from a time-based to a condition-based maintenance approach. This shift can potentially enhance the reliability and safety of critical plant components while optimizing maintenance efforts and minimizing unnecessary outages. The NRC is continuing to explore the regulatory aspects of advanced technologies as part of inservice inspection and inservice testing (ISI and IST) programs by pursuing additional research in this technical area.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

LANL Institutional Computing Report: Towards a digital twin of Arctic sea ice

Our goal is to develop a digital twin of Arctic sea ice that combines high-resolution predictive modeling with observational products. This effort will provide an optimized model for use in seasonal to sub-seasonal forecasting and a tool for policymakers to better anticipate, plan for, and mitigate the national security impacts of rapidly changing Arctic conditions. The modeling component uses the Discrete Element Model for Sea Ice (DEMSI), which uses discrete elements to represent the sea ice with an explicit representation of forces between them.

58 GEOSCIENCES↗