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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 325 records · Page 18
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A machining digital twin for hybrid manufacturing

Hybrid manufacturing consisting of metal additively manufactured preforms and computer numerical control (CNC) machining has been established to be an effective method for high material use rates. However, hybrid manufacturing introduces unique challenges. Near-net shape designs are typically selected, which result in a smaller margin for part placement within the stock and stringent requirements for work coordinate system identification. Additionally, less stock material reduces the preform stiffness, which limits the material removal rates during machining. This paper demonstrates a digital twin for CNC machining of a wire arc additively manufactured preform that implements: 1) structured light scanning for stock model identification and tool path generation; 2) a fused filament fabrication apparatus to attach temporary fiducials and scan targets to the preform that enable coordinate system definition for both the CAM and CNC machine; 3) preform and tool tip frequency response function measurements to enable stable milling parameter selection; and 4) post-manufacturing measurements of geometry, surface finish, and structural dynamics to confirm designer intent. These efforts define key components of the machining digital twin for hybrid manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Disconnection-Mediated Transition in Segregation Structures at Twin Boundaries

Twin boundaries play an important role in the thermodynamics, stability, and mechanical properties of nanocrystalline metals. Understanding their structure and chemistry at the atomic scale is key to guide strategies for fabricating nanocrystalline materials with improved properties. In this work, we report an unusual segregation phenomenon at gold-doped platinum twin boundaries, which is arbitrated by the presence of disconnections, a type of interfacial line defect. By using atomistic simulations, we show that disconnections containing a stacking fault can induce an unexpected transition in the interfacial-segregation structure at the atomic scale, from a bilayer, alternating-segregation structure to a trilayer, segregation-only structure. This behavior is found for faulted disconnections of varying step heights and dislocation characters. Supported by a structural analysis and the classical Langmuir–McLean segregation model, we reveal that this phenomenon is driven by a structurally induced drop of the local pressure across the faulted disconnection accompanied by an increase in the segregation volume.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Virtual sensing-enabled digital twin framework for real-time monitoring of nuclear systems leveraging deep neural operators

Abstract Real-time monitoring is a foundation of nuclear digital twin technology, crucial for detecting material degradation and maintaining nuclear system integrity. Traditional physical sensor systems face limitations, particularly in measuring critical parameters in hard-to-reach or harsh environments, often resulting in incomplete data coverage. Machine learning-driven virtual sensors offer a transformative solution by complementing physical sensors in monitoring critical degradation indicators. This paper introduces the use of Deep Operator Networks (DeepONet) to predict key thermal-hydraulic parameters in the hot leg of pressurized water reactor. DeepONet acts as a virtual sensor, mapping operational inputs to spatially distributed system behaviors without requiring frequent retraining. Our results show that DeepONet achieves low mean squared and Relative L2 error, making predictions 1400 times faster than traditional CFD simulations . These characteristics enable DeepONet to function as a real-time virtual sensor, synchronizing with the physical system to track degradation conditions and provide insights within the digital twin framework for nuclear systems.

Hossain, Raisa↗
DOE OSTI2023

Decentralized digital twins of complex dynamical systems

Abstract In this article, we introduce a decentralized digital twin (DDT) modeling framework and its potential applications in computational science and engineering. The DDT methodology is based on the idea of federated learning, a subfield of machine learning that promotes knowledge exchange without disclosing actual data. Clients can learn an aggregated model cooperatively using this method while maintaining complete client-specific training data. We use a variety of dynamical systems, which are frequently used as prototypes for simulating complex transport processes in spatiotemporal systems, to show the viability of the DDT framework. Our findings suggest that constructing highly accurate decentralized digital twins in complex nonlinear spatiotemporal systems may be made possible by federated machine learning.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Epitaxial nanotwinned metals and alloys: synthesis-twin structure–property relations

Extensive studies have been performed to understand the structure–property relationship in nanotwinned (NT) metals, where the average twin thickness or twin spacing is less than 100 nm. NT metals may have high strength, ductility, good electrical conductivity and corrosion resistance and have promising applications in microelectronics, structural materials and coatings for gas and oil industry. Most prior studies focus on the computational and experimental investigations of NT metals with low stacking fault energy (SFE) and often in polycrystalline forms. In this highlight, we review recent findings on epitaxial growth of NT metals and alloys with low and high SFEs deposited on single crystal substrates, and focus primarily on advancing our comprehension towards tailoring the microstructures and properties of NT metals via extrinsic factors, including the synthesis technique, parametric control and growth template, and intrinsic factors, such as SFE and thermodynamic, kinetic alloying effects. The review intends to illuminate how to synthesize and design epitaxial NT structures to achieve desirable properties.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Twin suppression effect of dihydroxy-benzene isomers during the secondary growth of b -oriented zeolite MFI nanosheet films

In this study, the presence of MFI twin crystals on b-axis oriented zeolite MFI nanosheet films was suppressed by adding dihydroxy-benzene isomers in the synthesis mixture. The resulting nanosheet films exhibit good intergrowth and a small grain thickness of 30–45 nm within a relatively short synthesis time (hours). The possible twin suppression mechanisms for the three isomers are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Automatic Lane-Level Road Network Extraction from Aerial Imagery for Transportation Digital Twins

Accurate road networks are essential for credible traffic microsimulation and transportation digital twins, yet high-definition maps are often difficult to obtain due to limited availability, high cost, or proprietary restrictions. Some build networks from crowdsourced data, such as OpenStreetMap, but these sources often contain geometric and semantic inconsistencies. Others create networks manually, a process that is labor-intensive and difficult to scale. To address these limitations, this work presents an end-to-end pipeline that automatically extracts georeferenced, lane-level road networks from publicly available high-resolution satellite imagery and converts them into simulation-ready assets. The developed end-to-end pipeline has three primary modules: (1) A computer-vision-based module first detects directed lane geometries and intersection layouts. (2) A heuristic-based topology construction module then identifies approach and exit legs and establishes conflict-free lane-to-lane connections. (3) Finally, an automatic simulation-building module converts the extracted network into standard formats, e.g., OpenDRIVE, and generates routable SUMO networks. The framework supports both complete network construction from scratch and local-scale refinement of existing networks through lane-count correction, transition recovery, and geometric regularization. The proposed pipeline provides a practical pathway to generate traffic simulation networks from satellite imagery, significantly reducing manual reconstruction effort and enabling scalable, continuously updated transportation digital twins.

Guo, Hetian [University of Georgia, Athens] (ORCID↗
DOE OSTI2026

Automated Signal Timing Plan Reconstruction Using High-Resolution Event-Based Controller Data for Digital Twins

Transportation digital twins are essential tools for evaluating emerging technologies such as connected and automated vehicles, adaptive traffic signal control, and mobility optimization strategies. Realistic digital twins require accurate emulation of real-world signal controllers and detailed signal timing plans. However, signal timing plans are often unavailable or difficult to access, forcing researchers and modelers to rely on assumed fixed timings or halt their analysis. To overcome this challenge, we present a method that directly estimates signal timing plan parameters using high-resolution, event-based data from traffic signal controllers. The proposed method extracts key parameters, including cycle length, offset, phase sequence, coordinated phases, phase-specific minimum and maximum green durations, vehicle extensions, and splits under coordination. A rule-based deterministic signal timing reconstruction algorithm based on traffic signal operation rules, such as those outlined in the Signal Timing Manual, is developed and validated. We evaluate this method, which uses high-resolution controller event logs and verified signal timing plans, on 94 signalized intersections in Nashville, Tennessee, demonstrating their ability to generate accurate, simulation-ready signal timing plans for tools such as SUMO and Vissim.

Saroj, Abhilasha [ORNL] (ORCID:0000000191178063)↗
DOE OSTI2023

Diffusion growth mechanism of penta-twinned Ag nanocrystals from decahedral seeds

Crystals with penta-twinned structures can be produced from diverse fcc metals, but the mechanisms that control the final product shapes are still not well understood. By using the theory of absorbing Markov chains to account for the growth of penta-twinned decahedral seeds via atom deposition and surface diffusion, we predicted the formation of various types of products: decahedra, nanorods, and nanowires. We showed that the type of product depends on the morphology of the seed and that small differences between various seed morphologies can lead to significantly different products. For the case of uncapped decahedra seeds, we compared predictions from our model to nanowire morphologies obtained in two different experiments and obtained favorable agreement. Finally, possible extensions of our model are indicated.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Confronting new NICER mass-radius measurements with phase transition in dense matter and twin compact stars

The (re)analysis of data on the X-ray emitting pulsars PSR J0030+0451 and J0740+6620, as well as new results on PSR J0437-4715 and J1231-1411, are confronted with the predictions of the equation of state (EoS) models allowing for strong first-order phase transition for the mass-radius (M-R) diagram. Here, we use models that are based on a covariant density functional (CDF) EoS for nucleonic matter at low densities and a quark matter EoS, parameterized by the speed of sound, at higher densities. To account for the variations in the ellipses for PSR J0030+0451 obtained from different analyses, we examined three scenarios to assess their consistency with our models, focusing particularly on the potential formation of twin stars. We found that in two scenarios, where the ellipses for PSR J0030+0451 and J0437-4715 with masses close to the canonical mass ∼ 1.4 M ⊙ are significantly separated, our models allow for the presence of twin stars as a natural explanation for potential differences in the radii of these stars.

X-ray binaries↗
DOE OSTI2022

Observations of twinning microstructure in iron ramp-compressed through the α – ε phase transition

Single crystal iron was ramp-compressed along the [100] axis at 4 GPa/ns through the α–ϵ phase transformation at 13 GPa. Unlike shock experiments, in these ramp compression experiments the bcc lattice is observed to be nearly isotropically relaxed before the phase transition. There was a mixed α/ϵ phase region starting at ~13 GPa which was observed for 0.75 ns until the peak stress of 18 GPa was reached. In situ x-ray diffraction measurements show the formation of new hcp orientations not reported in shock or quasistatic compression experiments. The new hcp orientations appear to be caused by {10¯11} <10¯1 ¯2> → {¯1011} <¯101¯2> sequential twins that occur during the phase transition. This twinning mechanism relieves the shear strain caused by the bcc-hcp phase transition from the isotropically relaxed bcc phase while subject to uniaxial compression. Furthermore, these results show that in iron the induced microstructure through a phase transition and the phase transition mechanism depend on the loading history.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Transport signatures of Fermi arcs at twin boundaries in Weyl materials

One of the most striking signatures of Weyl fermions in solid-state systems is their surface Fermi arcs. Fermi arcs can also be localized at internal twin boundaries where two Weyl materials of opposite chirality meet. In this work, we derive constraints on the topology and connectivity of these “internal Fermi arcs.” We show that internal Fermi arcs can exhibit transport signatures, and we propose two probes: quantum oscillations and a quantized chiral magnetic current. We propose merohedrally twinned B20 materials as candidates to host internal Fermi arcs, verified through both model and calculations. Our theoretical investigation sheds light on the topological features and motivates experimental studies on the intriguing physics of internal Fermi arcs. Published by the American Physical Society 2025

Kaushik, Sahal (ORCID:0000000286435528)↗
DOE OSTI2026

Digital Twin Based Condition Monitoring of LCC-LCC Inductive Power Transfer Systems

Inductive power transfer (IPT) systems provide a flexible, hands-free charging opportunity to electric vehicles (EV). The resonant network components and the transmitter and receiver coils are often subjected to high voltages or currents. Component aging in the compensation network and coils of resonant IPT systems is detrimental to the reliability and power transfer efficiency of the IPT system. Monitoring the component health of such multi-element complex systems requires robust optimization algorithms. This paper discusses condition monitoring of a resonant IPT system for an EV charger using a digital twin model. A hybrid estimation algorithm based on genetic algorithms and adaptive particle swarm optimization is developed to estimate the parameters of the digital twin model. Simulation results are used to verify the monitoring capabilities of the developed algorithm under various operating conditions of the IPT system.

Weldehawaryat, Lidya Mussie [graduate research ass↗
DOE OSTI2025

A Twin Circuit Theory-Based Framework for Oscillation Event Analysis in Inverter-Dominated Power Systems With Case Study for Kaua‘i System

Here, this paper proposes a real-world oscillation event analysis framework for power systems that include inverter-based resources together with synchronous generators. Specifically, the proposed framework combines both measurement-and model-based techniques to readily identify potential oscillation sources, replay the oscillation event with numerical simulation, unveil the underlying oscillation mechanism, and suggest mitigation methods for a wide range of oscillation events. To strengthen the theoretical foundation of our analysis framework, this paper proposes a twin circuit theory that provides theoretical support for one key utilized but not well-proven measurement-based oscillation source identification method-Dissipating Energy Flow. Our twin circuit theory also shows that adopting well-tuned grid-forming inverters can be a potential mitigation method for oscillation events. Finally, the effectiveness of our proposed oscillation event analysis framework is demonstrated by addressing a real-world 18-20 Hz oscillation event in Kaua‘i's power system on November 21, 2021.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Revealing extreme twin-boundary shear deformability in metallic nanocrystals

Metals containing abundant coherent twin boundaries (TBs) are able to sustain substantial plastic deformation without fracture due to shear-induced TB migration and sliding. Retaining ductility in these metals, however, has proven difficult because detwinning rapidly exhausts TB migration mechanisms at large deformation, whereas TB sliding was only evidenced for loading on very specific crystallographic orientations. Here, we reveal the intrinsic shear deformability of twins in nanocrystals using in situ nanomechanical testing and multiscale simulations and report extreme shear deformability through TB sliding up to 364%. Sliding-induced plasticity is manifested for orientations that are generally predicted to favor detwinning and shown to depend critically on geometric inhomogeneities. Normal and shear coupling are further examined to delineate a TB orientation-dependent transition from TB sliding to TB cracking. These dynamic observations reveal unprecedented mechanical properties in nanocrystals, which hold implications for improving metal processing by severe plastic deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A Digital Twin of Scalable Quantum Clouds

Quantum computing has emerged as a transformative technology capable of solving complex problems beyond the limit of classical systems. The rapid development of quantum processors has led to the proliferation of cloud-based quantum computing services offered by platforms such as IBM, Google, and Amazon. These platforms introduce unique challenges in resource allocation, job scheduling, and multi-device orchestration as quantum workloads become increasingly complex. In this work, we present a digital twin of quantum cloud infrastructures: a framework designed to model and simulate the behavior of real quantum cloud systems. Developed in Python using the SimPy discrete-event simulation library, the framework replicates key aspects of quantum cloud environments, including detailed quantum device modeling, job lifecycle management, and job fidelity. It incorporates noise-aware fidelity estimation, making it the first of its kind to simulate superconducting gate-based quantum cloud systems at an administrative level with job fidelity. We present use cases as proof of concept, demonstrating that our quantum cloud simulation framework can act as a digital twin of a quantum cloud and support the modeling and implementation of practical systems.

Luo, Waylon [Kent State University]↗
DOE OSTI2024

TwinMe4AD: WGAN-based Digital Twins for Anomaly Detection

SAND2024-08373O TwinMe4AD is a Python-based software tool designed for anomaly detection using digital twins that closely mimic real, wearable healthcare datasets. The tool is invaluable for scenarios where collecting data is either expensive or impractical, serving as a privacy-preserving solution. Sensitive information is protected by training deep learning models on synthetic data derived from real datasets. One of TwinMe4AD's key features is its anomaly detection capability, which is based on fourth-order moments of parameters. This versatile approach can be applied across a range of datasets, from univariate to multivariate, making it compatible with various types of data. It also generates synthetic twins using Wasserstein Generative Adversarial Networks (WGANs), allowing users to create a small cohort of a population similar to that of a village population. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Poorey, Kunal↗
DOE OSTI2025

Real-Twin

Real-Twin is a unified, model-agnostic scenario generation tool designed to streamline and standardize the evaluation of emerging mobility technologies. It provides an end-to-end framework that includes robust workflows, integrated tools, and comprehensive metrics to generate, calibrate, and benchmark microscopic traffic simulation scenarios across multiple platforms. Key Features of Real-Twin include: - Unified Scenario Generation: generate transferable, simulation-ready scenarios from heterogeneous data sources using a consistent workflow. - Automated Calibration Workflow: bridges simulation and real-world data, minimizing manual effort and making traffic simulation more accessible to researchers and engineers. - Model-Agnostic Compatibility: supports SUMO, VISSIM, and AIMSUN for cross-platform scenario generation and benchmarking. Enables reliable comparisons and reproducibility across different simulation tools. - Consistent Scenarios across Different Simulators: generate comparable simulation scenarios across different microscopic traffic simulators, providing users the ability to conduct benchmarking and cross-validation that are crucial for ensuring the reliability and reproducibility of simulation results. - Emerging Technology Support: includes a scenario database and pipeline for studying autonomous vehicles (AVs), with planned extensions to CAVs, EVs, and other advanced technologies.

Wang, Chieh (Ross) [Oak Ridge National Laboratory ↗