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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 Three-Tier Incremental Approach for Development of Smart Corridor Digital Twins

Development of an arterial smart corridor digital twin requires the integration of real time data streams, data storage, and simulation model execution. This process may be complex, time consuming, and susceptible to errors. To aid in smart corridor digital twin development this paper seeks to provide a framework, best practices, and development guidance. As such, a three-tier incremental approach to smart corridor digital twin development is presented. The paper highlights practical issues in digital twin construction along with key data challenges based on experiences from the development of digital twins for two large Smart Corridor deployments, one in Chattanooga, Tennessee, and the other in Atlanta, Georgia. The presented three-tier incremental approach includes: 1) development of a prepopulated offline simulation, 2) development of a pseudo digital twin that is driven by archived data, and 3) integration of real time data streams to create the online digital twin model. The three-tiered approach facilitates conducting multiple trials and scenarios with increasing complexity, allowing for incremental error processing and updating of the digital twin.

Saroj, Abhilasha↗
DOE OSTI2022

Digital Twins for Materials

Digital twins are emerging as powerful tools for supporting innovation as well as optimizing the in-service performance of a broad range of complex physical machines, devices, and components. A digital twin is generally designed to provide accurate in-silico representation of the form (i.e., appearance) and the functional response of a specified (unique) physical twin. This paper offers a new perspective on how the emerging concept of digital twins could be applied to accelerate materials innovation efforts. Specifically, it is argued that the material itself can be considered as a highly complex multiscale physical system whose form (i.e., details of the material structure over a hierarchy of material length) and function (i.e., response to external stimuli typically characterized through suitably defined material properties) can be captured suitably in a digital twin. Accordingly, the digital twin can represent the evolution of structure, process, and performance of the material over time, with regard to both process history and in-service environment. This paper establishes the foundational concepts and frameworks needed to formulate and continuously update both the form and function of the digital twin of a selected material physical twin. The form of the proposed material digital twin can be captured effectively using the broadly applicable framework of n-point spatial correlations, while its function at the different length scales can be captured using homogenization and localization process-structure-property surrogate models calibrated to collections of available experimental and physics-based simulation data.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Self Configuring Digital Twin for Optimizing E-Waste Recycling

Electronic waste recycling industry needs a decision support tool for optimizing their processes to become cost competitive. We developed a software called CMAT, Comprehensive Manufacturing Assessment Tool. The aim of CMAT is to provide the e-waste recycling companies with a fully customizable decision support framework that analyzes the optimal supply chain configurations. The software optimizes the logistics operations, helps to identify the best recycling process configuration, and generates valuable insights regarding the economic performance of different categories of e-waste. The ultimate purpose of the tool is to assist the users developing a digital twin of their processes and to provide insights on questions pertinent to the e-waste recycling industry including how to increase efficiency and reduce costs, energy consumption, and greenhouse gas emissions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Partial Support of the Fast-Track Consensus Study on Foundational Research Gaps and Future Directions for Digital Twins (Final Report)

This study from the National Academies of Sciences, Engineering, and Medicine was launched to explore the foundational research gaps and opportunities for digital twins. As part of the information gathering process, the committee organized three targeted workshops—in engineering, climate sciences, and biomedical sciences—to better understand domain-specific nuances and barriers to developing digital twins. These sessions enabled cross-sector experts to surface field-specific needs, challenges, and open questions related to digital twins. Thousands of participants across multiple domains engaged in the discussions, which workshops were summarized in three separate Proceedings-in-Brief.

42 ENGINEERING↗
DOE OSTI2021

A scalable digital platform for the use of digital twins in additive manufacturing

We report that while Additive Manufacturing promises to reshape the manufacturing landscape, challenges related to part, and process qualification hinder its widespread adoption. The Instance-Qualified approach seeks to qualify individual parts, even for processes with high variability, by leveraging the concept of a digital twin. This work proposes a scalable cyberphysical infrastructure to enable the construction and use of such digital twins. This work also introduces the concept of an Augmented Intelligence Relay, which allows Artificial Intelligence algorithms to predict component performance for a given application even when it is impractical to perform a large number of physical tests.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Improving the User Interface of the DeepLynx Data Warehouse

DeepLynx is an open-source ontology-based data warehouse created by INL to support the creation and life cycle of digital engineering projects, with a particular emphasis on digital twins [1]. Digital twins are systems that represent physical assets and process in a real-time digital environment [1]. Most well-known commercial data warehouses use Graphical User Interfaces (GUIs) for users to interact with their systems [3]. Limited publications have addressed the design of these interfaces and understanding of their target users. The current users and development team acknowledge the need to improve the current UI, not just for aesthetics but to improve functionality and workflow of DeepLynx. Traditional data warehouse users are developers, data scientists and business analysts [2]. DeepLynx users have a vast range of experience using data warehouses, and diverse roles, including engineers, scientists and management positions. Because there is a broader audience of target users for DeepLynx than a typical data warehouse, it is essential that DeepLynx has a useable and intuitive user interface. To achieve this the team performed human-computer interaction methods, including a Heuristic Evaluation of current UI using Neilsen’s Usability Heuristic, create personas based on current users by designing a user survey, data analysis and develop of personas. Followed by a redesign of the UI following using Neilsen’s Usability Heuristic and Norman’s Principles of Interactive Design in industry standard software Figma. Lastly a Heuristic Evaluation of new UI design, using Neilsen’s Usability Heuristic and User testing of redesign UI and have a group of users complete a Thinking Aloud Test of the new UI. Preliminary results of the Heuristic Evaluation of current UI arise issue with Consistency and Standards, Visibility of System Status, Match System and Real World and Recognition Rather than Recall. These issues were addressed in the proposed redesign by applying Neilsen’s Usability Heuristic and Norman’s Principles of Interactive Design. Next steps include formalized list of lessons learned and design implications for future publications.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Digital Twins for Predicting Nitrifier Population and Kinetics

Digital twins can be mechanistic biological process models that when regularly calibrated give an indication of nitrifier kinetics and nitrifier population. Having such information can inform waste rates and dissolved oxygen setpoints for ammonia-based aeration control.

Sparks, Jeff↗
DOE OSTI2025

Development of a Discrepancy Checker for the Digital Twin in a Supervisory Control System for a Thermal Energy Delivery System

Defined as a virtual representation of a physical object, process, or service, and used to support real-world decision-making, a digital twin (DT) can be utilized to combine classical and novel frameworks in sensors, state predictions, and multi-input/multi-output systems, and to enable optimal autonomous operations. However, a DT’s usefulness largely depends on its ability to adequately mirror the state of its physical counterpart, and this adequacy should be reflected by the level of uncertainty in the underlying simulation models when estimating and predicting quantities of interest (QOIs). Moreover, simulation models in a DT may involve multiple fidelities of representations—ranging from physics-based models to data-driven ones—but classical uncertainty quantification (UQ) methods struggle to handle numerous uncertainty sources, nor are they designed for real-time applications. This work presents a UQ-based discrepancy checking and diagnosis tool for a DT-based supervisory control system applied to a thermal energy delivery system (TEDS) at Idaho National Laboratory. The discrepancy checker was developed using metadata from an automated DT development process, and these metadata included different combinations of physical model forms and model parameters, training data and hyperparameters for surrogate models, and design parameters for supervisory control systems. Next, correlations between the uncertainty results and the metadata were established and then applied to the DT operations. The discrepancy checker evaluates the discrepancies between model predictions from virtual and sensor measurements and backtraces them to the corresponding major sources of uncertainty. The discrepancy checker showed reasonable performance in detecting discrepancies and diagnosing sources of uncertainty in testing scenarios.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Multi‐fidelity digital twin structural model for a sub‐scale downwind wind turbine rotor blade

Abstract This paper presents the development of a multi‐fidelity digital twin structural model (virtual model) of an as‐built wind turbine blade. The goal is to develop and demonstrate an approach to produce an accurate and detailed model of the as‐built blade for use in verifying the performance of the operating two‐bladed, downwind rotor. The digital twin model development methodology, presented herein, involves a novel calibration process to integrate a wide range of information including design specifications, manufacturing information, and structural testing data (modal and static) to produce a multi‐fidelity digital twin structural model: a detailed high‐fidelity model (i.e., 3D finite element analysis [FEA]) and consistent beam‐type models for aeroelastic simulation. A key element is that the multi‐fidelity structural digital twin method follows the rotor from the stages of design, to manufacturing, then to the ground testing and field operation. The result of this comprehensive approach is an accurate multi‐fidelity digital twin structural model for the geometric, structural, and structural dynamic properties of the as‐built blade within a 1% match in mass properties, 3.2% in blade frequencies, and 6% in deflection. The different stages of processing this information within the methodology are discussed. The rotor examined is the SUMR‐Demonstrator (SUMR‐D), which was installed on the Controls Advanced Research Testbed (CART‐2) wind turbine at the National Wind Technology Center. The digital twin model developed here was utilized to design controllers to safely operate SUMR‐D in field tests, which are providing additional data for further evaluation and development of the multi‐fidelity digital twin structural model.

Chetan, Mayank↗
DOE OSTI2025

Data Quality Assessment Process for Real-Time Data-Driven Traffic Microsimulation of Smart Corridor

Smart corridor digital twins are often created for the development and evaluation of emerging intelligent transportation systems and Connected and Autonomous Vehicle (CAV) technologies. However, limited guidance exists for data quality assessment for digital twin development. To address this, this paper discusses the data quality assessment utilized to develop data-driven real-time microscopic simulation models, i.e., digital twins, for two separate smart corridors: the North Avenue Smart Corridor in Atlanta, GA, and the Martin Luther King Smart Corridor in Chattanooga, Tennessee. This paper provides a summary of the author’s investigations of data requirements and data characteristics for the given smart corridor digital twin development efforts. With a focus on data, this summary includes a description of the data investigation process, key data issues observed, and strategies to address observed issues. Discussion is provided to help expand the lessons from these studies to other digital twin development efforts.

Saroj, Abhilasha [ORNL] (ORCID:0000000191178063)↗
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 OSTI2026

Advanced Facility Design and AI/ML Enabled Safeguards to Establish Secure, Economical Recycling of Fast Reactor Fuels (Final Scientific/Technical Report)

The project, "Advanced Facility Design and AI/ML Enabled Safeguards to Establish Secure, Economical Recycling of Fast Reactor Fuels," represents a significant advancement in nuclear fuel recycling technology. It integrates cutting-edge multimodal sensor fusion, machine learning (ML), and digital twin (DT) technologies to address challenges in material safeguarding, process optimization, and regulatory compliance for pyroprocessing facilities. This research has significantly enhanced the understanding of pyrochemical fuel recycling processes by developing innovative tools and methodologies. The Multimodal Safeguards Monitoring Unit (MSMU) combines electroanalytical techniques, Raman spectroscopy, and differential thermal analysis (DTA) to enable high-fidelity, near-real-time material accountancy measurements. Machine learning techniques, such as Long Short-Term Memory (LSTM) autoencoders, are utilized to detect anomalies in material balances and sensor data, improving the reliability of safeguards monitoring. Additionally, digital twin technology has been established to provide real-time system-level monitoring and diagnostics, integrating physics-based models with sensor data to optimize process safety and efficiency.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Machine Tool Data Analytics for Digital Twin and Machine Predictive Maintenance

The primary objective of this project is to improve machining process performance using in-process machining data from the machine tool controller and external sensors. Advances in the Industrial Internet of Things (IIoT) enable monitoring of machines using controller data. Examples of the data provided by a controller include execution status of the controller, part count, block of code being executed, door status, tool position, the spindle and axis load, etc. MTConnect and OPC-UA are the two common protocols for capturing machine information. In this collaboration, methods for retrieving the machine controller data from selected machine tool controls and making these data accessible in different subsystems (such as digital twins and machine maintenance portals, etc.) will be developed and tested. In addition, analytics to improve machining process performance (by increasing productivity and reducing downtime) will be developed.

42 ENGINEERING↗
DOE OSTI2024

Mapping TpPa-1 covalent organic framework (COF) molecular interactions in mixed solvents via atomistic modeling and experimental study

Complex solvent environments continue to limit the widespread adoption of organic solvent nanofiltration (OSN) in many chemical industry applications. In this paper we employ a commercially available covalent organic framework (COF), TpPa-1, and force field models to molecularly map separation performance of TpPa-1 membrane in mixed solvents. To minimize time and length scale mismatch between atomistic modeling and experiments, solvent permeance was normalized with water in modeling and experimental results to enable direct comparison. Model outputs, such as organic solvent permeance and solute rejection rate, matched well with filtration results. Since the atomistic models assume that all mass transfer is via through-pore transport, the discrepancies between modeling and experimental results provide insights on the effect of linear polymer defects, adsorption and interstitial mass transfer on polycrystalline COF membrane performance. In sum, force field models can serve as digital twins of COF membranes to simulate separation processes while capturing the effects of COF structure, chemistry, and crystallinity on membrane performance in complex organic solvent environments. Finally, this approach will provide insight into future COF design and synthesis for persisting separation challenges.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
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 OSTI2021

Supervisory control and health monitoring framework for large-scale additive manufacturing systems. Final CRADA report

ORNL worked with National Instruments (NI) to develop a large-scale, complex additive manufacturing (AM) systems framework for remote health monitoring and supervisory control. We found the framework, based on the Lincoln Electric Metal AM system located at ORNL’s MDF, capable of controlling the process, leading to improved part quality and digital twin creation.

42 ENGINEERING↗
DOE OSTI2023

Mobile Hot Cell Digital Twin: End-of-life Management of Disused High Activity Radioactive Sources

Sealed radioactive sources are used in various settings such as nuclear facilities, universities, hospitals, and industry. When these sources reach the end of their lifespan, they become waste and are recaptured and stored long-term. A digital twin can be used in the design of a solution for recapturing spent sources, offering benefits in deployment time, operator safety, and cost reduction. We propose a digital twin framework for managing the end-of-life process of disused high activity radioactive sources and have created a prototype implementation to demonstrate its feasibility.

61 RADIATION PROTECTION AND DOSIMETRY↗