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DOE OSTI2025

AI-driven neutrino diagnostics and radiation-hard beam instrumentation for next-generation neutrino experiments

The Long Baseline Neutrino Facility (LBNF) at Fermilab will deliver a high-intensity, multi-megawatt neutrino beam to the Deep Underground Neutrino Experiment (DUNE), enabling precision tests of the three-neutrino paradigm, CP violation searches, neutrino mass ordering determination, and supernova neutrino studies. To accelerate DUNE’s physics reach and ensure robust beam operations, we propose an integrated AI-driven framework with real-time diagnostics and radiation-hardened instrumentation. At its core is a Real-Time Beam Integrity Monitor using a physics-informed Digital Twin. By reconstructing pion phase space from muon profiles and exploiting magnetic horn optic linearity, it enables spill-by-spill beam correction and flux stabilization. By using this approach, flux-related systematics could be reduced from 5% to 1%, potentially accelerating the discovery of CP violations by four to six years. Complementing this, a US–Japan R&D effort will deploy a LAPPD-based muon monitor in the NuMI beamline. ToF measurements can be acquired with picosecond precision using this radiation-hard system, enhancing sensitivity to horn chromatic effects. Simulations confirm strong response to these effects. ML models predict beam quality and horn current to sub-percent accuracy from muon data, enhancing anomaly detection and stability. This scalable, AI-enabled strategy improves beam fidelity, reduces systematics, and sets a new standard for high-power accelerator operations.

Ganguly, Sudeshna [Fermilab] (ORCID:00000003163482↗

DOE OSTI2024

Assessment of Condition Monitoring Methods and Technologies for Inservice Inspection and Testing of Nuclear Power Plant Components

This report was prepared for the U.S. Nuclear Regulatory Commission (NRC) to explore the application of advanced technologies toward meeting the current and future regulatory requirements for maintenance and condition monitoring of structures, systems, and components. The advanced technologies considered in this work are advanced sensors and instrumentation, data analytics, machine learning and artificial intelligence (ML/AI), physics-based models, and digital twins (DT). The interest in the application of advanced technologies for condition monitoring in nuclear power plants continues to grow, and current and future licensees are expected to implement advanced technologies as part of their inservice inspection (ISI) and inservice testing (IST) programs. This report delineates the outcomes of an exploratory investigation into the implementation of advanced condition monitoring technologies to address ISI and IST requirements. A thorough review was conducted of the existing regulatory requirements for ISI and IST, along with an analysis of associated industry practices. Additionally, a state-of-the-art assessment was performed on advanced condition monitoring technologies frequently employed in non-nuclear sectors. This research incorporated two nuclear-specific case studies to illustrate the application of these technologies within the current nuclear fleet. The report provides an exhaustive discussion on the technical challenges, considerations, and opportunities associated with the deployment of advanced condition monitoring technologies. The following are key considerations in the application of advanced technologies for the ISI and IST of nuclear power plant components: • Developing adequate verification and validation procedures to confirm the functional and non-functional requirements, • Developing technical capabilities to conduct real-time asset condition monitoring, • Establishing guidance and protocol for modeling and simulation tools to continuously meet regulatory requirements, • Addressing trustworthiness, explainability, and interpretability of ML/AI methods, • Evaluating maintenance activities to maintain an adequate safety margin and avoid undesirable conditions, • Establishing cybersecure condition monitoring programs associated with a computer-based software system, and • Establishing standardized evaluation metrics for advanced condition monitoring programs. Interest in the use of advanced technologies for condition monitoring in ISI and IST programs continues to grow, and the technology is expected to experience rapid and wide industry adoption in the near future. Adoption of advanced technologies for condition monitoring could have novel and unique impacts on regulatory activities associated with ISI and IST programs. The NRC is continuing to explore the regulatory aspects of advanced technologies as part of ISI and IST programs by pursuing additional research in this technical area.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Tactical Analysis for Calculating Contextual Risk at Boundaries: Summary of Laboratory Directed Research & Development Effort

The Tactical Analysis for Calculating Contextual Risk at Boundaries (TACCRAB) tool is an innovative digital twin (DT) platform and automated risk algorithm designed to transform operational decision-making in structured screening environments, with an initial focus on Southern Border Land Ports of Entry (POEs). The invention provides integration points for advanced artificial intelligence, predictive modeling, and real-time data analysis to produce a comprehensive risk management tool that enables proactive, data-informed security strategies. The core inventive features of TACCRAB center on its unique risk algorithm, which dynamically calculates contextual risk by synthesizing historical data, near real-time streaming data from the checkpoints themselves, and AI-generated predictions. Unlike traditional risk assessment methods, TACCRAB utilizes a DT to provide comprehensive operational insights, allowing stakeholders to visualize, simulate, and optimize checkpoint configurations with unprecedented speed and contextual awareness. TACCRAB's key innovation lies in its ability to combine multiple complex inputs - including technology detection probabilities, resource availability, screening pathway characteristics, and threat actor behavioral patterns - into a unified risk calculation and update these inputs based on changing operational and environmental conditions. By leveraging a DT that continuously updates and learns from linked data, TACCRAB can suggest adaptive mitigation strategies that minimize risk while maintaining operational efficiency. Particularly novel is the platform's approach to decision support, which goes beyond static risk assessment. The DT provides dynamic metrics such as wait times, resource allocation effectiveness, and potential emerging threat scenarios, enabling users to view sophisticated, relevant what-if simulations and optimize checkpoint operations in near real-time. The system's architecture allows for generalized application across different screening environments, such as secure facilities, ports of entry, and soft targets, making it a versatile tool for security and operational management. The invention distinguishes itself through its comprehensive integration of predictive modeling, AI-driven pattern discovery, and user-friendly interface design. By combining these elements, TACCRAB transforms complex risk data into actionable insights, supporting decision-makers at various organizational levels - from booth agents making split-second screening decisions to checkpoint managers optimizing the day's resource allocation to strategic planners managing long-term investments.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2024

Strategy to Develop a Control Scheme for Core Thermal Performance Optimization

This report outlines a three-year research plan for optimizing reactor core thermal performance through use of a Digital Twin (DT) model and a set of neutron detectors to correspondingly adapt the reactor control strategy. It identifies reactor features and achievable neutron measurements that factor into this optimization task. It considers spatial effects that are important and how they can be managed by a real-time algorithm that controls reactivity actuators. The report presents a set of tasks, along with corresponding methods, for accomplishing this objective. The final task in this set is to validate the combined optimization procedure in the Purdue University’s PUR-1 reactor, for which we have an agreement of understanding. Additionally, we describe an alternative approach for overcoming some of the limitations inherent in the above approach, which includes the computational costs of high-fidelity simulations and achievable integration of neutron measurements into the DT. The proposed algorithms lower the technology readiness level (TRL) of the overall approach as some additional analysis and the development of a new neutron detector concept are necessary. In particular, a sensor measuring the gradient of the neutron flux is required, and the prototype is expected to be validated in the PUR-1 reactor. The potential benefits and the opportunity to significantly push forward the state-of-the-art make this approach worthy of further exploration in the upcoming years.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

A Real-Time Testbed for Smart Inverter Cyber Security Studies

Distributed energy resources (DER) have become a popular solution to modern-day issues surrounding the efficiency and reliability of power generation, as well as climate change concerns. Energy centers are shifting towards incorporating smart inverters with embedded functionalities such as high voltage ride through (HVRT), low voltage ride through (LVRT), active and reactive power compensation. However, the integration of smart inverters leave DER systems highly vulnerable to cybersecurity threats. The distributed network protocol 3 (DNP3) is a common method of communication between grid-tied hardware. Despite its popularity, the level of security leaves all hardware connected to the grid at risk of severe cyber-attacks. Thus, it is important to study any potential cybersecurity threats towards grid-tied smart inverters to mitigate cybersecurity vulnerabilities and refine existing cyber-security protections. This report describes the proposed testbed design to study cybersecurity threats to smart inverters. The testbed utilizes a real-time simulation case in RSCAD that includes a grid-tied wind turbine (WT) topology featuring two back-to-back two-level voltage source converters (BTB,2L-VSCs) and a permanent magnet synchronous machine (PMSM). The simulated case runs within the NovaCor real time digital simulator (RTDS). This report focuses on the design and implementation of a single module of the GTNETx2 card as a distributed network protocol and the configuration of an IEEE 1518 DNP database file that includes input and output variables mapped to different connection points in the grid that transmit and receive discrete, analog, and binary signals on command. This allows realistic emulation of the communication between the smart inverter and the grid for cybersecurity studies.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

A machine-learning-aided data recovery approach for predicting multi-material thermal behaviors in advanced test reactor capsules

Instrumented experiments conducted at test reactors are essential to the deployment of new advanced reactor systems. Designing new experiments and generating data on specific reactor conditions require significant investments in terms of both time and cost. Finite element analysis software can be used to create high-fidelity models of experiment environments in order to support the actual experiments, but computation time remains a concern in terms of applying outcomes to real-time usage of data (e.g., a digital twin [DT]). Here, the present research proposes a machine-learning (ML) aided approach to making temperature and displacement predictions based on the thickness of the outer gas gap on the experimental capsule used for in-pile demonstration of a novel new thermal conductivity probe in the Advanced Test Reactor (ATR). This capsule consisted of U10Zr fuel, a rodlet, sodium, and inner and outer capsules. Gas gaps existed between the fuel and the rodlet, and between the inner and the outer capsule. The learning data pertained to an experimental capsule's radial distributions of temperature and displacement, as obtained based on Abaqus and the physical features. For the first step of ML sequence, the temperature was predicted using three positional parameters. Next, the displacement was predicted using seven additional parameters. Each physical feature was normalized in order to be both nondimensional and standardized. The temperature and displacement predictions showed good agreement with the simulation results in all cases involving interpolation and extrapolation. Furthermore, data similarity enhancement increased the similarity between the training and the target data, thereby increasing the predictive accuracy of the ML models. In certain extrapolation cases involving limited original ML model accuracy, data similarity enhancement and data recovery was able to somewhat improve this accuracy.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Machine learning-driven design and self-sensing capabilities of automotive bumper lattices for adaptive impact response

We present a novel approach to design an automotive bumper energy absorber using carbon fiber reinforced polymer composites, optimized to meet conflicting performance requirements for two distinct impact scenarios. The design must satisfy both a low-speed (2.5 mph) pendulum intrusion test, simulating vehicle-to-vehicle collisions, and a high-speed (25 mph) leg flexion test, replicating pedestrian impacts. These tests demand opposing deformation characteristics: high flexibility (deformation < 85 mm) for the former and high stiffness (deformation < 22 mm) for the latter. To address these contradictory requirements, we developed a machine learning (ML) framework for inverse optimization of lattice designs and material selection. Unlike traditional iterative design processes, our ML model directly outputs optimal design parameters and material choices based on target performance inputs. The energy absorber was fabricated using advanced additive manufacturing techniques, including extrusion deposition and digital light processing. The integration of carbon fibers provides multifunctionality to the bumper structure, enabling self-sensing capabilities through changes in electrical resistivity under compression. This electrical response demonstrates high repeatability under multiple cycles at 2% compression and exhibits distinct signatures during crack formation under high deformation. This research offers adaptive performance through innovative design methodologies and smart material integration. The approach has potential applications in various fields requiring adaptive energy absorption and real-time structural health monitoring.

Chawla, Komal [ORNL] (ORCID:0000000190327565)↗

DOE OSTI2025

EUREICA: Efficient UltRa Endpoint IoT-enabled Coordinated Architecture

The electricity grid has evolved from a physical system to a cyber-physical system with digital devices that perform measurement, control, communication, computation, and actuation. The increased penetration of distributed energy resources (DERs) that include renewable generation, flexible loads, and storage provides extraordinary opportunities for improvements in efficiency and sustainability. However, they can introduce new vulnerabilities in the form of cyberattacks, which can cause significant challenges in ensuring grid resilience. The purpose of this project was to develop a framework ((Efficient, Ultra-REsilient, IoT-Coordinated Assets, or EUREICA)for achieving grid resilience through suitably coordinated assets including a network of Internet of Things (IoT) devices, and a local electricity market (LEM) to identify trustable assets and carry out this coordination. Situational Awareness (SA) of locally available DERs with the ability to inject power or reduce consumption is enabled by the market, together with a monitoring procedure for their trustability and commitment. Experiments conducted during this project demonstrated that, with this SA, a variety of cyberattacks can be mitigated using local trustable resources without stressing the bulk grid. The demonstrations were carried out using a variety of high-fidelity co-simulation platforms, real-time hardware-in-the-loop validation, and a utility-friendly simulator.

14 SOLAR ENERGY↗

DOE OSTI2025

Real-Time Testbed for Smart Grid Recloser Controller

The growing need for a low voltage recloser has become apparent due to the rise in requirements for a smart grid. This includes more detailed management of power flow forward (towards load) and backward (towards generation), source synchronization in real time, more indepth fault responses, and the use of green energy. The SEL-651R-2 relay is a device that can manage these needs, especially in fault response and synchronization, and is commonly used in systems called microgrids. Microgrids are distribution level systems that are able to operate separated from the main grid, are typically installed much closer to the load(s), and are fed by distributed energy resources (DERs), such as wind, solar or diesel generators. The SEL-651R-2 is normally used in the field with presets operative settings, but the Western Michigan University (WMU) Center for Interdisciplinary Research on Secure, Efficient and Sustainable Energy Technology (WMU InterEnergy Center) wished to test this device in its range of capabilities for microgrid application. A Hardware-In-the-Loop (HIL) testbed was implemented and used through the Real Time Digital Simulator (RTDS) using the RSCAD software to test the SEL-651R-2's use cases and functions. The testbed includes a microgrid with interconnection to a larger main grid, and the relay is meant to control the recloser at the point of common coupling (PCC) between the main grid and microgrid. The testbed shows how basic protections, reclosing, and synchronization checks function when handling faults that affect both the microgrid and the main grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Model-Based Detection of Coordinated Attacks (DCA) in Distribution Systems

The fast-paced growth in digitization of smart grid components enhances system observability and remote-control capabilities through efficient communication. However, enhanced connectivity results in heightened system vulnerability towards cybersecurity risks in the cyber-physical power system. Coordinated cyber-attacks (CCA), when undetected, lead to system-wide impact in terms of large disturbances or widespread outages. Detecting CCA in the cyber layer is critical to thwart cyber-attacks in real-time before the attack impacts the physical system. The challenge of locating CCA stems from the complex grid dynamics, making it difficult to distinguish between normal operational variations and cyber-attack impact. CCA often employs multiple attack vectors targeting geographically distributed components, further complicating CCA identification. Existing research in intrusion detection is primarily focused on the transmission network and limited to detecting individual attacks. In this paper, a novel proactive DCA strategy is proposed for early detection of CCA by establishing correlations among distinct attack events through model-based reinforcement learning that utilizes abductive reasoning to conclude the attacker goal. The solution includes understanding the system model, learning the system dynamics, and correlating individual cyber-attacks to extract the attacker’s objective. The developed learning algorithm identifies the most probable attack path to reach the attacker’s objective by predicting the next attack steps. A DNP3-based cyber-physical co-simulation testbed is developed to test the proposed algorithm using the IEEE 13-node test feeder.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Revolutionizing Energy Storage: AI, Automation, and Advanced Modeling as Catalysts for Next-Generation Breakthroughs

The Presidential Symposium (PRES) at the 2025 Fall Meeting, hosted by the President’s Office and Energy and Fuels Division, American Chemical Society (ACS) in Washington, DC, brought together a diverse group of chemists, engineers, and materials scientists working in battery materials & systems, automation and artificial intelligence from academia, industry, and national laboratories. The accelerating demand for high-performance, scalable, and sustainable energy storage has catalyzed a paradigm shift in how materials are dis-covered, devices are engineered, and systems are optimized. This Presidential Symposium, entitled “Revolutionizing Energy Storage: AI, Automation, and Advanced Modeling Driving Next-Gen Breakthroughs”, brings together global leaders to unveil transformative strategies anchored in the AAA framework: Artificial Intelligence, Automation, and Advanced Modeling. Artificial Intelligence is redefining the frontiers of energy storage by enabling predictive design, real-time optimization, and intelligent control across diverse chemistries and architectures. Automation is streamlining the synthesis, characterization, and testing of battery materials, dramatically accelerating innovation cycles and unlocking scalable solutions for grid and mobility applications. Advanced Modeling, spanning atomic to system-level scales, provides unprecedented insight into electrochemical dynamics, degradation pathways, and thermal behavior, particularly when coupled with physics-informed machine learning and digital twin technologies. Digital twins, in turn, leverage the AAA framework by integrating real-time data, physics-based models, and AI predictions into dynamic virtual replicas, enabling proactive diagnostics, optimization, and system resilience. Together, these synergistic pillars are not only re-shaping the scientific landscape but also forging a new era of reproducible, data-driven, and resilient energy storage innovation. In conclusion, this symposium marks a pivotal moment in the convergence of computational intelligence and experimental rigor, charting the course for next-generation breakthroughs in lithium-ion, solid-state, and flow battery technologies.

Artificial Intelligence (AI)↗

DOE OSTI2025

Advancements in Constitutive Model Calibration: Leveraging the Power of Full‐Field DIC Measurements and In Situ Load Path Selection for Reliable Parameter Inference

Accurate material characterization and model calibration are essential for computationally supported high-consequence engineering decisions. Historically, characterization and calibration methods (1) use simplified test specimen geometries and global data, (2) cannot guarantee that sufficient characterization data are collected for a specific model of interest, (3) use deterministic methods that provide best-fit parameter values with no uncertainty quantification, and (4) are sequential, inflexible, and time-consuming. This work brings together several recent advancements into an improved workflow called interlaced characterization and calibration (ICC) that advances the state-of-the-art in constitutive model calibration. The ICC paradigm (1) employs tools to efficiently use full-field data to calibrate high-fidelity material models, (2) aligns the data needed with the data collected by adopting an optimal experimental design protocol, (3) quantifies parameter uncertainty through Bayesian inference and (4) incorporates these advancements into a quasi real-time feedback loop. The ICC framework is demonstrated here on the calibration of a material model using simulated full-field data for an aluminium cruciform specimen being deformed biaxially. The cruciform is actively driven through the myopically preferred load path using Bayesian optimal experimental design, which selects load steps that yield the maximum expected information gain (EIG). Principal component analysis (PCA) is performed on the model predictions of full-field displacements, and fast surrogate models are built to approximate the input-output relationships of the expensive finite element model. Furthermore, the tools developed and demonstrated here show that high-fidelity constitutive models can be efficiently and reliably calibrated with quantified uncertainty, thus supporting credible decision-making and potentially increasing the agility of solid mechanics modelling by enabling utilization of computational simulations at earlier stages of the design cycle.

Bayesian optimal experimental design↗

DOE OSTI2024

The FRB-searching Pipeline of the Tianlai Cylinder Pathfinder Array

This paper presents the design, calibration, and survey strategy of the Fast Radio Burst (FRB) digital backend and its real-time data processing pipeline employed in the Tianlai Cylinder Pathfinder Array. The array, consisting of three parallel cylindrical reflectors and equipped with 96 dual-polarization feeds, is a radio interferometer array designed for conducting drift scans of the northern celestial semi-sphere. The FRB digital backend enables the formation of 96 digital beams, effectively covering an area of approximately 40 square degrees with the 3 dB beam. Our pipeline demonstrates the capability to conduct an automatic search of FRBs, detecting at quasi-real-time and classifying FRB candidates automatically. The current FRB searching pipeline has an overall recall rate of 88%. During the commissioning phase, we successfully detected signals emitted by four well-known pulsars: PSR B0329+54, B2021+51, B0823+26, and B2020+28. We report the first discovery of an FRB by our array, designated as FRB 20220414A. We also investigate the optimal arrangement for the digitally formed beams to achieve maximum detection rate by numerical simulation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Development of Emergency Vehicle Preemption Strategies on Smart Corridors in a Digital Twin Environment

Emergency Response Vehicles (ERVs), such as firetrucks, ambulances, etc. operate with the purpose of saving lives and mitigating property damage. As such, ERV travel-time reductions may result in significant benefits to the community. A common strategy to improve travel times is Emergency Vehicle Preemption (EVP). EVP seeks to reduce ERV delays by providing the right-of-way to ERVs as they approach an intersection. This study proposes a new Dynamic Preemption strategy that determines the need for preemption prior to the ERV reaching the vicinity of the intersection, utilizing real-time data streams. This paper evaluates the effectiveness of some existing and proposed preempt control strategies using a digital twin testbed consisting of a series of signalized intersections on an urban arterial in Georgia. The best EVP strategy maximizes the improvement in ERV travel time while minimizing the adverse effect of preemption on the traffic in conflicting directions. Therefore, this study evaluates both the positive impact of EVP on the ERV as well as the adverse impact on the cross-street traffic. The study found that the potential exists for significant improvements in ERV travel time with the proposed Dynamic Preemption strategy, with minimal impact to the conflicting traffic. For the simulation corridor there was a 20% reduction in the ERV travel times with the implementation of the Dynamic Preemption strategy, compared to traditional EVP practices.

Roy, Somdut [Georgia Institute of Technology]↗

DOE OSTI2025

AutoFocus: AI/ML-driven real-time wavefront diagnostics to autonomously align and optimize X-ray optics

We present an integrated system that combines advanced wavefront diagnostics with artificial intelligence (AI) to automate and optimize X-ray optics at synchrotron beamlines. This system couples real-time wavefront sensing with AI-driven control algorithms to achieve precise beam alignment, stabilization, and performance optimization. A key feature is the use of multi-fidelity transfer learning, which enables knowledge gained from both real-world beamline optimizations and ultra-realistic digital twin simulations to be effectively applied to in situ optimization. By leveraging multi-objective bayesian optimization, the system continuously refines its performance, reducing optimization time and minimizing the need for manual adjustments. Designed for seamless deployment, it operates with existing beamline hardware and provides an intuitive graphical interface. Initial deployments at the advanced photon source beamlines have demonstrated its ability to enhance beam stability, improve reproducibility, and significantly streamline alignment procedures. This AI-enhanced control framework represents a significant step toward fully autonomous beamline operation in next-generation synchrotron facilities.

Rebuffi, Luca [Argonne National Laboratory (ANL), ↗

DOE OSTI2025

Integration and Demonstration of Monitoring, Modeling, and Prediction of DV-1 Amendment Performance at the Bench Scale: DV-1 Amendment Demonstration

During fiscal years 2024 and 2025, the U.S. Department of Energy’s Hanford Field Office commissioned Pacific Northwest National Laboratory to conduct applied research aimed at reducing the cost, time, and uncertainty associated with in situ treatment of vadose zone contaminants at the Hanford Site. This report outlines the integration of three key research efforts into a meso-scale demonstration designed to advance field-scale solutions that aim to (1) optimize the delivery of chemical amendments to contaminated soils, (2) reduce uncertainty in amendment delivery performance assessment using advanced monitoring techniques, and (3) provide real-time insights into when and where amendment-induced precipitation reactions occur in the subsurface. To achieve these objectives, the tank-scale (~ 1 cubic meter) Geophysical Imaging of Flow and Transport (GIFT) system was developed. GIFT enables experimental testing of amendment delivery while incorporating automated multi-modal monitoring approaches, including pressure measurements, direct fluid sampling, and remote time-lapse geophysical imaging. The data generated from these monitoring techniques will serve as inputs for a generative artificial-intelligence-driven digital twin – a numerical simulation model designed to honor observed data while quantifying uncertainty in simulation accuracy. Using this simulator, researchers will refine an amendment injection strategy to maximize delivery efficiency within a low-permeability soil zone. Monitoring data will be interpreted through simulated outputs to enhance understanding of the injection process. The efficacy of this integrated approach will be evaluated through direct sampling at the conclusion of the experiment.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

36 MATERIALS SCIENCE↗