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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 OSTI2025

Data Centers and Digital Assurance Introduction to Supply Chain and Cybersecurity for Data Centers, Session 1

The first session of the TADA (Technical Assistance for Digital Assurance) Data Centers Cohort Workshop, held on October 30, 2025, introduced foundational concepts of Digital Assurance in the context of data center and grid integration. Sponsored by the U.S. Department of Energy, the workshop brought together utilities, data center operators, developers, and vendors to address cybersecurity and supply chain vulnerabilities. The session emphasized the growing criticality of data centers within the electric grid and the need for secure, real-time, bidirectional communication. Participants explored the principles of Digital Assurance, including cybersecurity, cyber-informed engineering (CIE), and lifecycle security, and applied a threat-vulnerability-consequence framework to identify and mitigate risks at the data center–grid interface. Discussions covered a range of threats such as spoofed dispatch signals and insider threats, architectural vulnerabilities like SCADA interfaces and insecure protocols, and potential consequences including cascading grid failures. The session also raised strategic questions about business value, vendor assurance, and defining cyber boundaries and responsibilities. This foundational workshop set the stage for deeper technical analysis and the development of actionable frameworks in subsequent sessions. Session 1 of 3.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

A Physics-Based Digital Twin for Wave Elevation and Seabed Moment Estimation of Offshore Monopiles: Preprint

In this work, we present a proof of concept of a physics-based digital twin for a monopile structure (with overhead inertia) subjected to wave loading. The digital twin is formulated using reduced-order models derived from first principles and combined with a Kalman filter for state estimation. The proposed framework estimates the monopile top motion, the wave elevation, and the section forces and moments along the pile using primarily acceleration measurements at the monopile top. Key innovations include the use of a hydrodynamic shape function to represent distributed wave loading in a compact and computationally efficient manner, and the introduction of a shaping filter to augment the state-space with wave kinematics. Synthetic measurement data are generated using OpenFAST and used as a reference to assess the performance of the digital twin. Results demonstrate that the wave elevation can be accurately reconstructed without direct sea-state measurements as long as the wave regime is inertia-dominated. Under the ideal tested conditions, the total hydrodynamic force and sea-bed bending moment are estimated with relative errors on the order of 1% and correlation coefficients exceeding 96%. Future work will evaluate the estimator's performance under operational uncertainties and more complex loading conditions.

17 WIND ENERGY↗
DOE OSTI2024

A novel digital lifecycle for Material‐Process‐Microstructure‐Performance relationships of thermoplastic olefins foams manufactured via supercritical fluid assisted foam injection molding

Abstract This research significantly enhances the applicability of thermoplastic olefins (TPOs) in the automotive industry using supercritical N 2 as a physical foaming agent, effectively addressing the limitations of traditional chemical agents. It merges experimental results with simulations to establish detailed material‐process‐microstructure‐performance (MP2) relationships, targeting 5–20% weight reductions. This innovative approach labeled digital lifecycle (DLC) helps accurately predict tensile, flexural, and impact properties based on the foam microstructure, along with experimentally demonstrating improved paintability. The study combines process simulations with finite element models to develop a comprehensive digital model for accurately predicting mechanical properties. Our findings demonstrate a strong correlation between simulated and experimental data, with about a 5% error across various weight reduction targets, marking significant improvements over existing analytical models. This research highlights the efficacy of physical foaming agents in TPO enhancement and emphasizes the importance of integrating experimental and simulation methods to capture the underlying foaming mechanism to establish material‐process‐microstructure‐performance (MP2) relationships. Highlights Establishes a material‐process‐microstructure‐performance (MP2) for TPO foams Sustainably produces TPO foams using supercritical (ScF) N 2 with 20% lightweighting Shows enhanced paintability for TPO foam improved surface aesthetics Digital lifecycle (DLC) that predicts both foam microstructure and properties DLC maps process effects & microstructure onto FEA mesh for precise prediction

Engineering↗
DOE OSTI2025

Physics augmented machine learning discovery of composition-dependent constitutive laws for 3D printed digital materials

Multi-material 3D printing, particularly through polymer jetting, enables the fabrication of digital materials by mixing distinct photopolymers at the micron scale within a single build to create a composite with tunable mechanical properties. Here, this work presents an integrated experimental and computational investigation into the composition-dependent mechanical behavior of 3D printed digital materials. We experimentally characterize five formulations, combining soft and rigid UV-cured polymers under uniaxial tension and torsion across three strain and twist rates. The results reveal nonlinear and rate-dependent responses that strongly depend on composition. To model this behavior, we develop a physics-augmented neural network (PANN) that combines a partially input convex neural network (pICNN) for learning the composition-dependent hyperelastic strain energy function with a quasi-linear viscoelastic (QLV) formulation for time-dependent response. The pICNN ensures convexity with respect to strain invariants while allowing non-convex dependence on composition. To enhance interpretability, we apply $L_0$ sparsification. For the time-dependent response, we introduce a multilayer perceptron (MLP) to predict viscoelastic relaxation parameters from composition. The proposed model accurately captures the nonlinear, rate-dependent behavior of 3D printed digital materials in both uniaxial tension and torsion, achieving high predictive accuracy for interpolated material compositions. This approach provides a scalable framework for automated, composition-aware constitutive model discovery for multi-material 3D printing.

Constitutive modeling↗
DOE OSTI2024

The Mu2e Digitizer ReAdout Controller (DiRAC): characterization and radiation hardness

The Mu2e experiment at Fermilab will search for the neutrino-less coherent conversion of a muon into an electron in the field of a nucleus. Mu2e detectors comprise a straw tracker, an electromagnetic calorimeter and a veto for cosmic rays. The calorimeter employs 1348 Cesium Iodide crystals readout by silicon photo-multipliers and fast front-end, and digitization electronics. The digitization board is named DiRAC (Digitizer ReAdout Controller) and 140 cards are needed for the readout of the full calorimeter. The DiRACs are hosted in crates located on the external surface of calorimeter disks, inside the detector solenoid cryostat and must sustain very high radiation and magnetic field so it was necessary to fully qualify it. Several version of prototypes were validated for operation in a high-vacuum (10−4 Torr) and under a 1T magnetic field. An extensive radiation hardness qualification campaign, carried out with photons, 14 MeV neutron beams, and 200 MeV protons, certified the DiRAC design to sustain doses up to 12 Krad, neutron fluences up to ∼ 1011 1 MeV neq/cm2, and very low occurrences of single-event effects. The qualification campaigns and quality assurance procedures will be reviewed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Thermalization and criticality on an analogue–digital quantum simulator

Abstract Understanding how interacting particles approach thermal equilibrium is a major challenge of quantum simulators 1,2 . Unlocking the full potential of such systems towards this goal requires flexible initial state preparation, precise time evolution and extensive probes for final state characterization. Here we present a quantum simulator comprising 69 superconducting qubits that supports both universal quantum gates and high-fidelity analogue evolution, with performance beyond the reach of classical simulation in cross-entropy benchmarking experiments. This hybrid platform features more versatile measurement capabilities compared with analogue-only simulators, which we leverage here to reveal a coarsening-induced breakdown of Kibble–Zurek scaling predictions 3 in theXYmodel, as well as signatures of the classical Kosterlitz–Thouless phase transition 4 . Moreover, the digital gates enable precise energy control, allowing us to study the effects of the eigenstate thermalization hypothesis 5–7 in targeted parts of the eigenspectrum. We also demonstrate digital preparation of pairwise-entangled dimer states, and image the transport of energy and vorticity during subsequent thermalization in analogue evolution. These results establish the efficacy of superconducting analogue–digital quantum processors for preparing states across many-body spectra and unveiling their thermalization dynamics.

Science & Technology - Other Topics↗
DOE OSTI2024

Stochastic machine learning via sigma profiles to build a digital chemical space

This work establishes a different paradigm on digital molecular spaces and their efficient navigation by exploiting sigma profiles. To do so, the remarkable capability of Gaussian processes (GPs), a type of stochastic machine learning model, to correlate and predict physicochemical properties from sigma profiles is demonstrated, outperforming state-of-the-art neural networks previously published. The amount of chemical information encoded in sigma profiles eases the learning burden of machine learning models, permitting the training of GPs on small datasets which, due to their negligible computational cost and ease of implementation, are ideal models to be combined with optimization tools such as gradient search or Bayesian optimization (BO). Gradient search is used to efficiently navigate the sigma profile digital space, quickly converging to local extrema of target physicochemical properties. While this requires the availability of pretrained GP models on existing datasets, such limitations are eliminated with the implementation of BO, which can find global extrema with a limited number of iterations. A remarkable example of this is that of BO toward boiling temperature optimization. Holding no knowledge of chemistry except for the sigma profile and boiling temperature of carbon monoxide (the worst possible initial guess), BO finds the global maximum of the available boiling temperature dataset (over 1,000 molecules encompassing more than 40 families of organic and inorganic compounds) in just 15 iterations (i.e., 15 property measurements), cementing sigma profiles as a powerful digital chemical space for molecular optimization and discovery, particularly when little to no experimental data is initially available.

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 OSTI2024

A Digital Twin Framework for Liquid-cooled Supercomputers as Demonstrated at Exascale

We present ExaDigiT, an open-source framework for developing comprehensive digital twins of liquid-cooled supercomputers. It integrates three main modules: (1) a resource allocator and power simulator, (2) a transient thermo-fluidic cooling model, and (3) an augmented reality model of the supercomputer and central energy plant. The framework enables the study of "what-if" scenarios, system optimizations, and virtual prototyping of future systems. Using Frontier as a case study, we demonstrate the framework's capabilities by replaying six months of system telemetry for systematic verification and validation. Such a comprehensive analysis of a liquid-cooled exascale supercomputer is the first of its kind. ExaDigiT elucidates complex transient cooling system dynamics, runs synthetic or real workloads, and predicts energy losses due to rectification and voltage conversion. Throughout our paper, we present lessons learned to benefit HPC practitioners developing similar digital twins. We envision the digital twin will be a key enabler for sustainable, energy-efficient supercomputing.

Brewer, Wes↗
DOE OSTI2026

Zero-day Attack Detection in Digital Substations Using In-Context Learning

In this paper, we address the critical challenge of detecting zero-day attacks in digital substations that employ the IEC-61850 communication protocol to ensure the security and reliability of modern power systems. While many heuristic and machine learning (ML)-based methods have been proposed for attack detection in IEC-61850 digital substations, generalization to unknown or zero-day attacks remains a challenge. We propose an approach that leverages the in-context learning ability of transformer architecture, which enables the model to learn from a few examples of a new task without explicit retraining. Our experiments on the IEC-61850 dataset demonstrate that the proposed method achieves more than 87% detection accuracy on zero-day attacks while the existing baselines fail. We believe this work has the potential to enhance the security of digital substations by enabling the effective detection of zero-day attacks.

LIu, Chen-Ching [Virginia Tech] (ORCID:00000002894↗
DOE OSTI2025

HPC Digital Twins for Evaluating Scheduling Policies, Incentive Structures and their Impact on Power and Cooling

Schedulers are critical for optimal resource utilization in high-performance computing. Traditional methods to evaluate sched- ulers are limited to post-deployment analysis, or simulators, which do not model associated infrastructure. In this work, we present the first-of-its-kind integration of scheduling and digital twins in HPC. This enables what-if studies to understand the impact of parameter configurations and scheduling decisions on the physical assets, even before deployment, or regarching changes not easily realizable in production. We (1) provide the first digital twin framework extended with scheduling capabilities, (2) integrate various top-tier HPC systems given their publicly available datasets, (3) implement extensions to integrate external scheduling simulators. Finally, we show how to (4) implement and evaluate incentive structures, as- well-as (5) evaluate machine learning based scheduling, in such novel digital-twin based meta-framework to prototype scheduling. Our work enables what-if scenarios of HPC systems to evaluate sustainability, and the impact on the simulated system.

Maiterth, Matthias [ORNL] (ORCID:000000018698460X)↗
DOE OSTI2024

Agn-201 Digital Twin

This is the repository for all code related to the AGN-201 Nuclear Reactor Digital Twin at Idaho State University. The goal of this code repository is to consolidate all pieces required to run the AGN-201 Digital Twin in the [DeepLynx](https://github.com/idaholab/Deep-Lynx) ecosystem. This is the first successfully launched digital twin of a fissile nuclear reactor that we are aware of. While the code is not complex, the problems of networking, policy, and initial groundwork were significant to overcome.

Darrington, JohnW.↗
DOE OSTI2025

RFSoC based digital low level RF control firmware and software suite (mimo_llrf) v1.0

It features a framework of a firmware and software architecture in support of building a digital low-level RF control system for accelerators, where precised digital RF generation and measurement are needed across many RF channels. It primarily supports the Xilinx RFSoC chips (xczu48dr, xczu47dr, xczu29dr) and their evaluation boards (zcu208, zcu216), for a highly integrated solution enabling the need for synchronous low-level RF systems, including: multi-tile synchronization, external reference for sampling clocks, deterministic delay, aligned NCO phase for digital mixers, and built-in EPICS IOC.

Du, Qiang [Lawrence Berkeley National Laboratory (↗
DOE OSTI2024

Comparative Assessment of U-Net-Based Deep Learning Models for Segmenting Microfractures and Pore Spaces in Digital Rocks

Segmentation of high-resolution X-ray microcomputed tomography (µCT) images is crucial in digital rock physics (DRP), affecting the characterization and analysis of microscale phenomena in the porous media. The complexity of geological structures and nonideal scanning conditions pose significant challenges to conventional image segmentation approaches. Motivated by the recent increasing popularity of deep learning (DL) techniques in image processing, this work undertakes a comparative study of DL models, specifically U-Net and its variants, for segmenting multiple targets with distinguished features in digital rocks, including discrete fracture networks (DFNs), pore spaces, and solid rock. Particularly, DFNs have a smaller volumetric fraction over others, bringing in a substantial challenge of imbalanced segmentation. The primary focus is to evaluate the architecture and feature enhancement strategies of various DL models, including U-Net, attention U-Net, residual U-Net, U-Net++, and residual U-Net++. The models were designed as 2.5D, utilizing a central 2D image and its two adjacent upper and lower 2D images as input to provide a pseudo-3D context. In addition, because the ground truth of segmentation was unknown for real-world digital rocks, we created a benchmark data set following the inverse operations of segmentation. The data synthesis started from the label images (i.e., solid rock, pore spaces, and DFNs), followed by simulating partial volume blurring, adding random background noise, and introducing ring artifacts to mimic real raw X-ray µCT images. The data set, which included various rock types (i.e., sandstone and artificial data), scanning resolution, and magnitudes of noise and artifacts, was divided into training and testing data sets with a 90% and 10% ratio, respectively. Moreover, in addition to the conventional pixel-wise evaluation metrics, the physics-based metric of the lattice-Boltzmann method (LBM) simulated permeability provided more comprehensive assessments. The results demonstrated that the residual connections, nested architectures, and redesigned skip connections contribute to the model performance and give the residual U-Net++ the highest accuracy. The improvements were mainly on the boundaries and small targets, especially the DFNs, which dominate the interconnectivity and therefore affect the permeability greatly. This study also rigorously evaluated the efficiency and generalization of each model, demonstrating that the sophisticated architectures achieved excellent practicability and maintained robust performance on completely unseen data, ensuring their suitability for diverse and challenging DRP applications.

58 GEOSCIENCES↗
DOE OSTI2024

Digital Assurance for High Consequence Systems: 2024 Mission Campaign White Paper

This Sandia National Laboratories Mission Campaign (MC) seeks to create the technical basis that allows national leaders to efficiently assess and manage the digital assurance of high consequence systems. We will call for transformative research that enables efficient (1) development of provably secure systems and secure integration of untrusted products, (2) intelligent threat mitigation, and (3) digital risk-informed engineering trade-offs. Ultimately, this MC will impact multiple national security missions; it will develop an informed Digital Assurance for High Consequence Systems (DAHCS) community and expand Sandia partnerships to build this national capability.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Evaluation of Rooftop Solar Potential in Chernihiv and Lviv, Ukraine, and Efficacy of High-Resolution 3D Data Digital Twins [Slides]

NREL evaluated rooftop solar photovoltaic (PV) siting opportunities in the cities of Chernihiv and Lviv, Ukraine, leveraging very-high-resolution 3D elevation data to calculate technical potential. The study assessed total rooftop solar capacity and annual energy production. In Chernihiv and Lviv, 116,503 buildings were analyzed for their rooftop solar potential. The buildings in the study areas include a mixture of residential, commercial, and industrial buildings, characterized by diverse roof shapes and sizes. The total estimated rooftop solar capacity is 332 MWDC in Chernihiv and 873 MWDC in Lviv with annual energy production up to 376.2 GWhDC in Chernihiv and 995.5 GWhDC in Lviv. This accounting provides a clear estimate of the potential rooftop solar installations that could be realized under optimal conditions, considering both technical constraints and the geographic distribution of available rooftop space. Related to Russia's invasion of Ukraine, NREL estimates loss from buildings damaged or destroyed of 2,754 buildings, 20.15 MWDC of capacity, and 22,869 MWhDC of annual energy production in Chernihiv as well as a loss of 1,316 buildings, 34.49 MWDC of capacity, and 39,369 MWhDC of annual energy production in Lviv. The study also assessed the feasibility of adapting this methodology on a national scale using either simulated digital surface models (DSMs) or a digital twin approach. While the very-high-resolution DSM provided more precise results, the simulated DSM demonstrated reasonable accuracy for broader applications in modeling aggregated distributed solar supply. The feasibility of using a digital twin for Ukraine's national rooftop solar potential is considered promising, with certain limitations in areas with highly variable building stock and heavy war damage.

14 SOLAR ENERGY↗
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 OSTI2025

Microreactor Automated Control System - Digital Twin Models and Advanced Control Systems Updates

Automation of control systems is expected to be important in the economic and safe operation of microreactors. Therefore, there is a need to develop and demonstrate automated control for microreactors, along with the development of testbeds for this purpose. This report provides updates on the status of a nonnuclear microreactor automated control system (MACS)—a real-time, hardware-in-the-loop testbed for non-nuclear testing of microreactor control system automation. A real-time hardware-in-the-loop testbed incorporates the realistic dynamics of physical systems into control system development and testing. The collaborative effort between Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL) resulted in the development of a prototypic microreactor plant-level digital twin that includes the reactor and a balance of plant system. Advanced control strategies were incorporated to demonstrate testing of control automation solutions. The gRPC communication protocol, which was implemented in the hardware-in-the-loop testbed by INL, was coupled to a digital twin model developed using the TRANsient Simulation Framework of Reconfigurable Models (TRANSFORM) library in Modelica. This digital twin simulation was tested with the ViBRANT hardware for realistic feedback and visual representation of control action in real time. A modular Python client structure was developed to manage functional mock-up unit-based simulation and real-time gRPC communication. Hardware-in-the-loop testing indicated that the modeled reactor—a natural-convection, molten-salt coolant loop configuration—responds well to control of drum positioning for modulation of reactor core power, as well as system-level control and downstream demand changes. Ongoing research is focused on integrating additional control algorithms that utilize data from newly included sensors within the MACS hardware testbed, as well as demonstrating and assessing the performance of the different automated control algorithms on multiple additional operational scenarios.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗