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At least 163 records · Page 9

Integration of sensors through additive manufacturing leading to increased efficiencies of gas turbines for power generation and propulsion

To realize the full capability of additively manufactured components in complex energy systems, it is imperative to minimize early component failures during development phases and during operation. Traditional field feedback timelines and offline inspection protocols significantly reduce the design-manufacturing iteration times. To address this specific question, the project developed and demonstrated a method for the integration of sensors into complex components through additive manufacturing. The team used gas turbine engines as a platform, which meets the need of both power generation and propulsion and offer opportunities for cost reductions and efficiency increases. The innovation of this intelligent integration of sensors into complex components uniquely customized to address questions of integrity and durability for additively manufactured components. With real-time sensing data from additively manufactured components, turbine manufacturers will realize higher efficiencies, reduced component failures, and a 30-50% acceleration in product deployment of high efficiency gas turbine components due to a faster reduction in component risk assessment under actual operating conditions. This is a transformative shift towards a data-driven design and qualification of additively manufactured gas turbine components. To directly integrate sensors into additively manufactured components with all the complexities of actual hardware, powder bed fusion (direct metal laser sintering) and laser metal deposition technologies was developed. Validation took take place in two university laboratories both of which contain actual engine hardware and closely simulate a gas turbine prior to demonstrating the technology in a turbine development test. Indeed, two major technologies from this research cold impact turbine systems in the near future: (1) higher efficiency materials and designs enabled by additive manufacturing with 50% faster design to manufacturing cycle time, to enable faster time-to-market targets; and (2) integration of sensors into additively manufactured components enabling broad health and condition based prognostics for faster component and engine risk reduction.

33 ADVANCED PROPULSION SYSTEMS↗

Basic Research Needs for Inverse Methods for Complex Systems under Uncertainty

Inverse problems, which aim to infer unknown properties of a system using experimental and observational data, are central to addressing many of the U.S. Department of Energy’s (DOE) most critical scientific and engineering challenges. Accurate, computationally efficient, and data-efficient solutions to inverse problems are essential for advancing DOE mission-critical science drivers, including analyzing data from large-scale experimental facilities, optimizing fusion reactor performance, accelerating materials discovery, enhancing geophysical imaging, improving wildfire predictions, and enabling autonomous systems and digital twins. However, these problems are becoming increasingly complex, often involving nonlinear, highdimensional, and interconnected systems and models that span multiple physics and scales, while relying on data with varying quantity, quality, and information content. Compounding these challenges is the uncertainty inherent in DOE-relevant systems, where errors in inputs, noise in data, incompleteness of data, and discrepancies between models and reality constrain the accuracy and precision of solutions. At the same time, the convergence of recent scientific computing trends—scientific machine learning, artificial intelligence, and computing advances such as exascale computing—is creating unprecedented opportunities for tackling these challenges. The cross-cutting nature of inverse problems, combined with their growing complexity and rapidly evolving data and algorithmic demands, strongly motivates the formulation of a prioritized research agenda to maximize their capabilities and impact. In response to this need, DOE’s Advanced Scientific Computing Research (ASCR) program in the Office of Science convened the Workshop on Basic Research Needs for Inverse Problems for Complex Systems Under Uncertainty in June 2025. This workshop brought together experts across disciplines to identify grand challenges and major opportunities in the field. Through collaborative discussions, the workshop defined transformative research directions aimed at addressing the mathematical, statistical, and computational challenges posed by inverse problems under uncertainty. As a result of these efforts, four priority research directions (PRDs) were identified to guide future research and development in this area. These PRDs, summarized below, represent a roadmap for advancing the foundational science and mathematics of inverse problems, enabling robust, scalable, and uncertainty-aware solutions that are critical for DOE applications.

97 MATHEMATICS AND COMPUTING↗

MHD, disruptions and control physics: Chapter 4 of the special issue: on the path to tokamak burning plasma operation

In this chapter, we review the progress in MHD stability, disruptions and control in magnetic fusion research that has occurred over the past (more than) one and a half decades since the publication by Hender et al in 2007 on the same topic as part of the update of ITER Physics Basis. During this period, remarkable progress has been achieved in the understanding of the basic physics and overall control of MHD instabilities through a wide spectrum of dedicated experiments, theory and modeling. The sawtooth activities are probably today one of the best understood of MHD events and very robust control schemes have been developed for reliable operation of tokamaks through core heating. Similarly, significant improvements have been achieved in understanding and control of neoclassical tearing modes, resistive wall modes or locked modes and their control through ECCD or error field control. The field of disruption prediction through application of artificial intelligence, machine learning or deep learning methods, which had already started at the time of the 2007 review, has progressed significantly due to general progress in these fields and application of newer, more sophisticated algorithms. However, although remarkable progress has been achieved in the field of Disruptions, their understanding, prediction, possible avoidance and mitigation still remain probably the most active fields of R&D globally in this field. This is especially because reactor grade machines like ITER and DEMO will be much less tolerant in respect of disruptions and runaway currents, and their occurrences must be either avoided altogether or minimized to an acceptable value without causing any significant hindrance to robust machine operations. This review is intended to present a broad spectrum of the R&D that has occurred in this field in support of ITER, which will also be of immense significance for all future machines, especially reactors like DEMO.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Preliminary Feasibility of Printing, Microstructure Analysis and Mechanical Performance of a Down Selected Ni Alloy

This report is submitted as completion of a Milestone 3 deliverable under work package ORNL CT-23OR1304051 in support of the Advanced Materials and Manufacturing Technologies (AMMT) program. The AMMT program is aiming at the faster incorporation of new materials and manufacturing technologies into complex nuclear-related systems. An integrated approach, combining advanced characterization, high-throughput and accelerated testing, modeling and simulation including machine learning and artificial intelligence will be employed. While 316H (Fe-16-18Cr-10-14Ni-2-3Mo-0.04-0.1C) has been identified as a key alloy to be integrated into the AMMT accelerated alloy qualification approach due its relevance for many current and future nuclear energy reactors, many other alloys could be considered for the advanced fabrication of innovate high-performance nuclear components. ANL, INL, ORNL and PNNL are collaborating on identifying the most promising alloy candidates relevant for the AMMT program. A selection criteria matrix was established to evaluate the alloys considering their relative importance and technological readiness levels for nuclear energy applications, with a focus on laser powder bed fusion (LPBF). Due to the broad range of potential candidate alloys, ORNL and INL focused on Ni-based alloys, while ANL and PNNL mainly evaluated Fe-based alloys. PNNL previously published materials scorecards reports on several key alloys and this report is providing a broader overview of Ni-based candidate alloys, expending beyond alloys well-known to the nuclear community. Of particular interest are alloys that are currently commercially available in powder form due to the growing demand from other industries that have invested heavily in additive manufacturing. Among these alloys, Haynes 282 (Fe-20Cr-20Co-8Mo) was selected due to its superior strength at high temperature compared to the code-qualified alloy 617 (Ni-20-24Cr-10-15Co-8-10Mo). To assess the integration of this new alloy into the AMMT digital manufacturing framework, we performed the rapid optimization of alloy 282 printing parameters on a Renishaw 250 machine, the fabrication of sufficient materials for extensive characterization and mechanical testing both at ORNL and INL, and added the printing data into the digital platform via the Peregrine software. A detailed analysis of the LPBF 718 alloy was also conducted, with creep specimens being tested at 600-650°C and characterized by advanced electron microscopy. The alloy superior mechanical strength and great printability associated with the extensive database that has already been generated highlight the promising potential of LPBF 718 as a candidate alloy for the AMMT program. INL, ANL and PNNL have generated similar reports and all the information will be compiled into a final M2 milestone report to provide the AMMT leadership team with clear recommendations on the down selection of reactor materials, as well as establish a roadmap for the qualification of these selected alloys.

36 MATERIALS SCIENCE↗

AI-Science for Performance Optimization and Diagnosis of Science Instrument Federations

Next generation of science workflows are expected to be executed over complex federations composed of supercomputers, science instruments, storage systems and networks, with new additions of the edge and cloud systems and services. The sheer complexity of these multi-domain federations makes it hard to manage them and optimize their performance, as small impedance mismatches (that can dynamically develop between systems) could drastically degrade the entire federation performance. Recent proliferation of Software Defined Everything (SDX) technologies combined with containerization frameworks provide custom instruments that can monitor and collect critical measurements at various levels to support diagnoses and performance optimization; but their data too enormous for human operators and analysts to process and generate decisions. Machine Learning (ML) methods that extract critical parameters, relationships and trends from the data offer general solutions. Artificial Intelligence (AI) and ML methods must be custom-developed for these problems based on solid, rigorous foundations, since black-box approaches are often ineffective and unsound.We propose to develop comprehensive AI-Science for the performance of science federations to (i) monitor and control storage, networks, experiments, and computing systems across multiple domains via softwarization layers, at speeds and scales orders of magnitude superior to current practice, (ii) optimally realize and orchestrate complex workflows with high performance by using dynamic state and performance estimation methods, and (iii) aggregate measurements across sites and time to develop infrastructure-level profiles, optimizations and diagnoses using AI-Science based on foundational principles from ML, game theory, and information fusion areas.

Rao, Nageswara↗

Towards Geospatial Knowledge Graph Infused Neuro-Symbolic AI for Remote Sensing Scene Understanding

Deep learning has proven its effectiveness in numerous tasks for remote sensing scene understanding. However there is an increasing interest to explore fusion of domain-specific background information to the deep neural network to further improve its performance. Remote sensing researchers are also working towards developing models that generalize and adapt to multiple applications. Generalization challenges coupled with the scarcity of large corpora of high-quality noise-free labelled data, have together fueled an interest for leveraging background information. Knowledge graphs serve as excellent choice to represent domain-specific information in a structured, standardized and extensible manner. Integrating symbolic knowledge representations in the form of Knowledge Graph Embedding (KGE) to perform neuro-symbolic reasoning is an emerging research direction promising significant impacts. This vision paper seeks to position ideas and provoke early thoughts toward advancing neuro-symbolic artificial intelligence in the context of geospatial challenges. Specifically, it conceptualizes and elaborates on an architecture for infusing geospatial knowledge from knowledge graph in a deep neural network pipeline. As guiding case studies - land-use land-cover classification, object detection and instance segmentation can benefit from infusing spatio-contextual information with remote sensing imagery. The discussion further reflects on and articulates the challenges and explainable AI opportunities anticipated when scaling and maintaining large-scale geospatial knowledge graphs.

Potnis, Abhishek↗

Quantum Computing for AI-based Design and Optimization of Electric Motors

Knowledge-based artificial intelligence and hierarchical fuzzy logic offer an interpretable framework for electricvehicle motor preliminary design, but their computational burden grows with linguistic granularity and coupled design-space size. This paper presents a reduced quantum reformulation of the hierarchical fuzzy inference of air-gap flux density, a representative level-one motor-design parameter. Starting from the published electric-vehicle motor-design framework, a three-term fuzzy prototype is constructed from the original inference structure. The reduced model is then reformulated as a modular quantum register-oracle system, in which each hierarchical subrelation is encoded as a block oracle and evaluated through superpositionbased candidate-label testing. The proposed modular quantum formulation reproduces the reduced classical prototype after block fusion. A resource analysis shows that the reduced modular system requires seven qubits per block and twenty-two qubits in a straightforward four-block implementation. Finally, a crossovercomplexity model is derived to identify the regime in which quantum candidate search may become favorable relative to hierarchical fuzzy inference. The results show that no quantum advantage should be claimed for the present one-output reduced benchmark, but that a plausible crossover emerges for larger joint candidate spaces and higher linguistic granularity. The work therefore establishes a technically consistent starting point for future quantum-assisted electric-vehicle motor-design optimization.

Kumar, Praveen [ORNL] (ORCID:0000000291877857)↗

Prioritization of Existing Reactor Materials

The Advanced Materials and Manufacturing Technologies (AMMT) Program is aiming at the faster incorporation of new materials and manufacturing technologies into complex nuclear-related systems. An integrated approach, combining advanced characterization, high-throughput and accelerated testing, modeling and simulation, including machine learning and artificial intelligence, will be employed. Although 316H (Fe–[16–18]Cr–[10–14]Ni–[2–3]Mo–[0.04–0.1]C) has been identified as a key alloy to be integrated into the AMMT accelerated alloy qualification approach because of its relevance for many current and future nuclear energy reactors, many other alloys could be considered for the advanced fabrication of innovative, high-performance nuclear components. Argonne National Laboratory (ANL), Idaho National Laboratory (INL), Oak Ridge National Laboratory (ORNL), and Pacific Northwest National Laboratory (PNNL) are collaborating on identifying the most promising alloy candidates relevant for the AMMT Program. A selection criteria matrix was established to evaluate the alloys considering their relative importance and technological readiness levels for nuclear energy applications, with a focus on laser powder bed fusion (LPBF). Because of the broad range of potential candidate alloys, ORNL and INL focused on nickel-based alloys, and ANL and PNNL mainly evaluated iron-based alloys. PNNL previously published material scorecards reports on several key alloys, and this report provides a broader overview of iron- and nickel-based candidate alloys, expending beyond alloys well-known to the nuclear community.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Recent progress in atomic-scale controlled plasma processing

Atomic-scale control in plasma processing is becoming increasingly critical for fabricating of advanced semiconductor devices, particularly as the industry shifts toward three-dimensional (3D) architectures and high-aspect-ratio (HAR) structures. This review presents a comprehensive overview of recent developments in atomic-scale controlled plasma processes, organized along two key directions: the hierarchical structure of plasma–surface interactions and the generational evolution of atomic layer processing (ALP) technologies. We examined the gas phase, where molecular design enables selective generation of ions and radicals; the boundary layer, where transport phenomena govern species delivery into nanoscale features, and the surface, where temperature-dependent reactions and cyclic processing determine etching selectivity and precision. Building on this foundation, we outline five generations of ALP—from thermal atomic layer deposition to transport-aware, temporally and structurally decoupled processes—highlighting the increasing sophistication of process control. The review further explores the transition from empirical recipe development to science-based, data-driven methodologies. By integrating quantum-chemical modeling, advanced diagnostics, and machine learning, we demonstrated how predictive models can link plasma species composition to process outcomes, enabling autonomous and adaptive control strategies. Finally, this review discusses the broader societal implications of plasma process innovation through the E4 quartet: energy and resource efficiency, environmental sustainability, evolutionary advancement, and educational promotion. These principles guide the development of sustainable and intelligent atomic-scale manufacturing technologies that are not only technically advanced but also socially responsible.

Ishikawa, Kenji [Nagoya Univ. (Japan)] (ORCID:0000↗

Enabling Interoperability in Earth System Digital Twins (ESDT): Integrating Observations, Models, and AI for Actionable Insights Through NASA'S Intelligent Systems Technology Program

NASA’s Intelligent Systems Technology Program (IST) is driving a paradigm shift in Earth science through the development of Earth System Digital Twins (ESDT). These integrated information systems create a dynamic "digital replica" of the Earth by harmonizing continuous, multi-source observations with high-fidelity models and state-of-the-art artificial intelligence (AI) that enable “What now?”, “What next?”, and “What if?” scenario building. These scenarios are reflected in NASA IST’s series of ESDTs, from the Coastal Zone Digital Twin that integrates complex data on the current state of the Chesapeake Bay to the Terrestrial Environmental Rapid-Replication and Assimilation Hydrometeorological (TerraHydro) AI-based ESDT that forecasts water movement across Earth’s surface, to the Agriculture Land Information System (AgLIS) which can be used to assess optimal planting dates and crop yield estimates. By bridging the gap between vast data archives and actionable insights, these projects enable a system-of-systems approach to understanding complex, interacting Earth processes. This poster will highlight recent innovations and future directions from NASA’s ESDT initiatives: Continuous Data Assimilation & Multi-Source Fusion. A core requirement of the ESDT work is the transition from static models to dynamic "living" replicas. This involves creating frameworks for the continual assimilation of near-real-time data from uncoordinated, heterogeneous sources, including satellite observations and airborne assets, and ground-based Internet of Things (IoT) sensors. These systems link design, operational status, and environmental data, ensuring the digital twin accurately reflects the current state of the physical Earth system. High-Fidelity Hybrid Modeling & Computational Acceleration to enable interactive "what-if" explorations, programs are moving beyond traditional, slow physical solvers by developing fast surrogate machine learning models and Deep Generative Models (DGMs). These hybrid approaches use neural networks to emulate complex physics, such as cloud feedback or ocean dynamics, at a fraction of the original computing cost, often leveraging advanced hardware like Graphics Processing Units (GPUs) to achieve the necessary scale. Federated Ecosystems & Interoperable Frameworks rather than building isolated tools, NASA IST is moving toward federated ESDTs and reusable analytic collaborative frameworks. This theme focuses on interoperability standards and common ontologies that allow specialized digital twins to interact and share data. This system-of-systems architecture supports multi-discipline investigations, such as analyzing how upstream watershed changes impact downstream urban flooding or how wildfire emissions affect regional air quality. By leveraging these advancements, ESDTs empower researchers and decision-makers to conduct real-time analysis and run complex hypothetical scenarios, ultimately improving our understanding of Earth’s evolving systems and informing critical real-world applications.

Earth System↗

Neural Network Based Sensory Fusion for Landmark Detection

NASA is planning to send numerous unmanned planetary missions to explore the space. This requires autonomous robotic vehicles which can navigate in an unstructured, unknown, and uncertain environment. Landmark based navigation is a new area of research which differs from the traditional goal-oriented navigation, where a mobile robot starts from an initial point and reaches a destination in accordance with a pre-planned path. The landmark based navigation has the advantage of allowing the robot to find its way without communication with the mission control station and without exact knowledge of its coordinates. Current algorithms based on landmark navigation however pose several constraints. First, they require large memories to store the images. Second, the task of comparing the images using traditional methods is computationally intensive and consequently real-time implementation is difficult. The method proposed here consists of three stages, First stage utilizes a heuristic-based algorithm to identify significant objects. The second stage utilizes a neural network (NN) to efficiently classify images of the identified objects. The third stage combines distance information with the classification results of neural networks for efficient and intelligent navigation.

Kumbla, Kishan -K.↗

A characterization of recombinant Arabidopsis FRIABLE1 (FRB1) reveals robust rhamnogalacturonan-I rhamnosyltransferase activity and critical catalytic residues

Plant cell walls are glycan-rich extracellular matrices that fundamentally impact essential cellular processes, such as growth, adhesion, and cell shape acquisition. Understanding plant cell wall glycans requires the identification and characterization of the biosynthetic enzymes that produce these polymers. Most successful in vitro protein expression studies of plant cell wall glycosyltransferases have relied on insect, fungal/yeast, or human cell expression systems, whereas prokaryotic expression systems have been generally unsuccessful. Here, we show that Arabidopsis FRIABLE1 (FRB1)/rhamnogalacturonan-I rhamnosyltransferase 8 (RRT8) can be produced in Escherichia coli RosettaGami2 cells as N-terminal maltose-binding protein fusion proteins containing C-terminal 6X-His-tags. We also report the catalytic constants of FRB1/RRT8 with apparent K M and K cat values of 226 μM and 33 min -1 for UDP-Rhamnose and 117 μM and 28.7 min -1 for rhamnogalacturonan-I (RG-I), respectively. We examine the catalytic activities of mutated FRB1/RRT8 proteins based on an AlphaFold 3-generated FRB1/RRT8 protein structural model with a virtually docked UDP-Rha donor. Enzymatic characterization of the mutated and wildtype FRB1/RRT8 protein confirmed that mutation of predicted catalytic site amino acid residues resulted in a 20-fold reduction in RRT activity. FRB1 also robustly polymerizes RG-I in combination with RG-I galacturonosyltransferase 1. These results show how a robust E. coli expression system combined with artificial intelligence tools can be used to increase understanding of plant cell wall glycosyltransferase structure and function.

glycosyltransferase↗

LandScan Mosaic

The LandScan program at Oak Ridge National Laboratory (ORNL), in collaboration with the National Geospatial-Intelligence Agency (NGA), continues to deliver the most accurate and up to date global, high resolution gridded population data. Additionally, the latest advancements in the LandScan HD methodology led to reduced latency in development of rapid updates for geopolitical events. With momentum towards reporting more up to date population estimates, feedback from the user community expressed interest in reporting population estimates in ranges - whether to express a level of uncertainty or confirm to leadership and stakeholders the modeled data are estimates. Building upon the need to understand uncertainty or confidence in the modeled data and report ranges at the global scale, LandScan Mosaic was developed. LandScan Mosaic represents the next generation of high-resolution population modeling, building upon the established success of previous LandScan HD iterations. While LandScan HD employed a deterministic big data fusion approach, LandScan Mosaic enhances this methodology by integrating advanced machine learning techniques to impute missing, yet crucial, population model parameters. This advancement allows for probabilistic modeling of building occupancy and population distribution, incorporating uncertainty quantification through Monte Carlo sampling methods. By combining big data fusion with machine learning-driven imputation and stochastic modeling, LandScan Mosaic provides a more comprehensive and robust representation of population dynamics. LandScan Mosaic will be following the in the footsteps of its longstanding counterpart LandScan Global and releasing a global gridded population raster, at the 3-arcsecond resolution. This technical report documents the current stage of development of LandScan Mosaic, detailing the methodologies and data sources behind the modeling. Stakeholders are encouraged to use this document as an authoritative reference for insight into Mosaic’s data development processes. However, readers should note that LandScan Mosaic remains in a late-stage research and development phase, and methodologies and data presented here are subject to refinements ahead of the anticipated global release in Summer 2025. Feedback and inquiries from users and stakeholders are welcomed as we continue to refine and enhance this important population resource.

97 MATHEMATICS AND COMPUTING↗

Integrating Oil Debris and Vibration Measurements for Intelligent Machine Health Monitoring

A diagnostic tool for detecting damage to gears was developed. Two different measurement technologies, oil debris analysis and vibration were integrated into a health monitoring system for detecting surface fatigue pitting damage on gears. This integrated system showed improved detection and decision-making capabilities as compared to using individual measurement technologies. This diagnostic tool was developed and evaluated experimentally by collecting vibration and oil debris data from fatigue tests performed in the NASA Glenn Spur Gear Fatigue Rig. An oil debris sensor and the two vibration algorithms were adapted as the diagnostic tools. An inductance type oil debris sensor was selected for the oil analysis measurement technology. Gear damage data for this type of sensor was limited to data collected in the NASA Glenn test rigs. For this reason, this analysis included development of a parameter for detecting gear pitting damage using this type of sensor. The vibration data was used to calculate two previously available gear vibration diagnostic algorithms. The two vibration algorithms were selected based on their maturity and published success in detecting damage to gears. Oil debris and vibration features were then developed using fuzzy logic analysis techniques, then input into a multi sensor data fusion process. Results show combining the vibration and oil debris measurement technologies improves the detection of pitting damage on spur gears. As a result of this research, this new diagnostic tool has significantly improved detection of gear damage in the NASA Glenn Spur Gear Fatigue Rigs. This research also resulted in several other findings that will improve the development of future health monitoring systems. Oil debris analysis was found to be more reliable than vibration analysis for detecting pitting fatigue failure of gears and is capable of indicating damage progression. Also, some vibration algorithms are as sensitive to operational effects as they are to damage. Another finding was that clear threshold limits must be established for diagnostic tools. Based on additional experimental data obtained from the NASA Glenn Spiral Bevel Gear Fatigue Rig, the methodology developed in this study can be successfully implemented on other geared systems.

Dempsey, Paula J.↗

CubeSat constellations provide enhanced crop phenology and digital agricultural insights using daily leaf area index retrievals

Satellite remote sensing has great potential to deliver on the promise of a data-driven agricultural revolution, with emerging space-based platforms providing spatiotemporal insights into precision-level attributes such as crop water use, vegetation health and condition and crop response to management practices. Using a harmonized collection of high-resolution Planet CubeSat, Sentinel-2, Landsat-8 and additional coarser resolution imagery from MODIS and VIIRS, we exploit a multi-satellite data fusion and machine learning approach to deliver a radiometrically calibrated and gap-filled time-series of daily leaf area index (LAI) at an unprecedented spatial resolution of 3 m. The insights available from such high-resolution CubeSat-based LAI data are demonstrated through tracking the growth cycle of a maize crop and identifying observable within-field spatial and temporal variations across key phenological stages. Daily LAI retrievals peaked at the tasseling stage, demonstrating their value for fertilizer and irrigation scheduling. An evaluation of satellite-based retrievals against field-measured LAI data collected from both rain-fed and irrigated fields shows high correlation and captures the spatiotemporal development of intra- and inter-field variations. Novel agricultural insights related to individual vegetative and reproductive growth stages were obtained, showcasing the capacity for new high-resolution CubeSat platforms to deliver actionable intelligence for precision agricultural and related applications.

54 ENVIRONMENTAL SCIENCES↗

Robotics for HVAC applications: A critical review and future perspectives

Recent advances in artificial intelligence (AI), enhanced computational capabilities, and innovations in sensors and hardware have driven the increasing development and application of robots in heating, ventilation, and air conditioning (HVAC) systems. We selected and reviewed 101 studies published between 2005 and 2025, sourced from IEEE Xplore, Scopus, Web of Science, and the ACM Digital Library. To analyze these works, we developed a five-dimensional analytical framework (morphology, sensing, navigation, task execution, and system integration), inspired by the Springer Handbook of Robotics and tailored specifically for robotic applications in HVAC. Based on the reviewed studies, six distinct tasks spanning the entire HVAC lifecycle have been identified. Among the six tasks, inspection and maintenance dominate (59 %), followed by indoor monitoring and auditing (21 %), whereas leakage detection, comfort support, and installation/retrofit remain less explored. To address the identified gaps, this review proposes future research directions including investigating robot-aware HVAC design principles, developing multimodal HVAC sensing and data fusion techniques, enhancing robot training and hardware capabilities, and expanding robotic applications beyond Maintenance and Operations (M&O). The findings from this review inform future robotics research for HVAC applications and ultimately enhance system affordability, energy efficiency, resilience or reliability, and occupant environmental comfort. Moreover, it seeks to inspire researchers to explore the intersections of robotics, computer science, building science, and HVAC engineering fostering advancements in this multidisciplinary field.

AI↗

2019 Budget Request for the DOE Computational Science Graduate Fellowship (CSGF) Grant

The Department of Energy Computational Science Graduate Fellowship (DOE CSGF) is necessary to meet the continual challenging national workforce needs that arise as computational science and engineering problems continue to grow in scope and complexity. Computational science and engineering (CSE) is a multidisciplinary approach that uses scientific computing to solve practical problems methods and to supply technical tools across the scientific discovery spectrum. In particular, the DOE CSGF emphasizes high-performance computing (HPC) that enables CSE that advances science and engineering in directions important to the DOE and the economy in general. Over the past half-century, HPC has been an essential tool for DOE’s success. During this period, important missions, such as nuclear stockpile stewardship, have turned to HPC as an essential technology. Entire science disciplines, such as biology and cosmology, have been transformed through the augmentation of scientific observation via HPC. At government laboratories and in industry, DOE CSGF alumni are helping push traditional HPC boundaries while contributing to discoveries in high-energy physics, renewable energy, fusion-reactor design, additive manufacturing, nanomaterials for next-generation batteries and transistors, and turbine and advanced nuclear reactor modeling. In addition, HPC is used to address national health needs that will eventually point to cures both by helping cancer researchers manage and analyze huge troves of data, by simulating biological mechanisms, and by accelerating drug development — including continuing to rise to the challenge of pandemic-related research. A 2023 report from the ASCAC Subcommittee on American Competitiveness and Innovation to the ASCR office, “Can the United States Maintain Its Leadership in High-Performance Computing?” says of the Program, “The CSGF program provides a barometer for disciplines that will be of interest to future DOE computing.” An explosion in scientific and technological data has driven the need for increasingly sophisticated HPC to transform those data into scientific understanding. With access to more and more data and the proliferation of HPC, Machine Learning and Artificial Intelligence are experiencing a renaissance, complementing the now well-established use of computational simulation. Indeed, in its September 2020 subcommittee report on “AI/ML, Data Intensive Science and High-Performance Computing”, the DOE Advanced Scientific Computing Advisory Committee (ASCAC) explicitly called for a fellowship program to train computational and data scientists to tackle exascale and data-intensive computing challenges. This collaboration of empirical and theory-based modeling will increasingly inform federal policymakers whose decisions affect American society and future generations, and it requires highly skilled and intellectually agile computational scientists who can support the fast-moving DOE National Laboratory research environment. In fact, the DOE CSGF program has explicitly and consistently addressed this need.

97 MATHEMATICS AND COMPUTING↗

MPEX AI Digital Twins

All magnetically confined plasma fusion power plant concepts (Tokamak, Spherical Tokamak, Stellarator, Mirror, ...) must exhaust the heat and plasma from the core confinement region to the material walls. The primary channel for this exhaust is through a plasma divertor which directs plasma along open magnetic field lines to a material target. The Material Plasma Exposure eXperiment (MPEX) illustrated in Figure 1, is a high-power, steady-state linear plasma device designed to produce the plasma material interaction (PMI) conditions of the divertor of future magnetic confinement fusion power plants: energy flux 20MW/m 2 , ion fluence 1031/m 2 , pulse duration 106 sec. These goals of plasma exposure in MPEX are well beyond those achieved in magnetic fusion experimental devices. Successfully achieving these high power steady state conditions for long pulses requires operational control of the heating and particle sources and the plasma flux to the walls and target. The MPEX AI Hot Spot Controller, proposed in this project, will help achieve the operational milestones of MPEX. The MPEX device will begin commissioning at the end of FY26. A smaller proto-MPEX was operated for 14,666 plasma discharges and will resume operation in September of 2025 as proto-MPEX-lite, with reduced capability, to test a new window for the Helicon plasma source. The proto-MPEX data has undergone surrogate modeling with machine learning methods (R. Archibald, 2022 IEEE International Conference on Big Data). This proto-MPEX data will be used to begin development of the AI digital twins described in this white paper. The scientific mission of MPEX is to qualify materials of different composition for use in the high energy and plasma flux conditions of a fusion power plant. The materials exposed in MPEX will in some cases be exposed to high neutron fluxes at other ORNL facilities to measure the changes to their PMI properties. The targets exposed in MPEX will be transported under vacuum to a Surface Analysis Station (SAS). The SAS will be equipped with the following diagnostics: Focused Ion Beam (FIB) for trench milling, 100-400 angstrom resolution scanning electron microscope (SEM), surface mapping x-ray spectrometer, high resolution camera, and a future upgrade to a laser induced breakdown spectroscopy quadruple mass spectrometer (LIBS-QMS). The MPEX experiments will generate diverse pre- and post-exposure measurement data of detailed material properties down to the crystal grain level in 3D for post-exposure assessment of PMI damage (e.g. cracking, melting, erosion and redeposition of the material). Physics models for the PMI, and how the material composition and manufacturing impact its performance under high energy plasma exposure, need to be validated with MPEX data to guide the selection of new candidate materials. Our vision for the MPEX AI Digital Twins project is to supply experimental and physics model simulation data to train Artificial Intelligence (AI) models for data processing, analysis, operational control, PMI and materials simulation to maximize the scientific output of the MPEX device. Ultimately, an AI digital twin of MPEX material assessment metrics for tested and synthetic material types with simulated PMI will be trained by the AI Modeling Teams on the experimental and physics simulation data submitted to the American Science Cloud by this project. A purely empirical search for the best material is inefficient given the finite number of samples that can be tested on MPEX. In order to expand the material properties database for training the MPEX Material Assessment AI Digital Twin, and to gain physics understanding of the PMI processes, physics models of the material properties and PMI processes are required. The physics simulations provide detailed simulation data, like impact angles for plasma ions, sputtering yields, transport of the ionized sputtered target material in the plasma, and redeposition locations. This simulation data expands the measurement data for deeper physics understanding. The experimental data is essential to validate the PMI and material structure simulation models. The validated models can then be used to generate new simulation data of MPEX material assessments for synthetic material compositions that have not been exposed in MPEX. These predictive simulations, plus the whole experimental dataset, will be used to train the MPEX Material Assessment AI Digital Twin allowing a rapid generative AI search for new materials with reduced PMI damage by interpolating the domain of the training set. These new optimum materials can be simulated with the physics codes and/or tested in MPEX. The ability of AI neural networks to interpolate multi-dimensional parameter spaces and generate virtual data is exploited for a more efficient search for optimum materials. The advent of the Transformational AI Models Consortium (TAIMC) is an opportunity to engage with state of the art private and public AI developers to achieve the goals of the AI digital twins and AI accelerated physics models proposed in this project. Our partners at ORNL from the Advance Scientific Computing Research (ASCR) organization will collaborate in accelerating the integrated plasma material interaction simulation framework. This simulation framework will provide a platform for generating simulation data across a range of physical fidelities, including hybrid methods that produce multi-fidelity results. This data will be leveraged for AI model development, both for generation of surrogates and the automation of simulation campaigns. A part of the research below will include collaborative efforts with the TAIMC to (i) adapt data storage approaches to ensure AI-readiness, (ii) provide a protypical exemplar to inform and exercise constructed workflows, and (iii) generate and share data, using the TAIMC unified AI data standard, for foundational models that will be trained from multiple sources across the DOE complex. We will also collaborate with the TAIMC, as well as the planned AI modeling teams, to develop approaches for reducing the cost of data generation. These include tailored multi-fidelity approaches as well as fine-tuning strategies to augment general, large-scale foundational models.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗