Effective real-time monitoring is a foundation of digital twin technology, crucial for detecting material degradation and maintaining the structural integrity of nuclear systems to ensure both safety and operational efficiency. Traditional physical sensor systems face limitations such as installation challenges, high costs, and difficulty measuring critical parameters in hard-to-reach or harsh environments, often resulting in incomplete data coverage. Machine learning-driven virtual sensors, integrated within a digital twin framework, offer a transformative solution by enhancing physical sensor capabilities to monitor critical degradation indicators like pressure, velocity, and turbulence. However, conventional machine learning models struggle with real-time monitoring due to the high-dimensional nature of reactor data and the need for frequent retraining. This paper introduces the use of Deep Operator Networks (DeepONet) as a core component of a digital twin framework to predict key thermal-hydraulic parameters in the hot leg of an AP-1000 Pressurized Water Reactor (PWR). DeepONet serves as a dynamic and scalable virtual sensor by accurately mapping the interplay between operational input parameters and spatially distributed system behaviors. In this study, DeepONet is trained with different operational conditions, which relaxes the requirement of continuous retraining, making it suitable for online and real-time prediction components for digital twin. Our results show that DeepONet achieves accurate predictions with low mean squared error and relative L2 error and can make predictions on unknown data 1400 times faster than traditional CFD simulations. This speed and accuracy enable DeepONet to synchronize with the physical system in real-time, functioning as a dynamic virtual sensor that tracks degradation-contributing conditions.

Under some initial and boundary conditions, the rapid reaction-thermal diffusion process taking place during frontal polymerization (FP) destabilizes the planar mode of front propagation, leading to spatially varying, complex hierarchical patterns in thermoset polymeric materials. Although modern reaction-diffusion models can predict the patterns resulting from unstable FP, the inverse design of patterns, which aims to retrieve process conditions that produce a desired pattern, remains an open challenge due to the non-unique and non-intuitive mapping between process conditions and manufactured patterns. In this work, we propose a probabilistic generative model named univariate conditional variational autoencoder (UcVAE) for the inverse design of hierarchical patterns in FP-based manufacturing. Unlike the cVAE, which encodes both the design space and the design target, the UcVAE encodes only the design space. In the encoder of the UcVAE, the number of training parameters is significantly reduced compared to the cVAE, resulting in a shorter training time while maintaining comparable performance. Given desired pattern images, the trained UcVAE can generate multiple process condition solutions that produce high-fidelity hierarchical patterns.

Metamaterials, synthetic materials with customized properties, have emerged as a promising field due to advancements in additive manufacturing. These materials derive unique mechanical properties from their internal lattice structures, which are often composed of multiple materials that repeat geometric patterns. While traditional inverse design approaches have shown potential, they struggle to map nonlinear material behavior to multiple possible structural configurations. This paper presents a novel framework leveraging video diffusion models, a type of generative artificial Intelligence (AI), for inverse multi-material design based on nonlinear stress-strain responses. Our approach consists of two key components: (1) a fields generator using a video diffusion model to create solution fields based on target nonlinear stress-strain responses, and (2) a structure identifier employing two UNet models to determine the corresponding multi-material 2D design. By incorporating multiple materials, plasticity, and large deformation, our innovative design method allows for enhanced control over the highly nonlinear mechanical behavior of metamaterials commonly seen in real-world applications. It offers a promising solution for generating next-generation metamaterials with finely tuned mechanical characteristics.

This paper investigates the structure-property relations of thin-walled lattices under dynamic longitudinal compression, characterized by their cross-sections and heights. These relations elucidate the interactions of different geometric features of a design on mechanical response, including energy absorption. We proposed a combinatorial, key-based design system to generate different lattice designs and used the finite element method to simulate their response with the Johnson-Cook material model. Using an autoencoder, we encoded the cross-sectional images of the lattices into latent design feature vectors, which were supplied to the neural network model to generate predictions. The trained models can accurately predict lattice energy absorption curves in the key-based design system and can be extended to new designs outside of the system via transfer learning.