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All sources NASA NTRS DOE OSTI

DOE OSTI2016

NR sulphur vulcanization: Interaction study between TBBS and DPG by means of a combined experimental rheometer and meta-model best fitting strategy

The paper is aimed at studying the possible interaction between two different accelerators (DPG and TBBS) in the chemical kinetic of Natural Rubber (NR) vulcanized with sulphur. The same blend with several DPG and TBBS concentrations is deeply analyzed from an experimental point of view, varying the curing temperature in the range 150-180°C and obtaining rheometer curves with a step of 10°C. In order to study any possible interaction between the two accelerators –and eventually evaluating its engineering relevance-rheometer data are normalized by means of the well known Sun and Isayev normalization approach and two output parameters are assumed as meaningful to have an insight into the possible interaction, namely time at maximum torque and reversion percentage. Two different numerical meta-models, which belong to the family of the so-called response surfaces RS are compared. The first is linear against TBBS and DPG and therefore well reproduces no interaction between the accelerators, whereas the latter is a non-linear RS with bilinear term. Both RS are deduced from standard best fitting of experimental data available. It is found that, generally, there is a sort of interaction between TBBS and DPG, but that the error introduced making use of a linear model (no interaction) is generally lower than 10%, i.e. fully acceptable from an engineering standpoint.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2016

Thermal Testing Quality Assurance of 24LCC & 3LCC Electronic Packages

The purpose of this project is to experimentally validate the thermal fatigue life of solder interconnects for a variety of surface mount electronic packages. Over the years, there has been a significant amount of research and analysis in the fracture of solder joints on printed circuit boards. Solder is important in the mechanical and electronic functionality of the component. It is important throughout the life of the product that the solder remains crack and fracture free. The specific type of solder used in this experiment is a 63Sn37Pb eutectic alloy. Each package was manufactured with conformal coating along with and without an underfill material below the device. Conformal coating helps protect the board from environments such as electrostatic discharge and humidity. It is commonly used in broad types of engineering disciplines such as commercial, military, research and development, etc. Conformal coating can also pose a risk for the life of the board because of its high thermal expansion coefficient. This can greatly decrease the life of the product if it regularly sees high temperature variations. This leads to a shorter fatigue life of the solder. The fatigue life is a common mechanical problem in the field of electronic devices. Adding underfill can help increase the fatigue life of the solder. However, applying underfill adds time to manufacturing and production. This ultimately increases the cost per unit. The study of conformal coated printed circuit boards with and without underfill was done on two different surface mount electronic packages. The electronic packages studied were 24 and 3 contact Leadless Ceramic Chips packages. When the package was not underfilled, the coating was allowed to flow underneath. The assembly was analyzed and tested to obtain the best available combination of conformal coating, underfill, and potting to design the most robust and reliable circuit board while keeping in mind certain factors such as cost, manufacturing time, and need. Different types of conformal coatings were considered with and without underfill for each device. 29 of each component were manufactured to have a large sample size and for the sake of individual defects and imperfections. Finite Element Analysis (FEA) was performed by an engineer at Sandia National Laboratories for both Leadless Ceramic Chips. From the FEA results, a test acceleration profile was derived and the number of temperature cycles to fail the solder interconnects were found for three different cases. Experimentation was done as a secondary measure to validate this data to show confidence in the theoretical analysis. Accelerated testing functions as a quality check for the product. Accelerated testing is extremely useful in the research and development phase of engineering. It can save money from the potential of early life defects and the costs that come along with warranties. Accelerated testing makes a weaker design more robust and checks the reliability of a strong design in a shorter period of time. It is extremely helpful in a world where deliverables are in high demand and scheduling is tight. Accelerated testing helps the engineer gain an understanding of what needs to be improved and what works well. There are many different types of accelerated tests. Our circuit boards were accelerated inside a closed thermal chamber because of the high number of use cycles. The ultimate goal of this experimentation is to help identify what will prevent any premature cracking or fracturing in the solder alloy. It is important to understand that underfilling each component may or may not be needed. If underfill is not needed, there are several production benefits.

42 ENGINEERING↗

DOE OSTI2014

Simulated Real-World Energy Impacts of a Thermally Sensitive Powertrain Considering Viscous Losses and Enrichment (Presentation)

It is widely understood that cold-temperature engine operation negatively impacts vehicle fuel use due to a combination of increased friction (high-viscosity engine oil) and temporary enrichment (accelerated catalyst heating). However, relatively little effort has been dedicated to thoroughly quantifying these impacts across a large number of driving cycles and ambient conditions. This work leverages high-quality dynamometer data collected at various ambient conditions to develop a modeling framework for quantifying engine cold-start fuel penalties over a wide array of real-world usage profiles. Additionally, mitigation strategies including energy retention and exhaust heat recovery are explored with benefits quantified for each approach.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Lessons Learned from Open-Source Software Training Toward Expanding the Fusion Workforce

Within the United States (U.S.), the Fusion Innovation Research Engine (FIRE) Collaboratives seek to accelerate fusion technology development through wide-ranging community-driven research activities that bring together industry, laboratories, research institutes, and academia. Increasing the maturity of key components and systems for future fusion power plants (FPPs) toward commercialization, will, by necessity, increase the need for knowledgeable engineers, designers, and researchers in industry capable of integrating and further improving these technologies within industry FPP concepts. Further, various modeling and simulation packages support these programs and are under-development within them to drive design iteration and the development of FPP digital twins. To derive the greatest benefit from model output and capabilities, training these same specialists will be vital. Thus, the development of effective and accessible software onboarding and professional development opportunities focused on fusion will be key to keeping the pace of growth high in the coming decade and beyond. A similar need exists within the advanced fission reactor community, driven by an ever-growing need for carbon-free baseload power for industrial and data center applications. Within the U.S. and around the world, several open-source packages and frameworks exist to support this endeavor, and two we will highlight here are the Multiphysics Object Oriented Simulation Environment (MOOSE) framework and OpenMC. These packages, notably, are also being utilized in the FIRE Collaboratives program. In this presentation, we will highlight the lessons learned from over 30 years of combined software development and training experience, focused on developing strong technical software foundations within the nuclear workforce, from students to professional engineers & scientists. We will connect this experience to present and emerging needs in the fusion energy community, and, finally, will outline possible paths forward to develop a large, robust, global fusion workforce.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Reference Design Cases for Floating Offshore Wind Arrays

Given the immature nature of the Floating Offshore Wind (FLOW) industry, there is a need for reference FLOW farm designs to allow researchers and technology developers to study the behavior of floating wind turbine systems, without having to design every part of those systems or without having to get access to a wide range of information that is often confidential. The International Energy Agency (IEA) Wind Task 49 is facilitating research collaboration on the integrated design of Floating Offshore Wind Arrays (FOWA), and will develop several reference FOWAs to facilitate R&D activities of the floating wind community and efficient scale change of the floating wind industry (from pilot farms to commercial ones). This paper will outline the key design considerations the task has identified for the sustainable deployment of large-scale FOWAs. The aim is to prepare a comprehensive overview of the different elements that impact the design of FOWA to support the development of best practices for FOWA design. The paper will also present three baseline reference design cases that are being prepared for shallow, intermediate and deep water sites. The final designs will be made open access including the engineering and cost inputs to accelerate further innovation, research and the deployment of FOWAs.

array layout↗

DOE OSTI2021

ECAR-6601 MARVEL Project Seismic Accelerations

The MARVEL reactor design requirements are currently listed within TFR-2576. Several MARVEL subsystems are required to be designed to seismic criteria of IBC 2015. This Engineering Analysis (EA) report documents the accelerations that need to be used in an equivalent-static method seismic analysis to satisfy this requirement.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

ECAR-6601 Rev 1 MARVEL Project Seismic Accelerations

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

DOE OSTI2022

Affordable Artificial Intelligence-Assisted Machine Supervision System for the Small and Medium-Sized Manufacturers

With the rapid concurrent advance of artificial intelligence (AI) and Internet of Things (IoT) technology, manufacturing environments are being upgraded or equipped with a smart and connected infrastructure that empowers workers and supervisors to optimize manufacturing workflow and processes for improved energy efficiency, equipment reliability, quality, safety, and productivity. This challenges capital cost and complexity for many small and medium-sized manufacturers (SMMs) who heavily rely on people to supervise manufacturing processes and facilities. This research aims to create an affordable, scalable, accessible, and portable (ASAP) solution to automate the supervision of manufacturing processes. The proposed approach seeks to reduce the cost and complexity of smart manufacturing deployment for SMMs through the deployment of consumer-grade electronics and a novel AI development methodology. The proposed system, AI-assisted Machine Supervision (AIMS), provides SMMs with two major subsystems: direct machine monitoring (DMM) and human-machine interaction monitoring (HIM). The AIMS system was evaluated and validated with a case study in 3D printing through the affordable AI accelerator solution of the vision processing unit (VPU).

3D printing↗

DOE OSTI2025

Engineering PHL7 for Improved Poly(Ethylene Terephthalate) Depolymerization via Rational Design and Directed Evolution

Enzymatic depolymerization of poly(ethylene terephthalate) (PET) has emerged as a promising approach for polyester recycling, and, to date, many natural and engineered PET hydrolase enzymes have been reported. For industrial use, PET hydrolases must achieve high depolymerization extent and exhibit excellent thermostability. Here, we engineered a natural PET hydrolase, Polyester Hydrolase Leipzig #7 (PHL7), through rational design and directed evolution using a high-throughput screening platform. Four new enzymes were engineered with enhanced properties compared with the parent enzyme, wild-type PHL7 (PHL7-WT), and other benchmark PET hydrolases, under the tested conditions. In bioreactors, the exemplary engineered enzyme, PHL7-Jemez, exhibited improved ability to depolymerize amorphous PET film compared with PHL7-WT at 2.9% and 20% substrate loadings, with 37% and 270% higher hydrolysis, respectively, after 48 h. This study develops several state-of-the-art PET hydrolases and demonstrates a directed evolution platform to engineer high-performance enzymes, which can accelerate enzyme discovery toward improved biocatalytic recycling.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Tailoring MoS 2 for Small-Molecule Electroreduction: The Role of Metal Doping and Heterostructures

The electrification of chemical transformations central to sustainable fuel production and waste valorization, such as overall water splitting (OWS), hydrogen evolution reaction (HER), and electrochemical reduction of CO 2 (CO 2 R), presents a powerful opportunity to advance carbon-neutral energy technologies. Transition metal dichalcogenides (TMDs), particularly MoS 2 , have emerged as promising electrocatalyst candidates, owing to their abundance, tunable active sites, and defect-rich structures. This review highlights recent progress in leveraging metal doping and heterostructure engineering of MoS 2 to enhance the electrocatalytic activity and selectivity. By compiling insights from experimental studies and density functional theory (DFT) predictions, we examine how defect creation, electronic structure modification, and interface design contribute to improved charge transport and catalytic efficiency. Particular emphasis is placed on rational design principles, synthetic strategies, and operando characterization methods that provide a pathway to understanding and optimizing MoS 2 -based materials. We also discuss the challenges of stability, mechanistic ambiguity, and scaling while outlining opportunities to bridge theory and experiment. Collectively, this review underscores how defect and heterostructure engineering of MoS 2 can accelerate the development of efficient, sustainable electrocatalysts for both fuel generation and waste-to-value generation.

CO2 reduction↗

DOE OSTI2025

Artificial intelligence–powered biofoundries for protein engineering and metabolic engineering

Synthetic biology is rapidly evolving through the integration of artificial intelligence (AI) and automated biofoundries. This convergence accelerates the design–build–test–learn cycle, shifting protein engineering and metabolic engineering from labor-intensive manual experimentation to autonomous experimentation. This review summarizes recent advances in workflow development, AI models, and their integration with biofoundries for automated or autonomous protein engineering and metabolic engineering. Particularly, we highlight the potential of AI-powered biofoundries for accelerated scientific discovery and innovation in synthetic biology.

Chen, Junyu [Univ. of Illinois at Urbana-Champaign↗

DOE OSTI2025

Coupled order parameters and photoinduced domain walls in the charge density wave of (TaSe 4 ) 2 I

The charge density wave in (TaSe 4 ) 2 I has drawn much attention recently as a controversial candidate for an axion insulator where the CDW breaks the chiral symmetry of the Weyl semimetal. Here we use ultrafast x-ray scattering to study the collective modes of this CDW. By measuring several diffraction peaks we find that the order parameter involves coupled optical and acoustic modes. For strong near-infrared excitation, the dynamics of the x-ray diffraction show evidence of photoinduced inversion of both components of the CDW order parameter, and associated domain walls. These results demonstrate the potential of ultrafast methods to induce topological defects through highly nonequilibrium dynamics. In (TaSe 4 ) 2 I these defects should lead to exotic electronic states due to the nontrivial topology of the band structure.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Design update on the transition beamline for the CEBAF Energy Upgrade

For Jefferson Lab’s 22GeV upgrade, two new permanent-magnet Fixed-Field Alternating Gradient (FFA) arcs will be integrated to serve the accelerator’s six highest-energy recirculation passes. Connecting these FFA arcs to the existing linear accelerator (linac) requires a carefully engineered transition section. The current design has two parts where the first part adiabatically matches the beam dispersion and orbit trajectories, while the second part aligns the Twiss parameters (alpha and beta functions) with those at the linac entrance. Given the tight spatial constraints and multiple matching requirements, a genetic algorithm is being explored to optimize the beam optics matching. This paper presents the current progress in developing and optimizing this transition.

Accelerator Physics↗

DOE OSTI2014

The OME Framework for genome-scale systems biology

The life sciences are undergoing continuous and accelerating integration with computational and engineering sciences. The biology that many in the field have been trained on may be hardly recognizable in ten to twenty years. One of the major drivers for this transformation is the blistering pace of advancements in DNA sequencing and synthesis. These advances have resulted in unprecedented amounts of new data, information, and knowledge. Many software tools have been developed to deal with aspects of this transformation and each is sorely needed. However, few of these tools have been forced to deal with the full complexity of genome-scale models along with high throughput genome-scale data. This particular situation represents a unique challenge, as it is simultaneously necessary to deal with the vast breadth of genome-scale models and the dizzying depth of high-throughput datasets. It has been observed time and again that as the pace of data generation continues to accelerate, the pace of analysis significantly lags behind. It is also evident that, given the plethora of databases and software efforts, it is still a significant challenge to work with genome-scale metabolic models, let alone next-generation whole cell models. We work at the forefront of model creation and systems scale data generation. The OME Framework was borne out of a practical need to enable genome-scale modeling and data analysis under a unified framework to drive the next generation of genome-scale biological models. Here we present the OME Framework. It exists as a set of Python classes. However, we want to emphasize the importance of the underlying design as an addition to the discussions on specifications of a digital cell. A great deal of work and valuable progress has been made by a number of communities towards interchange formats and implementations designed to achieve similar goals. While many software tools exist for handling genome-scale metabolic models or for genome-scale data analysis, no implementations exist that explicitly handle data and models concurrently. The OME Framework structures data in a connected loop with models and the components those models are composed of. This results in the first full, practical implementation of a framework that can enable genome-scale design-build-test. Over the coming years many more software packages will be developed and tools will necessarily change. However, we hope that the underlying designs shared here can help to inform the design of future software.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2018

Experience and Practice of Batch Scheduling on Leadership Supercomputers at Argonne

The mission of the DOE Argonne Leadership Computing Facility (ALCF) is to accelerate major scientific discoveries and engineering breakthroughs for humanity by designing and providing world-leading computing facilities in partnership with the computational science community. The ALCF operates supercomputers that are generally amongst the Top 5 fastest machines in the world. Specifically, ALCF is looking for the science that is either too big to run anywhere else, or it would take so long as to be impractical (i.e., “capability jobs”). At ALCF, batch scheduling plays a critical role for achieving a set of site goals within a set of constraints. While system utilization is an important goal at ALCF, its largest mission constraint is to enable extreme scale parallel jobs to take precedence. In this paper, we will describe the specific scheduling goals and constraints, analyze the workload traces collected in 2013–2017 from the 48-rack petascale supercomputer Mira, and discuss the upcoming scheduling challenges at ALCF.

Allcock, William↗

DOE OSTI2016

IDEAL: Images Across Domains, Experiments, Algorithms and Learning

Research across science domains is increasingly reliant on image-centric data. Software tools are in high demand to uncover relevant, but hidden, information in digital images, such as those coming from faster next generation high-throughput imaging platforms. The challenge is to analyze the data torrent generated by the advanced instruments efficiently, and provide insights such as measurements for decision-making. In this article, we overview work performed by an interdisciplinary team of computational and materials scientists, aimed at designing software applications and coordinating research efforts connecting (1) emerging algorithms for dealing with large and complex datasets; (2) data analysis methods with emphasis in pattern recognition and machine learning; and (3) advances in evolving computer architectures. Engineering tools around these efforts accelerate the analyses of image-based recordings, improve reusability and reproducibility, scale scientific procedures by reducing time between experiments, increase efficiency, and open opportunities for more users of the imaging facilities. This paper describes our algorithms and software tools, showing results across image scales, demonstrating how our framework plays a role in improving image understanding for quality control of existent materials and discovery of new compounds.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2016

Passive SCR for lean gasoline NO X control: Engine-based strategies to minimize fuel penalty associated with catalytic NH 3 generation

Lean gasoline engines offer greater fuel economy than common stoichiometric gasoline engines. However, excess oxygen prevents the use of the current three-way catalyst (TWC) to control nitrogen oxide (NO X ) emissions in lean exhaust. A passive SCR concept, introduced by General Motors Global R&D, makes use of a TWC that is already onboard to generate NH 3 under slightly rich conditions, which is stored on the downstream SCR. The stored NH 3 is then used to reduce NO X emissions when the engine switches to lean operation. In this work, the effect of engine parameters, such as air-fuel equivalence ratio and spark timing, on NH 3 generation over a commercial Pd-only TWC with no dedicated oxygen storage component was evaluated on a 2.0-liter BMW lean burn gasoline direct injection engine. NO X reduction, NH 3 formation, and reductant utilization processes were evaluated, and fuel efficiency was assessed and compared to the stoichiometric engine operation case. We found air-fuel equivalence ratio to be one of the most important parameters in controlling the NH 3 production; however, the rich operation necessary for NH 3 production results in a fuel consumption penalty. The fuel penalty can be minimized by adjusting spark timing to increase rich-phase engine out NO X emissions and, thereby, NH 3 levels. Additionally, higher engine out NO X during engine load increase to simulate acceleration resulted in additional fuel savings. Ultimately, a 10% fuel consumption benefit was achieved with the passive SCR approach by optimizing rich air-fuel equivalence ratio and spark timing while also utilizing acceleration load conditions.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Inverse design of hypoeutectoid pearlite steel microstructures using a deep learning and genetic algorithm optimization framework

Goal-oriented microstructure design in metallic materials is a challenging task due to complex structure-property relationships. Traditional experimental and computational approaches are time-intensive and economically inefficient, limiting their applicability for large-scale design space exploration. Here, in this work, we propose an end-to-end framework that integrates deep learning models with genetic optimization to design microstructures with targeted mechanical properties. Deep learning models enable accurate forward design, while their integration with genetic optimization enables efficient inverse design within a few hours, compared to days or weeks using conventional finite element simulations. The framework combines experimental characterization and finite element modeling to analyze the influence of microstructural features on the mechanical behavior of hypoeutectoid steels. Data from both experiments and simulations are used to train the deep learning models. To demonstrate its effectiveness, we apply the framework to 0.63% carbon steel with proeutectoid ferrite and pearlite phases, commonly used in industrial applications. In this study, 2D microstructures were used for modeling, selected primarily for computational efficiency and to establish proof of concept. The framework successfully optimizes microstructures for targeted yield strength, ultimate strength, and stress concentration factors while significantly reducing computational time. Beyond hypoeutectoid steels, this scalable framework can be extended to other material systems and integrated with additive manufacturing, offering an efficient approach for accelerating microstructure design for specific engineering applications.

ConvLSTM↗