Implementing a New Drift-Eliminating Design for Thread Wire Calibration
High accuracy measurement systems can drift with time. Implementing a drift-eliminating design reduces measurement uncertainty and improves quality control.
Mertes, Rick↗
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Results for “Quality by Design”
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Software Quality Assurance Plan: Cardinal
The Cardinal Software Quality Assurance (SQA) Program aims to provide the controls and processes necessary to enable continuous, high-quality software development while meeting user and program sponsor requirements. This SQA Plan (SQAP) delineates the SQA Program framework for Cardinal by describing the Program activities, organization, and documentation, and by clearly defining the interconnection of all Program items. It should be noted that this SQAP is aligned with the current version of the Argonne Quality Assurance Program Plan, which was designed to align with DOE O 414.1D. This SQAP is also aligned with the revision 10 of the SQAP for MOOSE and MOOSE-based applications.
97 MATHEMATICS AND COMPUTING↗
Storage and Algal Association of Bacteria That Protect Microchloropsis salina from Grazing by Brachionus plicatilis
Loss of algal production from the crashes of algal mass cultivation systems represents a significant barrier to the economic production of microalgal-based biofuels. Current strategies for crash prevention can be too costly to apply broadly as prophylaxis. Bacteria are ubiquitous in microalgal mass production cultures, however few studies investigate their role and possible significance in this particular environment. Previously, we demonstrated the success of selected protective bacterial communities to save Microchloropsis salina cultures from grazing by the rotifer Brachionus plicatilis. In the current study, these protective bacterial communities were further characterized by fractionation into rotifer-associated, algal-associated, and free-floating bacterial fractions. Small subunit ribosomal RNA amplicon sequencing was used to identify the bacterial genera present in each of the fractions. Here, we show that Marinobacter, Ruegeria, and Boseongicola in algae and rotifer fractions from rotifer-infected cultures likely play key roles in protecting algae from rotifers. Several other identified taxa likely play lesser roles in protective capability. The identification of bacterial community members demonstrating protective qualities will allow for the rational design of microbial communities grown in stable co-cultures with algal production strains in mass cultivation systems. Such a system would reduce the frequency of culture crashes and represent an essentially zero-cost form of algal crop protection.
59 BASIC BIOLOGICAL SCIENCES↗
Two-Stage Wildlife Event Classification for Edge Deployment
Camera-based wildlife monitoring is often overwhelmed by non-target triggers and slowed by manual review or cloud-dependent inference, which can prevent timely intervention for high stakes human–wildlife conflicts. Our key contribution is a deployable, fully offline edge vision sensor that achieves near-real-time, highly accurate wildlife event classification by combining detector-based empty-image suppression with a lightweight classifier trained with a staged transfer-learning curriculum. Specifically, Stage 1 uses a pretrained You Only Look Once (YOLO)-family detector for permissive animal localization and empty-trigger suppression, and Stage 2 uses a lightweight EfficientNet-based binary classifier to confirm puma on detector crops and gate downstream actions. Our design is robust to low-quality nighttime monochrome imagery (motion blur, low contrast, illumination artifacts, and partial-body captures) and operates using commercially available components in connectivity-limited settings. In field deployments running since May 2025, end-to-end latency from camera trigger to action command is approximately 4 s. Ablation studies using a dataset of labeled wildlife images (pumas, not pumas) show that the two-stage approach substantially reduces false alarms in identifying pumas relative to a full-image classifier while maintaining high recall. On the held-out test set (N = 1434 events), the proposed two-stage cascade achieves precision 0.983, recall 0.975, F1 0.979, accuracy 0.986, and balanced accuracy 0.983, with only 8 false positives and 12 false negatives. The system can be easily adapted for other species, as demonstrated by rapid retraining of the second stage to classify ringtails. Downstream responses (e.g., notifications and optional audio/light outputs) provide flexible actuation capabilities that can be configured to support intervention.
58 GEOSCIENCES↗
Subtask 1.5 – CO2 Injection Monitoring with an Optimized Scalable, Automated, Semipermanent Seismic Array
The scalable, automated, semipermanent seismic array (SASSA) method is a flexible and relatively cost-effective surface geophysical method for regular time-lapse monitoring of the movement of injected carbon dioxide (CO2) in a reservoir for CO2 enhanced oil recovery (EOR) or geologic CO2 storage operations. It has the advantages of a low-environmental-footprint while monitoring regions of a reservoir from the surface without the need for a regular grid distribution of receivers. Automated data collection is possible. As only time-lapse amplitude changes at the reservoir level due to CO2 movement within the reservoir are monitored, the turnaround time to deliver results from the SASSA method can be short, without the need for long, time-consuming data-processing workflows. As data is collected and processed, incremental information can be provided to the field operator. The Energy & Environmental Research Center (EERC) conducted a SASSA field test from September 2018 to November 2020 in a portion of the Bell Creek Field in Montana, which implemented new CO2 EOR field activities during the study period. Lessons learned from a proof-of-concept study were incorporated to improve the data quality of the SASSA method and demonstrate the viability of the technology. The EERC implemented several enhancements to improve data quality, including 1) an iterative survey design, which allowed placing the receivers in strategic locations where the movement of the CO2 in the reservoir could be tracked with minimum interference by the cultural noise in the study area; 2) the use of powerful seismic sources in the form of surface orbital vibrators, and 3) data acquisition during optimal periods. History-matched reservoir simulation was performed to predict gas saturation and pressure response induced by CO2 injection in the study area. The results were compared with the SASSA-measured responses to CO2 injection as a partial validation technique. A match between the two methods was observed for most of the SASSA points predicted to have intersected a CO2 saturation change. The validated results provide confidence that the SASSA method can be used independently as a CO2 saturation monitoring technique. As data are collected and processed, incremental information can be provided to the field operator. The critical components of the SASSA workflow for a successful application of the method are the following: Iterative survey design with information about CO2 injection activities from the oilfield operator. A detailed CO2 injection plan is the key driver to select the strategic monitoring location of the SASSA sensors. After this information is incorporated in the initial distribution of sources and receivers in the study area, high-resolution satellite images are used to identify ground locations not affected by cultural noise sources, such as power lines, pipelines/flow lines, or roadways. In the next iteration of the survey design, a scouting trip to the study area is needed to understand more details of the noise sources identified in the previous step and the intensity of the field activities that can also generate noise during the monitoring. Integrating the information from the scouting trip into the survey design to select the optimum source and receiver locations is the final step. Noise attenuation. The variety of noise types during seismic monitoring of an oil field is enormous. Tailored noise characterization and processing at a node-by-node level can enhance the performance and sensitivity of the SASSA technique. Future advancements that could improve the efficiency and application of the SASSA technology include: Gaining a better understanding of the noise field produced by the seismic source to aid the choice of receiver location. Surface noise from the source can overwhelm the small signal changes due to CO2 that the SASSA method measures. Improved data-processing workflow to automatically analyze and adapt to dynamic noise conditions associated with industrial settings. This subtask was funded through the EERC–DOE Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE- FE0024233.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Progress in the development and understanding of a high poloidal-beta tokamak operating scenario for an attractive fusion pilot plant
Abstract The high poloidal-beta ( $$\beta _{\textrm{P}}$$ β P ) regime was first proposed as a high bootstrap current scenario for a steady-state fusion pilot plant (FPP) in the 1990s (Kikuchi in Nucl Fusion 30:265, 1990). Since then, there have been many theoretical, modeling, and experimental research activities on this topic. A joint DIII-D/EAST research team began exploring the high- $$\beta _{\textrm{P}}$$ β P regime in 2013, focusing on addressing the needs of attractive FPP design by taking advantage of the extensive diagnostic set and sophisticated plasma control system on DIII-D and the well-developed integrated modeling capability at General Atomics. The ultimate goal is to demonstrate such a scenario on EAST with truly long pulse and metal wall compatibility. This paper summarizes the highlights of the research results on DIII-D by the joint team in the past decade. Experimental evidence and modeling analysis show the high- $$\beta _{\textrm{P}}$$ β P scenario has great advantages in addressing key needs for an attractive FPP design, such as high-energy confinement quality at low rotation, excellent core-edge integration, high line-averaged density above the Greenwald limit, low disruption risk, and high bootstrap current fraction for steady-state operation. This provides a relatively safe and economical option to base an FPP design on that will lead to commercial fusion energy.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Historic and modern nuclear graphite impurities: Pathways to improved waste strategies
Graphite has been used in large volumes as a structural material and neutron moderator since the earliest days of nuclear fission. However, no international consensus exists on the disposal of irradiated graphite, leaving much of the historic radioactive graphite inventory in interim vault or silo storage. With several new graphite-moderated reactors planned or under construction, the issue of graphite waste management is becoming increasingly urgent. This paper reviews and quantifies impurities in both historic and modern nuclear graphite, with emphasis on nitrogen—responsible for much of the 14 C inventory—and chlorine, which plays a critical role in repository performance and design. Modern graphites, benefitting from stringent quality-control measures developed for non-nuclear industries, meet or exceed the ASTM Ultra-High Purity nuclear standards, even without halide purification. Both chlorine and nitrogen concentrations have declined over time. For chlorine, identified as a key impurity influencing U.S. waste repository design, we propose a target of 0.1 appm in as-fabricated billets as a reasonable benchmark. Nitrogen sources are traced throughout the graphite production process, with surface and bulk concentrations characterized for all materials studied. Modern graphites commonly exhibit nitrogen levels below 5 appm, with values approaching 1 appm achievable. Using such reduced-nitrogen grades is critical to keeping graphite-induced radioactivity below the greater-than-Class-C waste threshold, thereby avoiding disposal cost penalties of nearly an order of magnitude.
Chlorine↗
Cool GTL for the Conversion of Biogas to Jet Fuel
Cool GTL is a new process under development for conversion of biogas from digestors or CO2 +H2 to high quality drop in jet fuel. Cool GTL is designed to be a streamlined simplified low cost process which can be cost effective for small scale biogas applications. Cool GTL has the advantage that it uses a high activity bi-reforming catalyst, in a streamlined electric reformer design, to make the synthesis gas for a high conversion slurry fischer Tropsch process followed by a trailing wax cracking reactor. In this way high quality jet fuel can be directly produced. Recent experimental test data will be presented showing product quality. The life cycle analysis LCA will also be presented as well.
09 BIOMASS FUELS↗
Designing Iowa Agricultural Landscapes to Improve Environmental Co-Benefits of Bioenergy Production
Cellulosic bioenergy feedstocks are needed to improve carbon (C) management while provisioning biomass for bioproducts and biofuel. The transition to increased cellulosic biomass production can be guided by land management plans designed to improve economic, environmental, and ecological performance. We constructed a sustainability model to compare landscape designs for biofuel production from corn (Zea mays L.) stover and switchgrass (Panicum virgatum L.) in central Iowa, USA. We used the model to compare environmental and socioeconomic outcomes associated with four landscape management strategies, with and without cellulosic biomass markets. We evaluated (1) a fuelshed area containing over 1.2 million ha (3 million acres) of corn and soybean (Glycine max (L.) Merr.) within 80 km (50 miles) of a commercial-scale cellulosic biorefinery in Nevada, Iowa, and (2) the South Fork watershed containing over 72,000 ha (178,000 acres) of these row crops within eight north central Iowa HUC-12 (hydrologic unit code) watersheds. At both landscape scales, we found that it is possible to achieve multiple environmental and socioeconomic benefits concomitantly with cellulosic biomass production by strategically collecting corn stover and converting the 10% of the lowest-profitability row crop land to perennial switchgrass. Potential benefits from landscape design include increased biodiversity, soil and water quality improvements, increased soil carbon sequestration for climate change mitigation, and reduced fertilizer use and cost. Our model results showed that increasing benefits can accrue when complementary conservation practices (e.g., reduced tillage, use of a rye cover crop) are combined and integrated throughout a fuelshed or watershed area. We conclude that ecologically based landscape designs offer valuable insights about costs and benefits of land management alternatives, with relevance for achieving stakeholder goals.
54 ENVIRONMENTAL SCIENCES↗
The ProtoDUNE-SP LArTPC electronics production, commissioning, and performance
The ProtoDUNE-SP detector is a large-scale prototype of the Single-Phase (SP) Liquid Argon Time Projection Chamber (LArTPC) design proposed for the Deep Underground Neutrino Experiment (DUNE). 15,360 LArTPC wires are instrumented with low electronic noise pre-amplifier and digitization ASICs integrated into Front End Motherboards (FEMBs) operating at cryogenic temperature within the cryostat. The large number of electronics channels and high performance specifications required a large-scale production electronics quality control effort, careful installation into Anode Plane Assemblies (APAs), and rigorous detector commissioning. This successful collaboration-wide effort achieved a working LArTPC electronics channel percentage of 99.7% (15,318 of 15,360 channels in total), whose operating performance exceeded expectations. We summarize the ProtoDUNE-SP cold electronics design and quality control, installation, and commissioning efforts that enabled this excellent electronics performance.
72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
Robot-based Additive Manufacturing of Lego-type Modular Molds for Wind Blades
The objective of this project is to reduce the cost and lead time of horizontal wind turbine blade mold tooling and blade transportation, while maintaining the highest standards of blade quality. The solution involves a smart-design family of modular molds that are easily transportable to fabrication sites near the place of service. Key innovations include the use of additive manufacturing (AM) to integrate conformal thermal management channels, offering enhanced control over the thermal profiles tailored to specific blade materials. This approach enables in-situ quality assurance during mold fabrication, significantly improves mold life, and allows for reuse across multiple production cycles. Ultimately, the solution aims to optimize both tooling and transportation costs, contributing to the scalability of wind turbine blade production. A significant barrier to scaling up the production of large wind turbine blades lies in the high costs associated with tooling and the transportation of blades. Traditional molds are expensive, bulky, and difficult to transport, adding considerable lead time and cost to the overall manufacturing process. Additionally, transporting blades to distant locations for final assembly further exacerbates these challenges. The project aims to address these inefficiencies by demonstrating a modularized, additive-manufactured mold that meets all necessary blade specification requirements, specifically for blade lengths between 120m and 150m.
17 WIND ENERGY↗
Indoor Air Quality (IAQ) Monitoring for Space Farming Institute [Slides]
Through the U.S. Department of Energy's Energy to Communities (E2C) program, NREL, other national laboratory experts, and select organizations provide Expert Match - free, short-term technical assistance to address near-term energy challenges and questions. Expert Match is for community stakeholders who have decision-making power or influence in their community but need access to additional energy expertise to inform key upcoming decisions. This Expert Match request supported the Space Farming Institute, a nonprofit organization located in Anchorage, AK, with an indoor air quality analysis. The NREL team analyzed indoor air quality data provided by the Space Farming Institute, which experts at PNNL used to design an indoor bioreactor to grow Ulva algae for indoor air quality mitigation purposes.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Towards Generalizable and Efficient Circuit Topology Design: A Graph-Transformer-based Surrogate Model with Curriculum Learning
Unlike circuit parameter and sizing optimizations, the automated design of analog circuit topologies poses significant challenges for learning-based approaches. One challenge arises from the combinatorial growth of the topology space with circuit size, which limits the topology optimization efficiency. Moreover, traditional circuit evaluation methods are time-consuming, while the presence of data discontinuity in the topology space makes the accurate prediction of circuit performance exceptionally difficult for unseen topologies. To tackle these challenges, we design a novel Graph-Transformer-based Network (GTN) as the surrogate model for circuit evaluation, offering a substantial acceleration in the speed of circuit topology optimization without sacrificing performance. Our GTN model architecture is designed to embed voltage changes in circuit loops and current flows in connected devices, enabling accurate performance predictions for circuits with unseen topologies. To address the cold start problem when scaling GTN to large-scale circuits, we further introduce a curriculum learning strategy that progressively trains GTN from small-scale to large-scale circuits. This approach enables the model to first learn fundamental physical principles from simpler topologies and gradually adapt to complex configurations, effectively bridging the circuit complexity gap and improving prediction accuracy. Taking the power converter circuit design as an experimental task, our GTN model significantly outperforms an analytical approach and baseline methods directly utilizing graph neural networks. Furthermore, GTN achieves less than 5% relative error and 196× speed-up compared with high-fidelity simulation. Notably, our GTN surrogate model empowers an automatic circuit design framework to discover circuits of comparable quality to those identified through high-fidelity simulation while reducing the time required by up to 98.2%. With curriculum learning, the enhanced GTN achieves a 51% improvement for performance prediction of large-scale circuits compared to the GTN model without this strategy. These advancements establish GTN as a scalable framework for automated analog circuit design across varying circuit complexity levels.
Lu, Haoshu [New Jersey Institute of Technology (NJ↗
PUFFIn Software Modeling for Quality Management
PUFFIn (PENELOPE User Friendly Fast Interface) was designed as a fast and simple Monte Carlo simulation tool for the transport of photons and electrons, with a primary purpose as a learning and education tool for a broad range of static configurations in the radiation processing industry. Development of the PUFFIn software is funded by the Office of Radiological Security (ORS) within the United States National Nuclear Security Administration (NNSA). PUFFIn helps fill the education and knowledge gaps in the industry, as identified in reports by Fermilab (2017) and the IAEA (2020). PUFFIn uses the PENELOPE (NEA-2023) physics engine to perform simulations on static configurations. PUFFIn has support for multiple geometry types from simple, single material simulations to full 3D configurations created from CAD input files or images from X-Ray Tomography scans. PUFFin was designed to be easy for the novice user, it will generate the input and geometry files required by PENLOPE and will display the output plots within the PUFFIn interface. PUFFin is distributed for free but requires a free workshop so users can be adequately trained in its use. Workshops have been presented in the past at Texas A&M university, the Aerial-CRT facility in Strasbourg France and Jakarta Indonesia. PUFFIn simulations have been validated by 10 MeV ebeam experiments done at Aerial-CRT in France (Radiation Physics and Chemistry 222 (2024) 111774). Further user experimental comparisons were made at the medical product hands on workshop at Texas A&M in October 2024.
73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
Biofuel Air Emissions Analysis
U.S. has goals to produce 3 billion gallons of sustainable aviation fuel (SAF) annually by 2030, increasing to 35 billion gallons by 2050 to decarbonize the aviation sector. Meeting these production targets will require large number of biorefineries to be set up. However, ability to comply with federal air quality standards is prerequisite to being issued a construction permit. Negotiating the permitting process for a new biorefinery can be quite onerous and cost the investors significant time and money. Although there can be numerous reasons for delayed biorefinery construction, air permitting is fraught with pitfalls because the permitting process relies on precedence, which the future SAF biorefineries lack. NREL's Biofuel Air Emissions Analysis project is unique and innovative in terms of the tools, approaches, and analyses provided. NREL is the only national laboratory that is actively working at the intersection of Federal air quality regulations, emissions and air quality analysis across the supply chain, and process design. This project is focused on providing much needed data and analyses that address biorefinery air permitting. This project develops models and quantitative analyses and measures progress towards meeting air quality regulatory requirements. These models and methods are applied to analyze air permitting related to wastewater sludge to biofuel conversion pathways using hydrothermal liquefaction (HTL), impacts of HTL pathway on local and regional air quality including an assessment of health and equity impacts. In addition to filling research gaps, this project also disseminates the findings to the relevant stakeholders at BETO, other national labs, and regulatory agencies.
air quality↗
Acceptance Test of WCTC with LEU Fuel at the IVG.1M Research Reactor Site in Kazakhstan
The water-cooled technological channels (WCTC) with low-enriched uranium (LEU) fuel, in the amount required for conversion, were delivered to the IVG.1M site by the manufacturer in February 2021 and thereafter the site acceptance test (SAT) of the WCTCs and the fuel elements started immediately. The paper provides an overview of the SAT conducted between March and November 2021 by the designated experts of the reactor operator and the manufacturer. It includes the introduction of the IVG.1M reactor and its unique WCTCs, and the inspection methodology to verify the conformity of the quality of the LEU fuel with the Technical Design (reference document). The paper presents results of the non-destructive and destructive tests, the outcomes of the thermohydraulic measurements, as well as the evaluation and corrective actions (if any), including the amendments (modifications) of the Technical Design initiated by the manufacturer based on the test results. Finally, the paper draws conclusions on the effectiveness of the SAT method used, captures consolidated experiential knowledge and shares lessons learned that can be used in general when planning and performing fuel verification.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Establishing the Quality Assurance programme for the strip sensor production of the ATLAS tracker upgrade including irradiation with neutrons, photons and protons to HL-LHC fluences
The successful pre-production delivery of strip sensors for the new Inner Tracker (ITk) for the upgraded ATLAS detector at the High Luminosity LHC (HL-LHC) at CERN was completed and based on their performance full production has commenced. The overall delivery period is anticipated to last 4 years to complete the approximately 22000 sensors required for the ITk. For Quality Assurance (QA), a number of test structures designed by the collaboration, along with a large area diode and miniature version of the main sensor, are produced in every wafer by the foundry Hamamatsu Photonics K.K (HPK). As well as Quality Control (QC) checks on every main sensor, samples of the QA pieces from each delivery batch are tested both before and after irradiation with results after exposure to neutrons, gammas or protons to fluences and doses corresponding to those anticipated after operation at the HL-LHC to roughly 1.5 times the ultimate integrated luminosity of 4000 fb -1 . In this paper the procedures are presented and the studies carried out to establish that the seven ITk QA Strip Sensor irradiation and test sites meet all the requirements to support this very extensive programme throughout the strip sensor production phase for the ITk project.
47 OTHER INSTRUMENTATION↗
Loss channels affecting lithium niobate phononic crystal resonators at cryogenic temperature
Here, we investigate the performance of microwave-frequency phononic crystal resonators fabricated on thin-film lithium niobate for integration with superconducting quantum circuits. For different design geometries at millikelvin temperatures, we achieve mechanical internal quality factors Qi above 10 5 –10 6 at high microwave drive power, corresponding to 5×10 6 phonons inside the resonator. By sweeping the defect size of resonators with identical mirror cell designs, we are able to indirectly observe signatures of the complete phononic bandgap via the resonators' internal quality factors. Examination of quality factors' temperature dependence shows how superconducting and two-level system (TLS) loss channels impact device performance. Finally, we observe an anomalous low-temperature frequency shift consistent with resonant TLS decay and find that the material choice can help to mitigate these losses.
71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗