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DOE OSTI2021

Software-defined Networking for Energy Delivery Systems (SDN4EDS): An Architectural Blueprint (Final Report)

This is the initial version of a reference for suppliers and energy companies of all sizes to deploy networks based on software-defined networking technology (SDN) to improve reliability, reduce cyber security attack surface, and facilitate mitigation of adversarial behavior. It is a living document and will progress over the life cycle of the Software-Defined Networking for Energy Delivery Systems (SDN4EDS) project. Version 2 of this report provides information on the Red Team tabletop assessment performed against the initial reference architecture. Version 3 of this report updates the reference architecture with lessons learned from the Red Team tabletop assessment, as well as provides additional details for the use cases. It also provides information on the decision process that could be used by an organization when considering deploying SDN in their environment. The final version of this report consolidates all the interim reports generated by the project into a final report. It also draws from PNNL’s experience in deploying SDN to make recommendations on how SDN could be deployed in a utility environment, and provides rationale for those decisions allowing individual utilities to make risk-based and knowledge-based decisions on how to best deploy SDN in their own environment

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Software-defined Networking for Energy Delivery Systems (SDN4EDS): An Architectural Blueprint (Final Summary Report)

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Overview of the Fiber System for the Dark Energy Spectroscopic Instrument

The Dark Energy Spectroscopic Instrument (DESI) is a revolutionary instrument designed for precise measurements of cosmic distances and the investigation of dark energy. DESI utilizes 5000 optical fibers to simultaneously measure the spectra of distant objects and aims to measure 40 million galaxies and quasars in a 5 yr survey. One of the critical challenges to DESI's success was ensuring that the fiber system was not only highly efficient but also delivered a highly stable beam enabling more reliable sky subtraction for measurements of faint objects. We achieved this stability by minimizing the stress on the fiber system during the manufacture and operation of the telescope and fiber positioning robots. We installed the DESI fiber system on the 4 m Mayall telescope with ≥99% of fibers intact, and the instrument has delivered superb optical performance throughout the initial years of the DESI survey, including ≥90% average throughput when injected with a focal ratio of ~f/3.9 as delivered by the primary focus corrector, excluding fiber absorption losses. The design of DESI required multiple innovations to achieve these requirements, such as cleaved fibers bonded with a UV-curing epoxy to glass ferrules in the focal plane and fusion splicing instead of physical connectors. In this paper, we describe the development, delivery, and installation of the fiber system, the innovations that made the state-of-the-art performance possible, and the key lessons learned that could benefit future projects.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2026

Enhancing segmentation fairness through curriculum learning and progressive loss: a centralized and federated perspective on radiograph analysis

Bias in medical image segmentation can lead to unequal performance across demographic subgroups, raising concerns about fairness and reliability in clinical AI systems. While deep learning models have achieved high segmentation accuracy, ensuring equitable performance across race and gender remains a significant challenge, particularly in privacy-sensitive healthcare environments. This study investigates fairness-aware medical image segmentation for hip and knee radiographs using deep learning models evaluated in both centralized and Federated Learning (FL) settings. We introduce Curriculum Learning (CL) strategies and Progressive Loss (PL) functions to regulate sample difficulty during training. In addition, we propose two novel fairness-oriented federated learning algorithms, Federated Intersection over Union (FedIoU) and Federated Intersection over Union with Outlier Analysis (FedIoUoutlier). Experiments are conducted using multiple segmentation backbones and simulated multi-site data partitions derived from the Osteoarthritis Initiative dataset. Model performance is evaluated using Intersection over Union (IoU), IoU standard deviation, Skewed Error Ratio (SER), and Min-Max Disparity across race and gender subgroups. Statistical significance was verified using paired t-tests to compare per-sample IoU performance against baseline configurations. Across both hip and knee segmentation tasks, curriculum learning and progressive loss strategies consistently improved segmentation accuracy and reduced demographic performance disparities in centralized training. In federated settings, fairness-aware aggregation further enhanced performance. Notably, FedIoUoutlier combined with balanced curriculum learning and tiered progressive loss achieved the highest mean IoU while yielding the lowest SER and Min-Max Disparity, indicating improved fairness without sacrificing accuracy. In several configurations, federated models matched or exceeded the performance of optimized centralized models, with statistically significant improvements in per-sample IoU over baseline configurations. The results demonstrate that structured training strategies and fairness-aware federated aggregation can jointly improve accuracy, stability, and demographic fairness in medical image segmentation. By integrating curriculum learning, progressive loss, and novel FL algorithms, this work provides a practical pathway toward equitable and privacy-preserving AI systems for medical imaging.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Design, Processing, and Integration of Pouch-Format Cell for High-Energy Lithium-Sulfur Batteries

This project objective was to develop and demonstrate a lithium-sulfur (Li-S) battery in a pouch-format cell capable of achieving an energy density ≥ 500 Wh/kg while achieving a 1,000 cycle life. The research focused on cell optimization and fabrication addressing different technical barriers and challenges including: 1) thin lithium anode optimization; 2) current collector and tab attachment design; 3) cathode porosity control; 4) electrolyte to sulfur ratio control; 5) cell design; and 6) cell fabrication. The project developed and demonstrated various technologies to address these technical barriers and challenges. The project demonstrated a thin lithium anode by vapor deposition, a collector design and validation of laser welding of tab attachment method, a cathode porosity control strategy by binder optimization, a calendaring process control and surface/interface treatment, and an electrolyte to sulfur ratio control with influence on cell energy density. The sulfur cathode was optimized by tuning the formulation, optimizing the calendaring process, and introducing a novel electrode fabrication process. To address the electrolyte performance issue, the electrolyte optimization was achieved with additive and formulation tuning and the introduction of a dual-phase electrolyte system. In addition to the demonstration of the optimized electrode with a novel fast-curing coating process and dual-phase electrolyte, a coating separator was further developed to address the polysulfide shuttling issue. The resulting new cell design with these optimized cell components was demonstrated in the 1 Ah pouch cell with medium sulfur loading and moderate porosity (~ 4.5 mAh cm-2, 65% porosity) and showed an energy density of > 400 Wh/kg (with E/S ratio of 2.8). The Li-SPAN cell configuration was also evaluated in combination with a new dual-phase electrolyte system. Initial coin cell performance demonstrated cycle stability of >300 cycles with an estimated energy density of 300 Wh/kg at the pouch format level. The corresponding 1 Ah pouch format SPAN cells with the new polymer electrolyte were developed which has shown a stable capacity at 800-900 mAh for ~40 cycles so far.

25 ENERGY STORAGE↗

DOE OSTI2021

Choosing Transport Events for Initiating Splitting and Rouletting

A study was performed to determine which transport events should be used to initiate a weight window lookup to achieve the best variance reduction performance. A weight window lookup potentially triggers particle splitting (in important regions of phase space) or rouletting (in unimportant regions), thereby optimizing computational effort. Potential initiating transport events include collisions (both pre- and post-collision), geometry surface crossings, traversing a mean-free path, and streaming across a weight window boundary. Permutations of these initiating events were tested on an urban model with background radiation sources and a spent fuel cask with a neutron dose mesh tally. Generally, all methods perform better with finer weight window meshes. Tracking on weight windows performs well for coarse weight window meshes, while a combination of splitting each mean-free path, geometric surface crossing, and before collisions performs well for fine weight window meshes.

42 ENGINEERING↗

DOE OSTI2023

Package Performance Study: A Historical Perspective and Planning for a Path Forward

The topic of spent nuclear fuel (SNF) transportation often draws public attention and concerns regarding safety, and with large-scale shipping campaigns expected in the future, public interest is anticipated to substantially increase. In 1999, the U.S. Nuclear Regulatory Commission (NRC) began an initiative called the Package Performance Study (PPS) that initially focused on SNF transportation cask responses to severe transportation accidents. A public participation approach was to be used to help guide the scope and parameters of the study, which was also to consider using full-scale physical testing of a SNF transportation cask, where appropriate. In 2010, the NRC decided not to go forward with physical testing as proposed. In 2006, the National Academy of Sciences (NAS) conducted a study on SNF and high-level radioactive waste transportation in the United States. The NAS study recommended that full-scale cask testing, as well as other accepted methodologies, continue to be used as part of the package performance evaluation. In 2012, the Blue Ribbon Commission on America’s Nuclear Future (BRC) recommended conducting the PPS with a full-scale rail transportation cask for the purpose of building public trust and confidence in the safety of SNF transport. In 2021, the U.S. Department of Energy (DOE) restarted a consent-based siting process, focusing on how to site federal facilities for the interim consolidated storage of SNF using a consent-based approach. Large-scale SNF transportation would be necessary for any such interim storage facility. As the planning activities begin for future large-scale shipping campaigns, the DOE is considering options for conducting a DOE-led PPS to help build public trust and confidence in the transportation of SNF. Therefore, the DOE is gathering information related to the previous NRC-led PPS efforts, as well as applicable international experience with the testing of SNF packages. This paper discusses previous NRC efforts, as well as the current status of a DOE-led PPS, which is in the early planning stages.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

On the Road to Achieving Safety Excellence at the Idaho Cleanup Project: The Initial Challenges, Solutions, and Positive Results of Striving to be the Best and Safest in the DOE Complex - 20518

When Fluor Idaho, LLC (Fluor Idaho) assumed the Idaho Cleanup Project Core contract (ICP Core) in mid-2016, it inherited the successful multi-faceted, employee-owned safety programs of two prior contractors supporting cleanup operations at the Idaho National Laboratory Site. Fluor Idaho incorporated the best of both safety programs along with Fluor Corporate's 106-year legacy of safety initiatives and successes. Fluor Idaho integrated the separate programs and cultures under a One Fluor approach - one project, one mission, One Fluor. Job changes, management changes, and procedures, processes, and system changes presented multiple challenges. Those challenges combined with the severe Winter of 2016/2017 resulted in numerous slips, trips, and falls first aids and reportable injuries. The road to safety excellence started off bumpy and stayed that way for some time. Since then, Fluor Idaho has successfully implemented several key initiatives including employee engagement; management engagement and time in the field; communications improvements; safety culture sustainment; injury/illness prevention; organizational learning; and DOE Voluntary Protection Program (VPP) readiness and preparation. Management became more engaged by making more workplace visits and increasing their supervision of 'life critical work' or complex activities. Additional training became mandatory for first-line supervisors and front-line workers. Most recently, Fluor Idaho increased its injury and illness prevention initiatives extensively. In the last year, things have turned around in a dramatic way. This shift is directly attributable to the significant number of initiatives launched in late 2017 and 2018. These initiatives addressed safety performance in the five key areas of the DOE VPP and promoted sustainability of the company's safety culture. The five key areas are: management leadership, employee involvement, work-site analysis, hazard prevention and control, and safety and health training. Employees and managers alike recommitted to making safety the highest value. The result of this laser-like focus on safety and accident and injury prevention is that injuries and first aids are a fraction of what they were. During FY 2019, employees worked more than 4.2 million hours without a serious injury or lost work-day and 1 million hours without a recordable injury. Fluor Idaho is proud of its safety trend. The company invested significant resources in improving its safety record, and that investment is paying off. Other contractors in the DOE Complex can learn and benefit from this discussion of the challenges Fluor Idaho faced, as well as its innovative safety initiatives that are producing results that are being recognized by our U.S. Department of Energy (DOE) customer. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Composite PEMs from Electrospun Crosslinkable Poly(Phenylene Sulfonic Acid)s (Final Technical Report)

The main objective of this project is to fabricate and demonstrate superior fuel cell performance of an electrospun composite all-hydrocarbon, non-PFSA membrane. The project builds on two earlier, DOE-funded studies demonstrating high proton conductivity, even at very low humidity of crosslinkable poly(phenylenesulfonic acid), cPPSA, solution cast films, and high durability of electrospun perfluorosulfonic acid (PFSA) composite membranes. Most project milestones were fully met but the best membrane conductivity and fuel cell performance were obtained with membranes that did not contain electrospun sulfonated polyphenylene, as initially planned. Instead, an excellent performance was achieved with membranes fabricated by pore-filling, either with electrospun poly(phenyl sulfone) scaffolds or with commercial, expanded polytetrafluoroethylene scaffolds. Fuel cell testing demonstrated performance better than that of Nafion 211 or Nafion XL, particularly at lower cell humidification levels with significantly lower hydrogen crossover. No accelerated stress testing was performed, due to the initial numerous difficulties with controlling the copolymerization reaction, which took excessive amount of time to overcome. Potential scale-up of the proposed composite membrane technology can aid in boosting the fuel cell power output and simplification of the cell hydration system.

08 HYDROGEN↗

DOE OSTI2021

Thermal loading analysis of the ring injection dump for the Spallation Neutron Source facility

The ring injection dump (RID) is the largest beam dump in the Spallation Neutron Source facility at Oak Ridge National Laboratory and accepts a fraction of the beam from the ring that is not captured in the ring during injection. Thermo-fluid modeling of the RID components was performed during the initial design by using the software ANSYS CFX to characterize the power rating for the RID. From the calculations, the power rating was lowered from 200 kW to 150 kW, at 1.3 GeV beam energy due to concerns regarding the heating of the concrete structure. The Proton Power Upgrade project scope included reevaluating the power limit to the RID in anticipation that increasing it would provide more operational flexibility. The focus was on the shielding because it was the limiting factor, and data collected from thermocouples installed on the structure were used to benchmark the analysis. A three-stage process was adopted in the latest study. First, the already existing steady-state calculations were validated and extended with the latest Monte Carlo N-Particle source term calculations. Second, transient calculations were conducted to capture the dynamic state of the system in response to the energy dumped to the RID during the following operational period of the beam from 2005–2019 (14 years), and sensitivity analyses of crucial parameters were performed to benchmark the model with reasonable accuracy. Finally, an idealized transient cycle analysis was conducted with realistic duty factors to predict the temperature distribution at higher beam powers. Overall, the results confirmed the accuracy of the original steady state model but allowed the development of a new validated transient model with higher accuracy for future analyses.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2021

Cement stress and microstructure evolution during curing in semi-rigid high-pressure environments

The process of cement slurry curing into a solid has a direct effect on the initial state of stress in a composite concrete and steel structure. Failure models for critical infrastructure and wellbores could benefit from measurements of this initial stress because it greatly influences structural performance. Here, we present measurements of the initial stress state (total stress, effective stress, and pore pressure) of multiple cement formulations cured under a high-pressure of 40 MPa within a semi-rigid steel pipe. Our results show that cements cured in this restrained environment exhibit dense microstructures with low permeability (nano-Darcy), develop an anisotropic stress state greater than zero and less than the curing pressure, and undergo a staged curing process where hydration and mechanical behaviors evolve from a slurry into a pre-stressed porous medium. Both drained and undrained scenarios were investigated, revealing a feedback from the semi-rigid boundary towards improved cement performance.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Photovoltaic module antireflection coating degradation survey using color microscopy and spectral reflectance

Abstract Commercial antireflective coatings (ARCs) on photovoltaic (PV) module glass can improve module power by 2.5%–3.0%, but their long‐term field performance requires additional study. In this paper, we investigate ARC performance on fielded modules using two nondestructive techniques: reflectance spectroscopy and RGB microscopy, finding a large variation in coating durability and performance. For new coatings, the fleet average nominal power enhancement is 2.8%. This power enhancement is observed to degrade at approximately −0.05%/year absolute over the first 8 years of fielding in arrays that are not regularly cleaned. Interferometry and imaging results imply that coating loss for these modules is due to slow chemical thinning of the initial 125 nm thick coating by 1.4 to 5.0 nm/year. Due to the physics of interference coatings, the performance loss is projected to accelerate as the coating is further thinned, resulting in a coating lifetime (time to 80% of initial performance) of 7.5 to 25 years. At the higher 5.0 nm/year coating loss rates, we estimate that −0.14%/year power degradation of the module can be attributed solely to ARC degradation over the first 20 years. Extreme coating loss is observed on some modules where after 8 years fielding, the coating can be completely removed with a single wet wipe with a lens tissue. A case study is also presented comparing ARC and noncoated modules installed at a single site in 2013. We find that the ARC modules have a 2.6% higher soiling power loss than the noncoated modules; this exceeds the ARC power enhancement of 2.4% and leads to the surprising conclusion that the ARC lowers production for modules in this location due to increased soiling. These results demonstrate that RGB microscopy is a powerful, field‐capable, and quantitative characterization technique for assessing degradation of PV module ARCs.

Karin, Todd↗

DOE OSTI2020

Atomic‐Resolution Imaging of Halide Perovskites Using Electron Microscopy

Abstract Atomic‐resolution imaging of halide perovskites (HPs) using transmission electron microscopy (TEM) is challenging because of the sensitivity of their structures to the electron beam. In this article, recent achievements in this area are reviewed, covering both all‐inorganic and organic–inorganic hybrid HPs, with an emphasis on the specific imaging conditions that have proven to be effective in avoiding electron beam‐induced structural damage. The discussion focusses on the total electron dose that HPs can bear before being damaged and the effects of different imaging modes, accelerating voltages, and temperatures. The crucial role of a direct‐detection electron‐counting camera in reducing the required electron dose is outlined, which is indispensable for imaging extremely sensitive organic–inorganic hybrid perovskites. In addition to reviewing published works, the results of initial attempts to perform atomic‐resolution elemental mapping for an all‐inorganic HP and image a hybrid HP using scanning TEM are introduced. The preparation of a TEM specimen from macroscopic crystals or devices of HPs, which is very important for practical applications but has not yet received attention, is also discussed. This article aims to provide guidance on the acquisition of atomic‐resolution TEM images of HPs and inspire the development of more imaging technologies for sensitive materials.

Song, Kepeng↗

DOE OSTI2023

Use of Longitudinal Serum Analysis and Machine Learning to Develop a Classifier for Cancer Early Detection

Early detection of solid tumors through a simple screening process, such as the proteomic analysis of biofluids, has the potential to significantly alter the management and outcomes of cancers. The application of advanced targeted proteomics measurements and data analysis strategies to uniformly collected serum or plasma samples would enable longitudinal studies of cancer risk, progression, and response to therapy that have the potential to significantly reduce cancer burden in general. In this article, we describe a generalizable workflow combining robust, multiplexed targeted proteomics measurements applied to longitudinal samples from the Department of Defense Serum Repository with a Random Forest machine learning method for developing and initially evaluating the performance of candidate biomarker panels for early detection of cancers. The effectiveness of this approach was demonstrated in a cohort of 175 head and neck squamous cell carcinoma patients. The outlined protocols include methods for sample preparation, instrument analysis, and data analysis and interpretation using this workflow.

Longitudinal analysis, machine learning, cancer, e↗

DOE OSTI2021

Quantitative concentration measurements in a turbulent helium jet using rainbow schlieren deflectometry

Rainbow schlieren deflectometry (RSD) is applied to acquire quantitative concentration measurements in a turbulent environment for the first time. RSD methodology is developed and validated using Rayleigh scattering data available in the literature. Experiments were performed in an initially laminar, momentum-driven helium jet injected into ambient air. Full-field measurements are acquired that span the laminar, transition, and fully turbulent regions of the jet. Furthermore, the RSD results are shown to provide accurate measurements in each region and also confirm the self-similar nature of the fully turbulent jet. Analysis shows that the transition from laminar to turbulent flow occurs across an axial span that decreases with increasing Reynolds number. Experiments with a long exposure time were conducted to evaluate the limitations of hardware averaging of the RSD signal in comparison with software averaging.

02 PETROLEUM↗

DOE OSTI2024

Evaluation of liquid metal embrittlement of F82H and 4340 steels in liquid lithium

Here, to evaluate the liquid metal embrittlement (LME) susceptibility of F82H, a reduced activation ferritic-martensitic (RAFM) steel, a testing procedure using hollow cylindrical tensile specimens was used. Tensile tests are compared between specimens filled with argon and lithium at 200 °C. To validate the procedure, initial testing was performed on type 4340 steel, which is well-known to exhibit LME. Compared to 4340 steel, F82H only showed minor effects of Li exposure, including pre-testing exposures with Li at 400 °C for 1 h and 500 °C for 500 h. Furthermore, changing the strain rate or tensile test temperature also did not show significant embrittlement.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Micro-tensile testing of the bond line in hot isostatic pressed aluminum

Considerable effort is being devoted to development and regulatory qualification of low enriched fuels for research and test reactors by many agencies worldwide. One promising fuel configuration being examined for United States higher power research and test reactors (USHPRRs) are plate-type fuels composed of a metallic uranium-molybdenum foil clad in an aluminum alloy. The two pieces of aluminum alloy cladding are bonded using a hot isostatic pressing method. The mechanical properties of the resulting bond line in the aluminum alloy cladding will vary by the HIP'ing parameters, requiring a need to characterize the bond line. Small scale mechanical testing can provide a path for evaluating the mechanical properties and deformation behavior of the bond line both prior to and following irradiation. Here, in this research, room temperature micro-tensile specimens of non-irradiated and irradiated samples containing an Al alloy (AA 6061) bond line were tested to evaluate its strength and deformation behavior. Observations indicated that the strain rate did not affect the deformation behavior or strength and most of the micro-tensile specimens failed in a ductile mode in grains around the bond line. There was no indication that the microstructural features from the bond line affected the mechanical properties of the micro-tensile specimens. An initial examination was performed on irradiated material but further systematic studies of the effects of irradiation can be performed in the future.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

PGM-Free Oxygen-Reduction Catalyst Development for Proton-Exchange Membrane Fuel Cells: Challenges, Solutions, and Promises

Proton-exchange membrane fuel cells (PEMFCs) are efficient and clean hydrogen energy technologies for transportation and stationary applications. Highly active and durable low-cost cathode catalysts for the oxygen-reduction reaction (ORR) under challenging acidic environments are desperately needed to address the cost and durability issues of PEMFCs. The most promising platinum group metal (PGM)-free catalysts for the ORR in acidic media are atomically dispersed and nitrogen-coordinated metal site catalysts denoted as M–N–C, M = Fe, Co, or Mn. Due to significant efforts in the past few decades, these catalysts have demonstrated much-improved ORR activity and promising initial fuel cell performance approaching traditional Pt/C catalysts. However, the insufficient long-term stability (up to 5000 h) under PEMFC operation represents a primary technical barrier to making current PGM-free catalysts less viable yet in PEMFCs. In this Account, we highlight recent advances in synthesizing efficient PGM-free catalysts for the ORR in PEMFCs, emphasizing effective strategies to improve mass and intrinsic activity and the possible degradation mechanisms. In particular, a chemical doping method based on the zeolitic imidazolate framework (ZIF)-8 represents the key to developing efficient M–N–C catalysts containing atomically dispersed and nitrogen-coordinated single metal active sites (i.e., MN 4 ). The newly acquired understanding of the formation mechanism of MN 4 active sites during the thermal activation and its correlation to catalytic properties guide the rational catalyst design rather than relying on current trial-and-error approaches. Considerable efforts have further been invested in increasing the active site density and enhancing intrinsic activity by regulating carbon-phase structures and the local coordination environment. Furthermore, these highly active catalysts usually suffer from significant activity loss during the ORR. Therefore, breaking the activity–stability trade-off is the key to simultaneously achieving activity and stability in one catalyst, which is discussed on the basis of our recent successes in regulating local carbon structures surrounding active single metal sites. Significant research efforts toward understanding the degradation mechanisms and improving the lifetime of PGM-free catalysts are still crucial for viable applications in the future. Novel electrode designing strategies are needed to translate the PGM-free catalysts’ ORR activity to solid-state electrolyte-based membrane electrode assemblies (MEAs) with robust three-phase (i.e., gas–liquid–solid) interfaces for efficient charge and mass transports for performance improvement. On the basis of our effort at the University at Buffalo supported by ElectroCat Consortium associated with U.S. DOE’s Hydrogen and Fuel Cell Technologies Office, we provide a perspective on PGM-free cathode catalysts concerning remaining bottlenecks and future opportunities, aiming to inspire the community in both mechanistic understanding and technological development.

08 HYDROGEN↗