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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Field Programmable Gate Array-Based Reactor Protection Systems and Potential for Inclusion of Secure Elements to Improve Cybersecurity

For acceptable implementations of technologies like wireless communications, remote monitoring, etc., strong mitigations must be developed and evaluated to ensure that new attack pathways do not increase risk for Advanced Reactors. Secure Elements can be adopted and adapted for this purpose based on tamper resistance and cryptographic abilities, but research must be done to properly integrate into critical components such as FPGA-based Important to Safety systems in conjunction with current and future regulations on cyber security features in Advanced Reactors. Typically, the integration of a Secure Element happens during the POST and UEFI boot of a computing platform, performed by the Operating System, which is not possible with FPGAs because they do not include these firmware components. Work must be done to identify a reliable and secure method for integration in FPGA-based systems which lack Operating Systems and therefore complex boot procedures, system calls, etc.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Hierarchical Hybrid Multifunctional Materials through Interface Engineering

This project focuses on the development of stimuli-responsive hybrid multifunctional materials. We place emphasis on the design, synthesis, structural characterization, evaluation of functional properties (electronic, thermal and optical) of several (1-x)Cu 2 Se/(x)WBGS hierarchical bulk composites between Cu 2 Se, a narrow band gap semiconductor (NBGS), with a range of wider band gap semiconductors (WBGS) such as CuMSe 2 (M = Al, Ga, In, Fe, Cr) and Cu 4 TiSe 4 . Cu2Se is a well-studied NBGS with excellent thermoelectric properties (high electrical conductivity, large thermopower, etc.) while CuMSe 2 and Cu 4 TiSe 4 are high performance solar absorber materials (large band gap, large absorption coefficient, etc.). Our primary objectives are (i) to demonstrate the ability to integrate dissimilar functional properties such as large optical absorption coefficient and high electronic conductivity, within (1-x)Cu 2 Se/(x)WBGS composite; and (ii) to establish the correlation between the hierarchical structural entanglement of Cu 2 Se with WBGS (CuMSe 2 or Cu 4 TiSe 4 ) phase, the interactions between native electronic defects within the coexisting phases in the resulting (1-x)Cu 2 Se/(x)WBGS bulk composites , and the impacts on their electronic conductivity, thermal transport and optical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of Anoxic Iron Corrosion on WIPP Brine Geochemistry FY23 Final Report (U)

A 280-day study was completed to evaluate the effect of zero-valent iron (Fe 0 ) on the Waste Isolation Pilot Plant (WIPP) brine geochemistry under anticipated reducing conditions. Hydrogen (H 2 ) gas is expected to be present in the repository after closure due to the anoxic corrosion of a vast quantity of iron contained in the waste forms disposed at WIPP; therefore, a background argon atmosphere containing H 2 was chosen for this study. WIPP groundwater brine pH and E h will impact the mobility and fate of plutonium within the repository. Modeling and laboratory results for Castile WIPP brine indicate that equilibrium fa values relative to the standard hydrogen electrode (SHE) are 40 mV more reducing (i.e., more negative) than those for Salado WIPP brine (-480 mV vs. -440 mV, respectively) because of the higher pH of the Castile brine (pH 9 .3 for Castile vs. pH 8.8 for Salado). The E h and pH data were corrected for the effects of high ionic strength. The experimental results for both brines are consistent with thermodynamic predictions using OLI Systems' Mixed Solvent Electrolyte chemical equilibrium model. The measured and corrected pH and E h data from this study are provided in Table ES-I and Table ES-2, respectively. The experimental study, with four test conditions in triplicate, was performed in a dual glovebox with a nominally 3 vol.% H 2 in argon atmosphere (target H 2 range: 3 ± I vol.%). Simulants containing MgO only ( experimental control) and MgO+Fe 0 (WIPP base case) were prepared for both the Salado and Castile brines. MgO was included in all simulants to account for the use of bulk magnesium oxide in the WIPP repository. Fe 0 was included in some simulants to incorporate the effects of the anoxic corrosion of iron and in-situ hydrogen generation in the study. The brine compositions were developed by Sandia National Laboratory (SNL; Xiong, 2008) and have been used in previous WIPP evaluations. The test method (agitation, etc.) is partially based on ASTM D3987-12. Twelve rounds of periodic measurements of pH and E h were performed over the course of the study. Chemical analysis results for liquids and solids (ICP-MS, ICP-ES, IC Anion, TIC, SEM-EDX) are consistent with the pH, E h , and thermodynamic modeling results. This study included the following conditions that deviate from anticipated post-closure conditions following brine intrusion, but were selected to facilitate bench-scale testing to validate modeling of pH and E h for the post-closure WIP P repository: an anoxic glove box atmosphere containing ≤ 4 vol. % H 2 vs. substantially higher H 2 gas concentrations assumed in the WIPP Performance Assessment (PA); a significantly higher liquid-to-solid test ratio compared to the much lower phase ratio anticipated in the WIP P repository; agitation of the simulant bottles to maximize mass transfer; and finally the use of Fe 0 reagents having a much greater surface area than expected in the WIP P repository. Non-representative conditions were chosen for various reasons such as: to provide bounding conservative results, to provide a margin of safety for testing, or to facilitate simulant sub-sampling and analysis. In a parallel effort, aqueous electrolyte thermodynamic models were developed for the synthetic Salado and Castile brines to inform the experimental design, facilitate laboratory data interpretation, and allow extension of evaluations beyond the parameters tested. Thermodynamic modeling simulations including the MgO and Fe 0 additives that are directly relevant to the experimental measurements (e.g., pH calibration curve, ORP corrections) are included in this report. The measured fa of the simulants was close to the OLI model predictions for both brines and was largely controlled by the background H 2 partial pressure in the vapor phase as well as H 2 generated in situ in the aqueous phase by the Fe 0 corrosion. The H 2 gas-phase concentration tested and thermodynamically evaluated was much lower than is assumed in the WIPP PA; however, H 2 (g) concentrations significantly below this level are still predicted to result in very reducing conditions. In conclusion: • The experimental results are consistent with thermodynamic model predictions for fa, pH, and the effects of high ionic strength. • Evidence to date suggests that the H2 concentration in the glovebox atmosphere ultimately determined the final E h values of the simulants and resulted in highly reducing conditions. As a result, little difference was observed between the control simulants containing only MgO and the WIPP base-case simulants that contained MgO and Fe 0 . • This test methodology is recommended for future studies evaluating WIPP repository conditions. The methodology includes: (1) background H 2 in argon with agitation ( or could alternatively include in-situ-generated H 2 in sealed bottles); (2) carefully measured and corrected ORP data ( with much effort focused on allowing the probes to fully stabilize); and (3) ionic-strength-corrected pH data. Other best practices, such as simulant sparging/handling, ORP probe replacement, etc., should also be considered. • The coupling of experimental studies and thermodynamic modeling is also highly recommended because these methods inform and direct one another leading to greater confidence in and understanding of the results.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Development of a Helical Closure for Radioactive Material Shipping Packages

Radioactive Material (RAM) Packagings Used to transport radioactive material • Weapons components • Medical isotopes • Spent nuclear fuel • Etc. • Packages must adhere to 10 CFR 71 which drive to NUREGs, ASME codes, etc. • Transport Index (A2 values) determine if a package is Type A, Type AF, Type B, Type B(U)F

Housley, William M. [Savannah River National Labor↗
DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

Resistance Spot Welding (RSW) is a critical process in the automotive industry, valued for its cost-effectiveness, short cycle time, and robustness. However, achieving consistent high-quality joints remains challenging due to the complex interplay of various factors, like materials, processes, and manufacturing uncertainties, etc. Under the collaborative project between Oak Ridge National Laboratory (ORNL) and General Motors (GM), we have developed a robust and expansible machine learning (ML) framework aimed at enhancing quality control in RSW. By harnessing the power of machine learning, we have developed the ability to ensure every aspect of the welding process, from the initial process design stage to the final weld joint quality. The framework operates by analyzing a variety of data streams, including in-line process signals, process parameters, materials, and postprocessed weld joint data. Through this analysis, the models have been trained to detect deviations from optimal quality standards, leveraging their ability to identify signature data patterns and anomalies within in-line signals and construct complex correlations between these signals and weld quality parameters. Meanwhile, the machine learning framework is designed to adapt to a variety of materials, including high strength steels and aluminum alloys, etc. Its flexible architecture facilitates the incorporation of diverse data sources and features, enabling precise modeling and prediction across a broad range of material properties and weld quality variables. The expansible ML frameworks represent a promising transformation in weld quality monitoring and control, empowering industry to achieve high levels of efficiency, consistency, and reliability in manufacturing.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Coupled Aerodynamic and Hydrodynamic Hybrid Simulation of Floating Offshore Wind Turbines

The development and innovation of floating offshore wind energy in the U.S. requires detailed high-fidelity observations and measurements of turbine and platform loading due to wind, waves, and currents. However, full-scale and quasi-full-scale experiments require significant financial and temporal investments for construction, experimental testing, and long-term field campaigns. To support the commercial advancement of the offshore wind energy industry, specialized wind tunnel and wave basin experimental facilities are critical to be able to test FOWT designs at small scale under controlled conditions prior to full-scale deployment. Oregon State University (OSU) is internationally known as a leader in water and energy research, development, and testing. The O.H. Hinsdale Wave Research Laboratory (HWRL) and the Wallace Energy Systems and Renewables Facility (WESRF) at OSU have extensive experience building, modeling, monitoring, controlling, and actuating scaled systems. Experiments on wave-structure interaction have been performed at the HWRL since its establishment in 1972. Studies have included the interaction of waves with coastal structures (breakwaters, seawalls, buildings, cylinders, bridges, fixed foundations of offshore wind turbines, etc.) and with floating structures (e.g., wave energy converters, maneuvering of vessels, etc.). Hinsdale is actively used by marine energy technology developers, both for private testing and OSU-collaborative research projects. However, despite the availability of several large-scale facilities for hydrodynamic testing (at OSU and elsewhere in the U.S.), existing experimental laboratories are generally limited in their ability to accurately generate combined wind and wave conditions. The simulation of both wind and waves in experimental testing is complicated due to a number of constraints, including: [i] incompatible similitude laws governing the wind and waves for scaled experiments, [ii] producing accurate wind over a large enough control volume via fans, and [iii] generating wind that reasonably represents the atmospheric boundary layer in existing wave basins/flumes. Hence, physical test data providing insight into the simultaneous wave- and wind-structure response of floating offshore wind components can be difficult to generate. Given the aforementioned challenges in classic hydrodynamic experiments, the motivation of this project is to establish a real-time hybrid simulation (RTHS) approach that can apply aero- and hydro-dynamic loading by augmenting wave-only experimental facilities with virtual aerodynamic forces through numerical models representing the remaining dynamic forces. RTHS is a physical-numerical approach that partitions a prototype system into physical and numerical sub-assemblies that interact with each other through actuators and sensors in real time. In coupling physical and numerical models, the hybrid simulation approach applied herein is ideal for problems with: (1) structures subjected to different scaling laws, such as floating offshore wind turbines subjected to combined aero/hydro-dynamic loading, (2) structures that are too large or complex to be tested entirely in a laboratory setting, such as deep-water mooring applications, and (3) component testing, where the behavior of a portion of the assembly is uncertain but still interacts with other portions of the structure, such as testing the fatigue life of turbine blades. Few U.S. experimental facilities are able to test simultaneous aero- and hydro-dynamic loading and none can accurately produce aero/hydro-dynamic response on scaled FOWT models due to conflicting similitude laws between the wind (commonly Reynolds) and the waves (commonly Froude). To aid in accelerating the development of the U.S. floating offshore industry, there is a significant need to develop a flexible, modular framework that can expand the capacities of existing wave-only laboratories. The project goal is to demonstrate a hydrodynamic real-time hybrid simulation (hydro-RTHS) framework that couples numerical wind and physical waves acting on a FOWT, thus representing simultaneous aero/hydro-dynamic loading. The FOWT is partitioned into a full-scale numerical sub-assembly associated with the aerodynamics and a model-scale physical sub-assembly associated with the hydrodynamics. The numerical-physical partition associated with hydro-RTHS mitigates scaling constraints by supplying different scaling laws to the physical and numerical sub-assemblies. Herein, length, force, and time are scaled and exchanged between the sub-assemblies using Froude scaling to represent the open-channel flow in the physical sub-assembly. Other similitude laws could also be utilized depending on the problem definition. It is envisioned that the ability to model FOWTs under waves and wind, with mitigation of similitude distortions, would result in reduced development costs (currently, FOWT concept development is performed with full-size pro- totypes at enormous expense and risk) and increase the reliability of the FOWT industry (since extreme wave and wind conditions and contingency events can be tested safely in a controlled environment).

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

Machine Learning for Automated Weld Quality Monitoring and Control

Resistance Spot Welding (RSW) is a critical process in the automotive industry, valued for its cost-effectiveness, short cycle time, and robustness. However, achieving consistent high-quality joints remains challenging due to the complex interplay of various factors, like materials, processes, and manufacturing uncertainties, etc. Under the collaborative project between Oak Ridge National Laboratory (ORNL) and General Motors (GM), we have developed a robust and expansible machine learning (ML) framework aimed at enhancing quality control in RSW. By harnessing the power of machine learning, we have developed the ability to ensure every aspect of the welding process, from the initial process design stage to the final weld joint quality. The framework operates by analyzing a variety of data streams, including in-line process signals, process parameters, materials, and postprocessed weld joint data. Through this analysis, the models have been trained to detect deviations from optimal quality standards, leveraging their ability to identify signature data patterns and anomalies within in-line signals and construct complex correlations between these signals and weld quality parameters. Meanwhile, the machine learning framework is designed to adapt to a variety of materials, including high strength steels and aluminum alloys, etc. Its flexible architecture facilitates the incorporation of diverse data sources and features, enabling precise modeling and prediction across a broad range of material properties and weld quality variables. The expansible ML frameworks represent a promising transformation in weld quality monitoring and control, empowering industry to achieve high levels of efficiency, consistency, and reliability in manufacturing.

42 ENGINEERING↗
DOE OSTI2025

Preliminary Analysis of Nuclear-Powered Data Center Scenarios

This report provides a comprehensive analysis of the potential for nuclear energy to meet the growing energy demands of data centers (DCs). It evaluates the technical, economic, and socio-environmental implications of coupling Nuclear Power Plants (NPPs) with DCs, providing initial responses to several key research questions: What is the potential increased energy demand from DCs in the U.S., in the short, medium and long term? The U.S. is experiencing a rapid increase in energy demand from DCs, with projections indicating a total increase of 24-74 GWy(e) by 2028. Meeting this demand with nuclear energy would require 27–85 GWe of installed capacity. While this surge is expected to slow in the long term, the DC industry needs reliable, scalable, and clean energy sources. How much nuclear capacity can be deployed to meet DC demand and in which timeframe? Several pathways for increasing nuclear capacity were identified, including uprates, restarts of recently retired reactors, power purchase agreements with existing fleet, and new construction. Approximately 20‒28 GWe of nuclear capacity could be dedicated to DCs by the early 2030s. How much High Assay Low Enriched Uranium (HALEU) would be needed to support some nuclear deployment scenarios for DCs? Meeting the deployment targets announced by Google and Amazon for the Kairos Power Fluoride-Salt-Cooled High-Temperature Reactor or KP-FHR (~500 MWe by 2035) and the Xe-100 (~1 GWe by 2040), respectively, requires ramping up 19.75% enriched HALEU production to ~6 t/yr by 2040. What types of nuclear energy/DC coupling options exist, and what are the different benefits/challenges? Five coupling options were analyzed, ranging from grid-connected configurations to colocated, behind-the-meter setups. Key design considerations include the proximity to high- and/or medium-voltage transmission lines, the desired internal fault tolerance, and the sources of alternative/backup power during outages. Each coupling option offers unique benefits and challenges in terms of reliability, system costs, regulation, timeline, etc. A list of NPP/DC deployment scenarios was developed, considering existing or newly built NPP or DC projects. Colocated DCs with new small modular reactors or large reactors on greenfield and brownfield sites are the focus of this report. What types of reactors, especially what size, may be incentivized by DCs? Reactor sizing optimization revealed that the ideal reactor size and number of units depend on DC demand, coupling configurations defined in this report, and other economic factors. Larger reactors are preferred for high-demand DCs and grid-connected systems, while larger number of smaller reactors are better suited for DC configurations without grid backup. Which sites may be compatible with co-located nuclear-powered DCs? Siting those projects is a complicated evaluation factoring local water resources, grid connection availability and reliability, IT infrastructure, local work force, proximity to population zones, etc. For this effort greenfield and brownfield sites such as retired coal-fired plants were used to evaluate this question. This evaluation is not meant to recommend any particular site but it highlights key siting criteria and demonstrates large-scale site availability. What are the socio-economic impacts of co-located nuclear-powered DCs? Those projects generate substantial economic benefits to the local economy, particularly in urban settings. Hyperscale DCs colocated with nuclear power plants (sized around 1 GW of power) can create nearly 1,700 jobs for annual operations and more than 7,300 jobs among the supply chain and local businesses as a result of increased household spending. Rural projects also provide significant benefits, but at lower magnitudes compared to urban deployments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Report on Retrieval of the Reactor Pressure Vessel A-60 Surveillance Capsule from Palisades Nuclear Generating Station

Located on the shores of Lake Michigan, the Palisades Nuclear Generating Station (PNGS) was a nuclear power plant that operated in Covert Township, Michigan. The plant had a single pressurized water reactor that produced electricity for the region. The PNGS was shut down in 2022 after more than four decades of service. The PNGS included in its surveillance program a surveillance capsule, designated A-60, containing specimens of a weld metal with nickel content of about 1.36 wt% and copper content of about 0.20 wt%. The capsule was removed from its surveillance position in the early 1995 and has been resident in the spent fuel pool since that time. This capsule was irradiated to a fluence of 1.87×10 20 n/cm 2 (E> 1MeV) that is equivalent for more than 120 effective full power year (EFPY) for the US reactor pressure vessel (RPV) fleet. The material is also of special interest because of its very high nickel content and potential for development of NiMnSi (nickel-manganese-silicon) precipitates. Combination of very high fluence and very high Ni and Cu content makes the material in this capsule of the great interest as benchmark for currently developing embrittlement trend curves (ETC) aiming to predict embrittlement at high fluences. Thus, several years ago the Light Water Reactor Sustainability Program (LWRSP) initiated negotiations with Entergy to harvest this high fluence capsule since it did not present any regulatory interest for PNGS but could play a very important role for LWRSP efforts for developing ETC for very long-term operation. The negotiations resumed once PNGS ownership moved to the Holtec International in June 2022 which was very supportive to the LWRSP efforts to harvest the A-60 capsule from the spent fuel pool. As a result, the contract was placed with the Westinghouse Electric Company (WEC) to come to PNGS site, retrieve the A-60 capsule, bring it to WEC Churchill hot cell facility, open the capsule and send all surveillance specimens in the capsule to ORNL for future characterization. These specimens from the PNGS A-60 capsule have arrived to ORNL in July 2023 and this report summarizes activities to retrieve and deliver specimens to ORNL site for future evaluation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2026

Data Summarization and Inference at Scale

This is the final report for the DOE ASCR grant SC-0022260, Data Summarization and Inference at Scale, PI: Alex Pothen, Purdue University. The goal of the project was to solve data-intensive and compute-intensive problems in the physical sciences, engineering, information science, data science, etc. by designing and implementing new algorithms that could work with a subset of the data. The four subgoals were: (a) The solution of problems where the data is too large to be stored in the memory of a computer. In this streaming model of computation, the data arrives as a stream of elements to the computer, each element is processed as it arrives, and a decision is made to discard the data or to store it; only a small subset of the data proportional to the size of the output solution is stored, and when all the data has been streamed, a solution to the problem is computed from the stored subset. (b) The use of machine learning methods to compute solutions to data-intensive problems. The use of GPUs is critical to obtain high performance on machine learning tasks, but their memory sizes are smaller relative to that of CPUs. For large-scale problems, the data is sampled many times, and small samples are used with repetition, for robustness, to compute solutions to inference tasks. This sampling reduces the memory required to solve the problem, but attention is needed to avoid slow convergence to the solutions, and reduced accuracy of inference. We propose submodular optimization, Large Language Models, and physics-informed neural networks to enable GPU computations here. (c) Modeling and visualization of high-dimensional data using interpretable features. Clinical proteomic data sets from immunology for the detection of cancer and other diseases are temporal and high-dimensional, and algorithms for visualizing these data sets using clinically interpretable features are lacking. We propose methods that compute distances based on the optimal transportation problem and graph edit distances to address this problem. We also propose the use of optimal transport-based distances, spatial statistics, and network structure to classify image data sets, We apply these algorithms to electron micrographs of the peripheral nervous system in the digestive tract. (d) The design of data-intensive algorithms on emerging architectures, specifically, noisy, intermediate-scale quantum (NISQ) devices. Quantum computers offer the possibility of exploring large solution spaces due to the principle of superposition, but current quantum computers are limited by few qubits, short coherence times due to noise, poor interconections among the qubits, etc. We propose the use of the divide and conquer paradigm to solve large-scale problems, wherein collections of small subproblems are solved on the quantum devices, and the solutions to the subproblems are integrated into a solution for the original problem on a classical computer.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

The Levelized Cost of Exergy Framework

Exergy is the amount of energy within a substance or within a transfer of energy that can be used to produce work or some other useful output when interacting with some reference environment. Two different energy systems that produce the same output with the same exergetic efficiency must necessarily have the same amount of exergy input, even if the amount of energy input to the two systems is vastly different. For example, a low-grade heat-driven desalination would require far more energy input than a reverse osmosis (RO) plant producing the same amount of water, but if their exergetic efficiencies were the same, they would require the same amount of exergy input. Thus, comparisons between different energy sources on the basis of energy is not always appropriate. Instead, a comparison on a per unit exergy basis provides more insight on the cost-effectiveness of different energy sources and systems. In this presentation, we describe a framework for analyzing the levelized cost of exergy (LCOEx) for both inputs and outputs of various energy systems. Our framework illustrates how the cost per unit exergy of a system's energy source, as well as the exergetic efficiency of the system, greatly affect the cost of the system output. We use the levelized cost of electricity as a benchmark value for LCOEx, due to electricity's ubiquity as an energy source, and because it is relatively inexpensive on a per unit exergy basis. The LCOEx of various heat sources are then compared to the LCOEx of electricity. Medium- and high-grade industrial heat (> 150 degrees C) produced by natural gas tends to have an LCOEx on par with electricity. This is due to the low cost of natural gas, as well as the high exergy content of heat at higher temperatures. Meanwhile, low-grade heat tends to be an expensive exergy source, owing to the low exergy content of the low-grade heat. We first apply our framework to desalination, where RO has come to dominate, due to the low LCOEx of the energy source (electricity) and relatively high exergetic efficiency of RO compared to thermal desalination systems. We then use this framework to highlight an opportunity for dehumidification systems to experience a similar cost improvement as desalination has. If an electrically-driven, high exergetic efficiency dehumidification system were developed (such as the membrane-based dehumidification systems proposed in literature), it would use a low cost exergy source with a high exergetic efficiency and could potentially lower the cost of dehumidification in the way that RO has done for desalination. Finally, we apply our framework to various fuels (natural gas, hydrogen, gasoline, etc.) and energy systems across different sectors (desalination, dehumidification, vehicles, etc.) to understand the variation in the cost of exergy input and exergetic efficiency of different systems and technologies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Machine Tool Data Analytics for Digital Twin and Machine Predictive Maintenance

The primary objective of this project is to improve machining process performance using in-process machining data from the machine tool controller and external sensors. Advances in the Industrial Internet of Things (IIoT) enable monitoring of machines using controller data. Examples of the data provided by a controller include execution status of the controller, part count, block of code being executed, door status, tool position, the spindle and axis load, etc. MTConnect and OPC-UA are the two common protocols for capturing machine information. In this collaboration, methods for retrieving the machine controller data from selected machine tool controls and making these data accessible in different subsystems (such as digital twins and machine maintenance portals, etc.) will be developed and tested. In addition, analytics to improve machining process performance (by increasing productivity and reducing downtime) will be developed.

42 ENGINEERING↗
DOE OSTI2026

Blueprint: Coordinated Vulnerability Disclosure (CVD) Adoption for Information Sharing and Analysis Center (ISAC)-Like Groups

The electric vehicle supply equipment (EVSE) industry is an incredibly diverse set of participants (EVSE manufacturers, charge network operators (CNOs), original equipment manufacturers (OEMs), etc.), and with the potential for an Information Sharing and Analysis Centers (ISAC) or ISAC-like group, it requires a series of guidance for doing a multiparty coordinated vulnerability disclosure (CVD) such that a group like this could be successful. This blueprint provides a template and guidance to stakeholders in the EVSE industry for conducting a multiparty CVD. It also formalizes what multiparty CVD could look like in an ISAC-like group with multiple entities as well as vulnerability coordinators by specifically calling out who in the ISAC-like group may be involved, and which industry members it may apply to. This blueprint leverages tools such as Vultron, VINCE, etc. along with open resources such as the Software Engineering Institutes guide for coordinated vulnerability disclosure, for the stakeholder in the EVSE industry to start up a CVD program of their own.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Predicting Li-Ion Battery Capacity Fade Using Early-Life Data and a Hybrid Data-Driven Gaussian Process-Bayesian Regression Approach

Accurately predicting Li-ion battery capacity trajectories using early-life data can dramatically improve battery-life understandings and be used to rapidly evaluate design/cost/performance trade-offs when developing new battery materials. Accurate early-life predictions enable researchers to quickly iterate over cell designs and material precursor properties without consistently cycling cells to failure. To this end, we present a toolbox that uses a combined Gaussian Process and Bayesian regression approach that capitalizes on signals other than just capacity (e.g., dQ/dV, voltage drops) to rapidly predict capacity-fade trajectories. The prediction tool uses Bayesian regression to fit functional forms, e.g., power law, sigmoids, etc., to predict capacity-fade dynamics. By fitting functional forms, the capacity fade can be interrogated at any point in the future, allowing for early cell-failure prediction. Additionally, Bayesian regression allows for accurate uncertainty estimates that account for cell-to-cell variability (aleatoric uncertainty) and the lack of observation data (epistemic uncertainty). By only using early cycle data to predict the capacity fade trajectory, uncertainty bounds at end-of-life can be extremely large. The large uncertainty bounds are further exacerbated because there is no systematic way to define the prior distribution of the functional forms' parameters. We improve our the predicted trajectory confidence interval of our predicted trajectory using two methods. First, we shows that a small amount of held-out cycling data is sufficientuse some train cells, that have been cycled to failure to derive information regarding the appropriate prior distributions for the functional forms' parameters of the functional form, effectively leading to data-driven priors.. We propose constructing the data-driven priors by first running a Bayesian regression starting with uninformed priors to generate intermediate cell-specific posterior parameter distributions. These posterior distributions are combined using a Ggaussian mixture model for each parameter to create the data-driven priors. These mixture models serve as the data-driven prior distributions for the parameters for. Second, we derive multiple features, e.g., C_dchg 0.5 DoD 0.5, log (|mean(dQ/dV_(w_3-w_0 ) (V)|), etc., from the train cellsheld-out cycling data, identify which the features are that best predicting capacity at early/mid-life cycles, and then create Ggaussian process regression models that are used for predicting capacity at early/mid-life cycles for the test cells (see blue dots with error bars in Fig 1b). Finally, these predicted data-points are used in addition to the actual early cycle data capacity fade to construct the Bayesian regression trajectory for the test cell s. Notably. We note that these two methods are complementary and can be combined with each other. We evaluate the performance of our proposed method on an testing open-source dataset from Iowa State University and Iowa Lakes Community College (ISU-ILCC). This dataset comprises of 251 nickel-manganese-cobalt/graphite Lithium-ion cells that are cycled under 63 different conditions. We compute the mean average percentage error (MAPE) and negative log predictive density (NLPD) to quantify the efficacy of our method. Our initial findings suggest that, when only few observations are available, for test cells, when using only Bayesian regression with uninformed priors, a power law functional provides the most accurate predictions. with very few data points. However, asHowever, a the number of data points increases, a twin sigmoidal function becomes more accurate as the number of observations further increases. We also find that using as little as 10% of the data set towards generating data-driven priors can lead to significant improvement in prediction accuracy when using early cycle data. Lastly, we found that augmenting early-cycle data with Gaussian process-predicted capacity data for Bayesian regression greatly improves the prediction accuracy. We will present a comprehensive comparison of our methods to other methods available in the literature and apply this method to additional battery datasets.

42 ENGINEERING↗
DOE OSTI2026

Direct Air Capture Using Trapped Small Amines in Hierarchical Nanoporous Capsules on Porous Electrospun Fibers (Final Technical Report)

This report summarizes the carbon capture research and development conducted by The State University of New York at Buffalo (UB) and GTI Energy (GTI) for award “DE-FE0031969: Direct Air Capture Using Trapped Small Amines in Hierarchical Nanoporous Capsules on Porous Electrospun Fibers” sponsored by the U.S. Department of Energy (DOE). The objective of this project is to develop an innovative sorbent structure of trapped small amines in HNC embedded in PEF for DAC. This involves tailoring both sorbent and PEF materials to achieve a compact system for DAC with high capacity for CO 2 at concentrations typically available in air and at near ambient conditions. An innovative sorbent structure of trapped small amines in hierarchical nanoporous capsules (HNC) embedded in porous electrospun fibers (PEF) was developed for direct air capture (DAC). This involves tailoring both sorbent and PEF materials to achieve a compact system for DAC with high capacity for CO 2 at concentrations typically available in air and at near ambient conditions. An interfacial polymerization process was developed, which utilized loaded amines inside mesoporous silica and trimesoyl chloride (TMC) dissolved in organic solvents as the precursors, to generate a polyamide (PA) coating layer on mesoporous silica and thus trap amines. Reaction conditions, including TMC concentration, organic solvents, reaction time, etc., for interfacial polymerization were optimized to effectively trap loaded amines, and cyclic heating-cooling operation was conducted to evaluate the coating quality. Larger pore volume mesoporous silica was also synthesized to increase amine loading and thus increase CO 2 capacity. The optimized sorbent material exhibited CO 2 capacity as high as 4.88 mmol/g under humid DAC conditions and negligible loss (<1%) during 10 cyclic heating-cooling operations. The optimized PA-coated sorbent also showed fast adsorption and desorption kinetics, with <20% t1/2 increase compared to uncoated sorbent. PEF fabrication conditions, including organic solvents for dissolving core and shell polymers, voltage, distance from the nozzle to the collection panel, etc. were adjusted to better incorporate HNC. After incorporating the optimized sorbent material into PEF, the structured sorbent had a CO 2 capacity of approximately 4.0 mmol/g under humid DAC conditions, with capacity loss of 0.17% per cycle and t1/2 increase less than 10%. A techno-economic analysis (TEA) for the process design for a DAC system based on our developed sorbent structure of trapped small amines in HNC embedded in PEF was conducted. The process design included process description and major equipment sizing and energy and mass balances in addition to scale-up research results and estimated capture cost. Aspen Adsorption Simulator was used to fit the experimentally measured breakthrough curves and extract equilibrium and kinetic data of the optimized sorbent. Our results indicated that for a DAC plant with CO 2 productivity of 3,000 tonne/year, the levelized cost of CO 2 capture was $\$$612/tonne, with the largest contribution of 44.33% from the fixed operation cost. Increasing CO 2 productivity, while maintaining similar fixed operation cost, is expected to significantly reduce the CO 2 capture cost. A sensitivity study was also conducted to understand the influence of total plant cost, sorbent cost, CO 2 concentration in the feed, sorbent mat lifetime, sorbent regeneration electricity, and adsorption blower pressure drop on the levelized cost of CO 2 capture, revealing a capture cost range of $\$$520-870/tonne.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Development of in-situ polymerized intrinsically conductive resin and low-cost carbon pigments offering high conductivity for sensing, EMI shielding and lighting protection

Electrically conductive composites are emerging across diverse industries such as electronic, automotive, aerospace, advanced air mobility, biomedical, infrastructure, defense and security offering static charge dissipation, electromagnetic interference shielding, lighting protection, sensing, dicing, corrosion monitoring, etc. Conductivity enhanced composites provide several advantages compared to conventional metals including weight reduction, corrosion resistance, energy efficient processability, tunable properties and multifunctionality. Polymers are typically insulating in nature and require conducting filler for electron transport. However, dispersion and polymer-filler interphases are critical and often disrupt conducting pathways. Besides, conductive fillers such as graphene, carbon nanotube, MXene, silver nanowire, etc. are expensive, limiting their wide adoption in composite industry. On the other hand, a limited number of intrinsically conductive polymers are available among which polyaniline (PANI) has been widely studied due to its high conductivity, thermal and chemical stability. However, PANI is difficult to process and exhibits weak mechanical properties. In brief, there is a significant demand for electrically conductive polymer formulation with cost-effective conducting fillers that offer processability in scale to expand the market of conductivity enhanced materials.

Kumar, Vipin [Oak Ridge National Laboratory (ORNL)↗
DOE OSTI2025

HydroFish: freshwater fish co-occurrence with hydropower plants and non-powered dams in conterminous United States sub-basins

The HydroFish dataset lists all existing hydropower plants (EHAs) and non-powered dams (NPDs; ≥ 0.001 MW potential nominal capacity), delineates the hydrologic sub-basins in which they are situated, and then lists all freshwater fish species reported to occur in those sub-basins. This dataset was compiled using the HydroBio dataset (https://hydrosource.ornl.gov/data/datasets/hydrobio/) and contains 24 total variables that describe hydrologic sub-basins, each unique EHA (plant ID and name, geographic coordinates, permit type, capacity, etc.) and NPD (ID value, known names, geographic coordinates, and estimated potential nominal capacity), and freshwater fish species in the sub-basin (common and scientific name, origin, and migratory and threat status). The HydroBio dataset was built using Oak Ridge National Laboratory’s Existing Hydropower Assets Dataset (2024 version) and Non-powered Dam Technical Potential Dataset (2024 version), and NatureServe’s fish species distribution dataset (2023 version). The dataset also contains summary variables that report the unique number of EHAs, NPDs, and freshwater fish species per sub-basin. The HydroFish dataset contains two unique data files: 1) a .csv metadata file describing the dataset variables, and 2) a .csv data file containing the actual dataset. Note that there may be many rows per unique existing hydropower plant or non-powered dam given that distinct species are listed per existing plant or NPD per sub-basin. The dataset is downloadable as a zip file containing the metadata and dataset files.

Bozeman, Bryan [Oak Ridge National Laboratory (ORN↗
DOE OSTI2021

Applications of Kinetic Methods in Thermal Analysis: A Review

Determining kinetic parameters such as activation energy (Ea), pre-exponential factor (A), rate constants, and reaction order (n) via thermal analysis techniques is important to material synthesis and fabrication, industrial production, biomedicals, energy storage, catalysis, etc. Various kinetic methods based on the non-isothermal techniques have been developed to obtain the kinetic parameters. In this review, we focus on introducing various kinetic methods in non-isothermal analysis and their applications in different reactions, including thermal decomposition, solid-state phase transformation, crystallization, thermal ignition, curing process, etc.

Zhang, Xin↗