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Supply Chain Binary Program Assessment Annual Report
Secure environments face a steadily increasing threat from the introduction of scientific equipment that includes extensive software components. Devices such as powerful microscopes, 3d printers, programmable logic controllers, and many others, increase our capability and scientific output. Unfortunately, they now frequently include an entire computing stack with custom software bundled along with entire operating systems. Our ability to introspect and understand binary software is extremely limited, opening up the possibility of malicious third-parties including software that compromises our critical missions.
Modeling Gray Zone Tactics Used Against Green Energy Supply Chains
This report documents a project demonstrating capabilities within Lawrence Livermore National Laboratory’s Cyber and Infrastructure Resilience program to place newly developed numeric simulations into the current, larger geopolitical context. The emergence of state-backed gray zone threats introduces an unprecedented challenge because they fall short of armed conflict and involve ambiguous tactics, requiring a fresh analytical approach to understanding their potential impact and countering them. In the context of our project, we analyze how China might use gray zone tactics to degrade the power of the United States, including our influence over global efforts to combat climate change.
Manufacturing Supply Chain Development for Modular Solar-Thermochemical Conversion Platform [Abstract]
We will develop a tunable pulsed electron source capable of generating variable intensity highly-focused electron pulses at high repetition rates. Specifically, we need to demonstrate a high-speed variable electron gun capable of generating a variable intensity electron pulse containing between 102 and 105 electrons with an accelerating voltage of 1kV focused into a spot size <100nm in diameter at with a pulse rate >10MHz (with path to 300MHz). This combined performance cannot be achieved by commercially available electron sources. The primary technology path selected for this work will be to use a photocathode approach, where an easily modulated UV laser is used to stimulate electron emission. The approach utilizes the advances made in the development of the Dynamic TEM (DTEM), though this project will be simpler in that the pulse intensity is lower and there is no requirement for coherency. Alternate paths, including using a traditional electron beam modulated using a v-shaped slit and electrostatically deflecting the beam to adjust intensity; will also be considered for future capabilities. The electron source will then be used generate optically stimulated luminescence (OSL) in lithium fluoride (LiF) substrates to demonstrate the potential for OSL to serve as a basis technology for next generation data storage systems.
SOTERIA: Automating Software Supply Chain Risk Management
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Evaluation of Directed Energy Deposition and Laser Powder Bed Fusion Nickel-Based Alloys Process Application Envelopes Based on Performance, Process Economics, Supply Chain Risks, and Reactor-Specific Targeted Components
The goal of the Advanced Materials and Manufacturing Technologies (AMMT) program is to accelerate the deployment of new materials and manufacturing technologies into advanced nuclear-related systems. Although 316H stainless steel fabricated by laser powder bed fusion (LPBF) has already been identified as an alloy that could have a significant effect on various reactor technologies, many other materials and manufacturing techniques are being evaluated. Nickel-based alloys typically offer higher-temperature capabilities compared with advanced stainless steels, and previous reports looked at three Ni-based alloy categories: low-Co alloys with a potential use close to the reactor core; high-temperature, high-strength alloys; and molten salt–compatible alloys. Due to the increasing interest in the low Co 625 alloy for nuclear applications, the alloy was compared at the Oak Ridge National Laboratory (ORNL) with 617, 230, two high-temperature, high-strength solution-strengthened alloys. Hot cracking could not be suppressed for alloy 230, and it was shown that these cracks, which were elongated along the build direction (BD), had a drastic effect on the ductility of alloy 230 at room temperature when specimens were machined perpendicular to the BD. Cracking was not as significant for alloy 617, but still led to significant variation in ductility at room temperature along the build direction. On the contrary, LPBF printing of crack-free alloy 625 was achieved using similar printing parameters, and the alloy looks like a very promising candidate for various reactor technologies.
Evaluation of DED and LPBF Fe-based Alloys Process Application Envelopes based on Performance, Process Economics, Supply Chain Risks, and Reactor-specific Targeted Components
The U.S. Department of Energy (DOE), Office of Nuclear Energy (NE), Advanced Materials and Manufacturing Technologies (AMMT) program aims to develop extreme-environment materials solutions for use in the deployment of advanced nuclear reactors and the sustainment of the current fleet. To achieve this objective, a combination of experiment, a computational tool, and machine learning (ML) for the design of materials is adopted for the maturation of materials for nuclear technology. Through advanced manufacturing techniques such as laser powder bed fusion (LPBF) and laser powder direct energy deposition (LP-DED), components with complex geometries can be fabricated with reduced time and effort. Such advanced manufacturing methods can also provide the opportunity to improve materials performance through optimized microstructures and mechanical properties. However, existing engineering alloys are not always well suited for fabrication with additive manufacturing (AM), as their compositions have been tuned to optimize fabrication via conventional methods. Thus, similar alloys with modified compositions that are better suited for AM can be studied for improved performance. Over the past three years, the AMMT teams from Argonne National Laboratory (ANL) and Pacific Northwest National Laboratory (PNNL) studied various known Fe-based alloys by evaluating their initial printability using LPBF, and an AMMT-developed down-selection and decision matrix reduced the number of alloys to be studied from six to three in fiscal year (FY) 2024. Additionally, in FY 2024, for parallel evaluation, these three alloys were studied using LPDED. While LPBF is better for small- to medium-sized components with high detail and internal features, LP-DED combines a material feed system to place the powder onto the exact spot where the laser will melt the material. This AM method can be easily scaled to extremely large components and provides high build rate speeds compared to those of conventional LPBF systems. Additionally, DED is a better choice for complex geometries and compositional gradients.
Utilization of Carbon Supply Chain Wastes and Byproducts to Manufacture Graphite for Energy Storage Applications
This project explored how coal and waste coal can be transformed into high-value graphite used in batteries for electric vehicles and power grids. A manufacturing technique that converts coal into carbon foam and subsequently graphite was developed and refined to improve the thermal and mechanical properties of the resulting materials. Cost-effectiveness and environmental impacts were also evaluated. Coal-derived graphite, especially when processed at high temperatures, was shown to perform comparably to commercial graphite in battery tests. Advanced computer simulations were used to model battery behavior and predict long-term performance, demonstrating that coal-based graphite has the potential to support electric vehicle deployment while reducing reliance on imported materials. This work offers a promising pathway for cleaner energy storage solutions and creates economic opportunities for coal-reliant communities by generating new uses for mining byproducts.
SOTERIA for Software Supply Chain Assurance
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Minnealloy: A novel supply-chain-secure soft ferromagnet with broad applications
A poster presentation on a novel soft ferromagnetic material for transformers and inductors for the REHEDS Research Foundation External Review
Supply Chain Improvement & Process Modification Printing in Tantalum
Refractory metals and alloys are distinguished by their exceptional thermophysical properties, including high melting and recrystallization temperatures, remarkable strength, and superior corrosion resistance, all of which surpass those of conventional alloys. These unique characteristics position these materials as ideal candidates for applications in extreme environments. However, their potential has historically been underexploited due to limitations in processing capabilities. Recent advancements in melt-based additive manufacturing (AM) processes present opportunities to overcome these limitations. Previous Sandia studies have successfully characterized pure tantalum produced through laser powder bed fusion (LPBF) externally at Castheon, revealing that LPBF-fabricated tantalum exhibits properties exceeding those of wrought materials. This promising outcome sparked increased interest in the internal additive manufacturing of tantalum. This project aimed to establish the new SLM 280 machine at SNL-CA to successfully produce the first tantalum prints and characterize the material. Additionally, efforts were made to enhance the machine by incorporating Inert equipment to minimize oxygen content within the print volume. The results demonstrated that internally manufactured LPBF tantalum not only met but exceeded the standards of wrought materials, even prior to the integration of the additional equipment. The inert equipment is almost successfully integrated and ready for use. Future research should focus on understanding how this equipment influences the process-structure-property relationships, as well as further optimizing the printing parameters for tantalum.
Feasibility and Compatibility of Alternative Fuels in the U.S. Rail Sector: Technoeconomic, Lifecycle, and Supply Chain Analysis
The U.S. rail sector is a cornerstone of the United States’ freight transportation system, responsible for moving approximately 40% of long-distance freight ton-miles each year (AAR, 2025). Freight demand is projected to grow over time (BTS, 2017) thereby necessitating the investigation of alternative fuels that can sustain operational efficiency while reducing emissions and cost impacts. At the same time, it is important to explore alternative fuels as new sources of energy that can increase energy security and resilience for this sector. This report investigates the feasibility and compatibility of seven alternative fuels in the U.S. rail sector, focusing on biofuels and fuels from other renewable energy sources. The study evaluates alternative fuel pathways, considering their technical, economic, and environmental aspects to provide stakeholders with a comprehensive understanding of potential solutions.
Bridging Fusion Energy and Fission Energy: Synergistic Supply Chains for Fuel and Materials
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2026 Gas Turbines Supply Chain Workshop
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U.S. Hydropower Supply Chain Manufacturing Locations, 2025
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Haughton-Mars Project Expedition 2005: Interplanetary Supply Chain Management & Logistics Architectures
The 2005 expedition to the Haughton-Mars Project (HMP) research station on Devon Island was part of a NASA-funded project on Space Logistics. A team of nine researchers from MIT went to the Canadian Arctic to participate in the annual HMP field campaign from July 8 to August 12, 2005. We investigated the applicability of the HMP research station as an analogue for planetary macro- and micro-logistics to the Moon and Mars, and began collecting data for modeling purposes. We also tested new technologies and procedures to enhance the ability of humans and robots to jointly explore remote environments. The expedition had four main objectives. We briefly summarize our key findings in each of these areas.
NASA Goddard Space Flight Center Supply Chain Management Program
This slide presentation reviews the working of the Supplier Assessment Program at NASA Goddard Space Flight Center. The program supports many GSFC projects to ensure suppliers are aware of and are following the contractual requirements, to provide an independent assessment of the suppliers' processes, and provide suppliers' safety and mission assurance organizations information to make the changes within their organization.