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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Captan+X Data Converter Integration

Fermi National Accelerator Laboratory's CAPTAN (Compact And Programmable daTa Acquisition Node) series provides a flexible hardware platform for data acquisition across a range of experiments and facilities. The latest iteration, CAPTAN+X, is built around a Kintex-7 FPGA supporting four FPGA Mezzanine Card (FMC) connections. As part of a broader laboratory effort to bring facility systems under a Model-Based Systems Engineering (MBSE) framework, CAPTAN+X is one of several systems slated to be incorporated into this modeling environment in the near term. A necessary step toward that goal is incorporating the platform's core functionality, which centers on integration with the LXD31K4 FMC, a data converter module combining dual AD9652 analog-to-digital converters and dual AD9142A digital-to-analog converters. Achieving compatibility required resolving pin-mapping conflicts between the LXD31K4's High Pin Count connector and the CAPTAN+X's available pin types, adapting a Board Support Project originally written for an UltraScale-class evaluation board to the Kintex-7 architecture, replacing incompatible primitives, restructuring clock distribution, and manually configuring chip initialization in place of an unsupported soft-processor-based approach. Functional verification of the ADC and DAC channels, followed by closed-loop testing combining both converters with real-time filtering, confirmed correct operation of the integrated system. These results establish a working hardware and firmware baseline for the CAPTAN+X platform, positioning it for future inclusion in the laboratory's growing MBSE modeling effort.

Espinoza, David [Illinois U., Urbana (main)]↗
DOE OSTI2026

CAPTAN+X Data Converter Integration

Fermi National Accelerator Laboratory's CAPTAN (Compact And Programmable daTa Acquisition Node) series provides a flexible hardware platform for data acquisition across a range of experiments and facilities. The latest iteration, CAPTAN+X, is built around a Kintex-7 FPGA supporting four FPGA Mezzanine Card (FMC) connections. As part of a broader laboratory effort to bring facility systems under a Model-Based Systems Engineering (MBSE) framework, CAPTAN+X is one of several systems slated to be incorporated into this modeling environment in the near term. A necessary step toward that goal is incorporating the platform's core functionality, which centers on integration with the LXD31K4 FMC, a data converter module combining dual AD9652 analog-to-digital converters and dual AD9142A digital-to-analog converters. Achieving compatibility required resolving pin-mapping conflicts between the LXD31K4's High Pin Count connector and the CAPTAN+X's available pin types, adapting a Board Support Project originally written for an UltraScale-class evaluation board to the Kintex-7 architecture, replacing incompatible primitives, restructuring clock distribution, and manually configuring chip initialization in place of an unsupported soft-processor-based approach. Functional verification of the ADC and DAC channels, followed by closed-loop testing combining both converters with real-time filtering, confirmed correct operation of the integrated system. These results establish a working hardware and firmware baseline for the CAPTAN+X platform, positioning it for future inclusion in the laboratory's growing MBSE modeling effort.

Espinoza, David [Illinois U., Urbana (main)]↗
DOE OSTI2020

Evaluation and Demonstration of Blockchain Applicability Framework

Blockchain technology has been gaining great interest from a variety of industry sectors, including financial, food processing, and power and energy markets. Realizing the strength of blockchain technology beyond the successful application in the cryptocurrency arena, researchers have been evaluating and using blockchain for applications such as supply chain management, transactive industry (both financial and energy), system integrity, device cybersecurity, identity management, and much more. One of the unique elements of the blockchain technology that made it such a captivating technology to researchers is its plethora of features. Some of the features include smart contracts, cryptocurrency and tokenizing, immutable distributed ledger, cryptographic hashing, and digital signature. In addition, there are multiple types of blockchains, such as permissioned/private and permissionless/public, and various consensus models, such as proof-of-work, proof-of-authority, proof-of-burn, and proof-of-stake. Therefore, it is often non-trivial to determine if an application requires a blockchain. If so, what kind of blockchain and consensus is most appropriate? This paper discusses the blockchain applicability framework (BAF), which was specifically designed with the purpose to answer those questions. BAF is divided into five domains, 18 subdomains, and about 100 controls. It is designed to ingest detailed user requirements to perform a weighted evaluation that is built on mathematical constructs to determine the ideal combination of blockchain that is appropriate for an application. Along with the core logical formulation of BAF, this paper depicts the efficacy of BAF through two use cases

Gourisetti, Sri Nikhil G.↗
DOE OSTI2020

Real-time Electromagnetic Transient Simulation of Multi-Terminal HVDC-AC Grids based on GPU

High-fidelity electromagnetic transient (EMT) simulation plays a critical role in understanding the dynamic behavior and fast transients involved in operation, control, and protection of Multi-Terminal dc (MTdc) grids. Here, this paper proposes a cost-effective high-performance real-time EMT simulation platform for large-scale cross-continental MTdc grids based on graphics processing unit (GPU). The proposed simulation platform: i) assembles detailed EMT models of all components within an MTdc-ac grid into a single platform. This setup provides a complete simulation solution to capture fast transient signals required for high-bandwidth controller design and protection studies without any compromise; ii) implements the first GPU-based simulation architecture and corresponding algorithms for MTdc-ac grids with real-time performance at scales of 1s; iii) is highly-efficient and balances the high utilization of GPU resources and low latency required for the simulation; and iv) outperforms the existing central processing unit (CPU)- or digital signal processor (DSP)/field-programmable gate array (FPGA)-based simulators in terms of its higher scalability on large-scale MTdc-ac grids and superior price-performance ratio on the hardware. Accuracy and performance of the proposed platform are evaluated with respect to the reference results from PSCAD/EMTDC environment.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Requirements Document for a Replacement Data Acquisition System

A flight vehicle is in the developmental stages. While in development flight testing is required by both the manufacturer and customer to rate design performance. The performance of the vehicle must fulfill the agreed upon requirements. Testing of a flight vehicle during operation requires various sensors in order to record and monitor performance for evaluation. A Data Acquisition System (DAQ) is needed in order to control and capture data from various sensors placed throughout the vehicle during flight. This DAQ will receive the analog data from the suite of sensors and convert them to a digital signal that can be transmitted to a recording station where the data will later be analyzed by test experts. Some of the key features to be included in the DAQ will be a self-check operation to verify the health of all sensors including the DAQ. The DAQ will also have the capability to store sensor calibration data files loaded during assembly and transmit those files to the recording station during flight. Breakthroughs in new technologies has allowed for higher resolution recording systems and faster sampling rates. Improved sensor data using a new Data Acquisition System (DAQ) can provide important answers to questions discovered during the last few flight tests. These questions arose when the flight system expressed unexpected behaviors. Having the capability of the new DAQ in flight tests would allow for more high-fidelity data to be captured from the system during flight tests and ultimately reducing the number of required flight test. Reducing the number of flight tests also reduce developmental cost and schedule.

42 ENGINEERING↗
DOE OSTI2024

Global Geo-processed Data of Aquifer Properties by 0.5° Grid, Country and Water Basins

This repository of global hydrogeologic datasets contains aquifer properties on 0.5° scale, including depth to groundwater (Fan et al., 2013), aquifer thickness (de Graaf et al., 2015), WHYMap aquifer classes (Richts et al., 2011), recharge (Döll and Fiedler, 2008; Gleeson et al., 2016), lakes (Messager et al., 2016), porosity and permeability (Gleeson et al., 2014), digitized and geo-processed from their respective sources. Globally gridded aquifer properties could be used independently to estimate global groundwater availability or used as critical inputs to the superwell model to simulate groundwater extraction and provide estimates of pumped volumes and unit costs under user-specific scenarios. Key resources related to this data are: Niazi, H., Ferencz, S. B., Graham, N. T., Yoon, J., Wild, T. B., Hejazi, M., Watson, D. J., & Vernon, C. R. (2025). Long-term hydro-economic analysis tool for evaluating global groundwater cost and supply: Superwell v1.1. Geoscientific Model Development, 18(5), 1737-1767. https://doi.org/10.5194/gmd-18-1737-2025 superwell model repository which uses this data to simulate groundwater extraction and provides estimates of the global extractable volumes and unit-costs ($/km3) of accessible groundwater production under user-specified extraction scenarios. Repository Overview Main output: aquifer_properties_rec.csv contains all processed outputs, including aquifer properties like porosity, permeability, recharge, lake areas, aquifer thickness, and depth to groundwater. shapefiles.zip: contains all digitized GIS databases and shapefile for all aquifer properties prep_inputs.R and prep_inputs_recharge_lakes.R: R scripts that process the shapefiles to produce the aquifer_properties_rec.csv file plot_inputs.R: R script for plotting the maps and conducting preliminary analysis on the available groundwater volume basin_to_country_mapping.csv, basin_country_region_mapping.csv and continent_county_mapping.csv provide the mapping between continents, 32 energy-economic macro regions, countries, and water basins for post-processing aquifer_properties_rec.csv Maps: Each map visualizes the spatial distribution of one of the aquifer properties across the globe map_in_Porosity.png map_in_Permeability.png map_in_Aquifer_thickness.png map_in_Depth_to_water.png map_in_Recharge.png map_in_Grid_area_km.png map_in_Lake_area_km.png map_in_WHYClass.png Sample inputs sample_inputs.py: this script samples inputs from the aquifer_properties_rec dataset, ensuring the sampled and original inputs maintain the same distributions sampled_data_100.csv contains 100 sampled data points and sampled_data_100.png compares their distributions Dataset Overview The main outputs are consolidated in a comprehensive aquifer_properties_rec.csv file and include the following fields: GridCellID: Unique identifier for each (roughly 0.5°) grid cell Continent: Continent name Country: Country name GCAM_basin_ID: Identifier for GCAM hydrologic basin Basin_long_name: Full name of the basin WHYClass: Hydrogeologic classification based on WHYMap aquifer classes (Richts et al., 2011) Porosity: Soil porosity (%) (Gleeson et al., 2014) Permeability: Soil permeability (in square meters; Gleeson et al., 2014) Aquifer_thickness: Thickness of the aquifer (in meters; de Graaf et al., 2015) Depth_to_water: Depth to groundwater (in meters; Fan et al., 2013) Recharge: long-term annual averaged recharge rates (in m/yr; Döll and Fiedler, 2008; Gleeson et al., 2016) Grid_area: Area of the grid cell (in square meters) Lakes_area: Area of inland lakes (in square meters; Messager et al., 2016) Key References The datasets are digitized versions of global hydrogeologic properties from the following key literature sources: Depth to Groundwater: Fan, Y., Li, H., & Miguez-Macho, G. (2013). Global Patterns of Groundwater Table Depth. Science, 339(6122), 940-943. https://doi.org/10.1126/science.1229881 Aquifer Thickness: de Graaf, I. E. M., Sutanudjaja, E. H., van Beek, L. P. H., & Bierkens, M. F. P. (2015). A high-resolution global-scale groundwater model. Hydrol. Earth Syst. Sci., 19(2), 823-837. https://doi.org/10.5194/hess-19-823-2015 Porosity and Permeability: Gleeson, T., Moosdorf, N., Hartmann, J., & van Beek, L. P. H. (2014). A glimpse beneath earth's surface: GLobal HYdrogeology MaPS (GLHYMPS) of permeability and porosity. Geophysical Research Letters, 41(11), 3891-3898. https://doi.org/10.1002/2014GL059856 Aquifer classes: Richts, A., Struckmeier, W. F., & Zaepke, M. (2011). WHYMAP and the Groundwater Resources Map of the World 1:25,000,000. In J. A. A. Jones (Ed.), Sustaining Groundwater Resources: A Critical Element in the Global Water Crisis (pp. 159-173). Springer Netherlands. https://doi.org/10.1007/978-90-481-3426-7_10 Recharge: Döll, P., & Fiedler, K. (2008). Global-scale modeling of groundwater recharge. Hydrol. Earth Syst. Sci., 12(3), 863-885. https://doi.org/10.5194/hess-12-863-2008; Gleeson, T., Befus, K. M., Jasechko, S., Luijendijk, E., & Cardenas, M. B. (2016). The global volume and distribution of modern groundwater. Nature Geoscience, 9(2), 161-167. https://doi.org/10.1038/ngeo2590 Inland Lakes: Messager, M. L., Lehner, B., Grill, G., Nedeva, I., & Schmitt, O. (2016). Estimating the volume and age of water stored in global lakes using a geo-statistical approach. Nature Communications, 7(1), 13603. https://doi.org/10.1038/ncomms13603 Cite as Niazi, H., Watson, D., Hejazi, M., Yonkofski, C., Ferencz, S., Vernon, C., Graham, N., Wild, T., & Yoon, J. (2024). Global Geo-processed Data of Aquifer Properties by 0.5° Grid, Country and Water Basins. MultiSector Dynamics-Living, Intuitive, Value-adding, Environment. https://doi.org/10.57931/2484226 Contact Reach out to Hassan Niazi or open an issue in the superwell repository for questions or suggestions.

aquifer thickness↗
DOE OSTI2022

Digitally manufactured air plasma-on-water reactor for nitrate production

The sustainable production of food to support the increasing world population is one of humanity’s most pressing challenges. Plasma activated water, produced using renewable energy, can help fulfill plants’ needs in sustainable agriculture approaches. The design, implementation, and characterization of a digitally manufactured air plasma-on-water reactor (POWR) for the synthesis of nitrate as green nitrogen fertilizer is presented. The interaction of air plasma-generated reactive oxygen and nitrogen species with water produces nitrate (NO 3 - ) and related species, which are the main nitrogen-containing nutrients for plants. The mild conditions of the operation of the POWR opens the possibility to use plastics, particularly through digital manufacturing strategies such as 3D-printing, for its fabrication. A pin-to-plate reactor configuration powered by high-voltage alternating power is chosen due to its simplicity and efficacy. A computational thermal-fluid model is used to evaluate the design and attain expected operational characteristics. The experimental characterization of the POWR encompassed design and operation parameters, namely electrode-water spacing, air flow rate, and voltage level. A machine learning approach is implemented to extract and quantify characteristic features of the plasma–water interaction, such plasma volume and plasma–water interface area. Experimental results revealed that the nitrate production rate varies linearly with dimensionless plasma volume. The design, fabrication, and characterization methods presented can be adapted to other POWRs and help enable on-demand nitrogen fertilizer production at low environmental and economic cost.

Physics↗
DOE OSTI2024

Achieving Cyber-Resilience for Power Systems using a Learning, Model-Assisted Blockchain Framework

The secure integration and management of distributed energy resources (DER) and power aggregators in the electric grid requires secure communications and a physics-aware Command and Control (C2) strategy. A Blockchain (BC)-based overlay network was developed to provide a security layer for the existing power grid network that mitigates risks in current and legacy network and C2 protocols. By integrating a Model-Assisted Machine Learning (MAML) framework with a Secure Blockchain Overlay Network (SBON) a defense-in-depth strategy was achieved. In our approach, the MAML framework leveraged a smart contract framework to gather network data and learn the dynamics of DER to develop detection strategies for attacks targeting sensors and actuators used by DER. The MAML framework learned dynamical systems models for individual DERs to detect sensor attacks. For DER we utilized a Digital Twin (DT) to accelerate the learning process for a model resistant to stealthy attacks. The project created DT for PV inverters and BESS. The DTs were coupled with a model-assisted, data-driven learning of DER behavior. Specifically, we evaluated architectures for model-based learning with model-free fine-tuning. Additionally, differential privacy techniques were used to obfuscate data, while still allowing the computation of attack detection results based on obfuscated data. The SBON developed leverages a private permissioned blockchain network orchestrated with the Hyperledger Fabric framework. To connect the cyber world, which orchestrates the blockchain fabric, and the physical world where the power network resides, we developed a system implementation to enable the secure interaction of the physical world and the abstracted blockchain.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Multimodal Freight Energy Model for Emerging Freight Technology Analysis

While freight movement represents a small portion of the volume in the transportation sector, they are a critical contributor for energy consumed in that sector. To reduce logistics costs, energy consumption and negative environmental impact, emerging technologies, such as digitalization of logistics and alternative powertrain, have been developed and extended applications in freight. These trends are expected to grow and provide opportunities for greater efficiencies in freight movement and corresponding energy use. Still, the complexity of freight systems present challenges in evaluating these benefits, especially in the multimodal inter-city freight. Addressing the research need, this paper develops a multimodal freight energy modeling framework for the analysis of emerging freight technology scenarios. The framework is a bi-level optimization problem: network cost minimization problem (lower-level) and energy minimization problem (upper-level). The lower-level problem is a mode-path assignment problem in multimodal inter-city freight networks, where commodity-specific congestion effects on trans-shipment links are considered. For this model, an inverse modeling approach is applied to infer parameters of the lower-level model. The upper-level problem is designed to search for an optimal scenario that has the lowest energy consumption among different levels of technology applications. The proposed model is empirically tested to analyze truck load-pooling and multimodal load-pooling scenarios through stand-alone and mixed applications using freight shipments originating from or destined to the Chicago region. This framework can be used to explore the impact of emerging freight technologies on mode-path freight flow and energy consumption in the national multimodal freight network.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Influence of sun zenith angle on canopy clumping and the resulting impacts on photosynthesis

Addressing the impact of vegetation architecture on shortwave radiation transfer in land surface models is important for accurate weather forecasting, carbon budget estimates, and climate predictions. This paper investigates to what extent it is possible to retrieve structural parameters of two different parameterization schemes from direct transmittance derived from digital hemispherical photography and 3D radiative transfer modeling for two study sites with different vegetation canopy architectures. Neglecting the representation of 3D canopy structure in radiative transfer schemes leads to significant errors in shortwave radiation partitioning (up to 3.5 times more direct transmittance in the 3D model). Structural parameters, referred to as whole canopy ‘clumping indices’, were obtained in order to evaluate the impact of angular variation in clumping on shortwave radiation transfer. Impacts on photosynthesis were evaluated at site level with the UKESM land surface model, JULES. A comparison between flux tower derived and modeled photosynthesis indicates that considering zenith angular variations of structural parameters in the radiative transfer scheme of the UKESM land surface model significantly improves photosynthesis prediction in light limited ecosystems (from RMSE = 2.91 μmol CO 2 .m -2 .s -1 to RMSE = 1.51 μmol CO 2 .m -2 .s -1 , 48% smaller), typically with enhanced photosynthesis from bottom layers.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

ASIC Scoping Study Final Report

This report documents the results and findings of a one-year scoping study investigating multichannel readout application specific integrated circuits (ASICs) for interfacing to, and processing data from, silicon photomultiplier (SiPM) arrays. We document ASIC desired and required specifications for four applications supporting national security mission areas: neutron radiography, associated particle imaging, and two versions of kinematic neutron imaging cameras. While each application has a few unique requirements that stress capability, there is generally good agreement among most. Two recently developed ASIC devices were evaluated in a system-like configuration by interfacing these to scintillator crystals exposed to gamma and neutron sources. The 64-channel ORNL device delivered functional capability while meeting most mission requirements for neutron radiography. The Nalu Scientific device, a 32-channel full waveform digitizer, did not demonstrate reliable neutron / gamma separation but it is unclear if this was an ASIC issue or problems with test setup or firmware. A literature survey of other commercial and academic ASICs was undertaken to with the conclusion that existing devices do not meet all requirements.

42 ENGINEERING↗
DOE OSTI2022

Characterizing the Thermal-Induced Distortion of Large-Scale Polymer Composite Printed Structures

The Big Area Additive Manufacturing (BAAM) system has been used to print large-scale parts, such as automotive structures and molds for tooling, with fiber-reinforced polymer composites. Incorporating reinforcing fibers in printed parts is commonly used to increase stiffness and strength, but it also introduces significant anisotropy in the thermomechanical performance, which can lead to distortion and warping during thermal cycling. Characterizing and understanding how a printed tool distorts is crucial to maintaining tolerances and avoiding part failure. This study uses digital image correlation (DIC) to measure the coefficient of thermal expansion (CTE) of a printed part from room temperature and to a known steady state temperature. The samples were printed with carbon fiber reinforced acrylonitrile butadiene styrene (CF-ABS). Various nozzle geometries were evaluated in this study with the intent of minimizing the thermal- induced distortion experienced by printed parts.

Corum, Tyler↗
DOE OSTI2020

A Tool for Furthering GNSS Security Research: The Oak Ridge Spoofing and Interference Test Battery (OAKBAT)

A new global navigation satellite system (GNSS) dataset of digitized RF signals named Oak Ridge Spoofing and Interference Test Battery (OAKBAT) has been created. OAKBAT contains digitized spoofing signals that serve as both a supporting “sibling” and an advancement to the widely used Texas Spoofing Test Battery (TEXBAT) dataset [1]. OAKBAT at its core was developed to 1) allow for 100% reproducibility of the data, 2) provided more detailed metadata and contextual information about each dataset such as the precise moment that the spoofing and/or interference signals begins, positions used, constellations visible, etc., and 3) to provide datasets generated using the same key parameters as the TEXBAT ds1 through ds6 datasets. Through these “sibling” datasets it will now be possible to determine if the behavior of algorithms and designs developed using these datasets are being affected by possible intrinsic behavior and properties of the equipment used in the generation and digitization of the two datasets. The end goal of OAKBAT is to be a new resource for the community of researchers and developers working in the field of GNSS. This additional source of data provides a GNSS “playground” on which to experiment, explore, and evaluate new ideas.

Albright, Austin P.↗
DOE OSTI2025

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Personalized, disease-stage specific, rapid identification of immunosuppression in sepsis

Introduction Data overlapping of different biological conditions prevents personalized medical decision-making. For example, when the neutrophil percentages of surviving septic patients overlap with those of non-survivors, no individualized assessment is possible. To ameliorate this problem, an immunological method was explored in the context of sepsis. Methods Blood leukocyte counts and relative percentages as well as the serum concentration of several proteins were investigated with 4072 longitudinal samples collected from 331 hospitalized patients classified as septic (n=286), non-septic (n=43), or not assigned (n=2). Two methodological approaches were evaluated: (i) a reductionist alternative, which analyzed variables in isolation; and (ii) a non-reductionist version, which examined interactions among six (leukocyte-, bacterial-, temporal-, personalized-, population-, and outcome-related) dimensions. Results The reductionist approach did not distinguish outcomes: the leukocyte and serum protein data of survivors and non-survivors overlapped. In contrast, the non-reductionist alternative differentiated several data groups, of which at least one was only composed of survivors (a finding observable since hospitalization day 1). Hence, the non-reductionist approach promoted personalized medical practices: every patient classified within a subset associated with 100% survival subset was likely to survive. The non-reductionist method also revealed five inflammatory or disease-related stages (provisionally named ‘early inflammation, early immunocompetence, intermediary immuno-suppression, late immuno-suppression, or other’). Mortality data validated these labels: both ‘suppression’ subsets revealed 100% mortality, the ‘immunocompetence’ group exhibited 100% survival, while the remaining sets reported two-digit mortality percentages. While the ‘intermediary’ suppression expressed an impaired monocyte-related function, the ‘late’ suppression displayed renal-related dysfunctions, as indicated by high concentrations of urea and creatinine. Discussion The data-driven differentiation of five data groups may foster early and non-overlapping biomedical decision-making, both upon admission and throughout their hospitalization. This approach could evaluate therapies, at personalized level, earlier. To ascertain repeatability and investigate the dynamics of the ‘other’ group, additional studies are recommended.

Immunology↗
DOE OSTI2024

Environmentally Assisted Fatigue in Light Water Reactor Environment

This report summarizes the Environmentally Assisted Fatigue (EAF) research conducted at ANL under the US DOE Light Water Reactor Sustainability (LWRS) program. Starting from a rich background in theoretical and experimental EAF, ANL previously developed an approach to evaluate fatigue performance of reactor materials in light water reactor environments with the correction factor F en . The approach was based on a large body of experimental work performed at ANL and elsewhere, and was consistent with American Society of Mechanical Engineers (ASME)’s methodology governing the design and construction of reactor components. In recent years, the program was focused on component fatigue prediction and made several major and fundamental contributions in this area. These accomplishments help meet the needs identified by the industry concerning component level fatigue predictions in complex, transient conditions. The main contribution of the ANL program involved the development of a system-level model for estimating residual strain and life of nuclear reactor coolant system components under connected-system-thermal-mechanical boundary conditions. The goal was to predict the stress hotspots, strain residuals, strain amplitudes and the resulting fatigue lives. Thermal-mechanical stress analysis was performed considering thermal stratification and a design-basis reactor loading cycle. Based on the finite element (FE) model results, the strain residuals, strain amplitudes and resulting fatigue lives of reactor coolant system (RCS) components were predicted. The results show that some of the RCS components can have significantly different strain amplitudes, residual strain, and fatigue lives, despite having similar geometry and material. In addition, the simulated component-level strain profile can guide the selection of appropriate test inputs for conducting laboratory-scale EAF tests. Building upon the system-level model, ANL developed a digital twin (DT) framework to predict the structural states and associated fatigue life of components in real-time. This framework is a comprehensive system designed to predict the structural states and fatigue lives of reactor components. It includes multiple models and integrates artificial intelligence (AI), machine learning (ML), and FE based modeling tools to evaluate the structural states and fatigue lives.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Analyzing the Validity of Brazilian Testing Using Digital Image Correlation and Numerical Simulation Techniques

Characterizing the mechanical behavior of rocks plays a crucial role to optimize the fracturing process in unconventional reservoirs. However, due to the intrinsic anisotropy and heterogeneity in unconventional resources, fracture process prediction remains the most significant challenge for sustainable and economic hydrocarbon production. During the deformation tracking under compression, deploying conventional methods (strain gauge, extensometer, etc.) is insufficient to measure the deformation since the physical attachment of the device is restricted to the size of the sample, monitoring limited point-wise deformation, producing difficulties in data retrieval, and a tendency to lose track in failure points, etc. Where conventional methods are limited, the application of digital image correlation (DIC) provides detailed and additional information of strain evolution and fracture patterns under loading. DIC is an image-based optical method that records an object with a camera and monitors the random contrast speckle pattern painted on the facing surface of the specimen. To overcome the existing limitations, this paper presents numerical modeling of Brazilian disc tests under quasi-static conditions to understand the full-field deformation behaviors and finally, it is validated by DIC. As the direct tensile test has limitations in sample preparation and test execution, the Brazilian testing principle is commonly used to evaluate indirectly the tensile strength of rocks. The two-dimensional numerical model was built to predict the stress distribution and full-field deformation on Brazilian disc under compression based on the assumptions of a homogenous, isotropic and linear elastic material. The uniaxial compression test was conducted using the DIC technique to determine the elastic properties of Spider Berea sandstone, which were used as inputs for the simulation model. The model was verified by the analytical solution and compared with the digital image correlation. The numerical simulation results showed that the solutions matched reasonably with the analytical solutions where the maximum deviation of stress distribution was obtained as 14.59%. The strain evolution (normal and shear strains) and displacements along the central horizontal and vertical planes were investigated in three distinguishable percentages of peak loads (20%, 40%, and 90%) to understand the deformation behaviors in rock. The simulation results demonstrated that the strain evolution contours consistently matched with DIC generated contours with a reasonable agreement. The changes in displacement along the central horizontal and vertical planes showed that numerical simulation and DIC generated experimental results were repeatable and matched closely. In terms of validation, Brazilian testing to measure the indirect tensile strength of rocks is still an issue of debate. The numerical model of fracture propagation supported by digital image correlation from this study can be used to explain the fracturing process in the homogeneous material and can be extended to non-homogeneous cases by incorporating heterogeneity, which is essential for rock mechanics field applications.

58 GEOSCIENCES↗