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DOE OSTI2024

The future of self-driving laboratories: from human in the loop interactive AI to gamification

Recent developments in artificial intelligence (AI) and machine learning (ML), implemented through self-driving laboratories (SDLs), are rapidly creating unprecedented opportunities for the accelerated discovery and optimization of materials. This paper provides a joint analysis of SDLs from both academic and industry perspectives, highlighting the importance of integrating human intelligence in these systems. It discusses the necessity of careful planning in SDL design across physical, data, and workflow dimensions, including instrumental setup, experimental workflow, data management, and human–SDL interaction. The significance of integrating human input within SDLs, especially as the focus shifts from individual tools and tasks to the creation and management of complex workflows, is emphasized. The paper stresses on the crucial role of reward function design in developing forward-looking workflows and examines the interplay between hardware evolution, ML application across chemical processes, and the influence of reward systems in research. Ultimately, the article advocates for a future where SDLs blend human intuition in hypothesis formulation with AI's precision, speed, and data-handling capabilities.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Atomistic and phase field simulations of three dimensional interactions of {$10\bar12$} twins with grain boundaries in Mg: twin transmission and dislocation emission

In polycrystals, the interaction of dislocations and twins with grain boundaries (GBs) plays a role in hardening and formability during plastic deformation. While dislocation-GB interactions are relatively well-understood, twin-GB interactions remain mostly unknown. In this work, an approach using molecular dynamics and phase-field simulations is followed to study the forward and lateral interactions between {$10\bar12$} twins and tilt grain boundaries in Mg. Molecular dynamics results show that the resolved shear stress on slip/twinning modes of the neighboring grain, not the geometric alignment, is the dominant factor in determining the outcome of the twin-GB interactions. For some lateral interaction configurations, as the misorientation angle increases, the resolved shear stress on the same {$10\bar12$} twin variant of the neighboring grain reduces while it increases for slip or I 2 stacking fault emissions or other twin modes such as {$11\bar12$} and {$10\bar11$}, explaining why twin transmission is not seen at high misorientation angles. Furthermore, lateral and forward interactions of the twin with tilt grain boundaries whose misorientation axes are normal to the coherent twin boundary show significantly different outcomes. For the forward interaction, the twin is absorbed and stacking faults are emitted when interacting for low misorientation angles (up to 30°) while the lateral interaction results in twin transmission, nucleation of a {$11\bar12$} twin, and emission of I 2 stacking faults. Finally, comparisons between twin interactions with symmetric and asymmetric tilt GBs with different GB structures show similar outcomes.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Measurement of the Hugoniot and shock-induced phase transition stress in wrought 17-4 PH H1025 stainless steel

Uniaxial strain, reverse-ballistic impact experiments were performed on wrought 17-4 PH H1025 stainless steel, and the resulting Hugoniot was determined to a peak stress of 25 GPa through impedance matching to known standard materials. The measured Hugoniot showed evidence of a solid–solid phase transition, consistent with other martensitic Fe-alloys. The phase transition stress in the wrought 17-4 PH H1025 stainless steel was measured in a uniaxial strain, forward-ballistic impact experiment to be 11.4 GPa. Linear fits to the Hugoniot for both the low and high pressure phase are presented with corresponding uncertainty. The low pressure martensitic phase exhibits a shock velocity that is weakly dependent on the particle velocity, consistent with other martensitic Fe-alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Performance and durability of electrically conductive tape for shingled Si heterojunction technology cells

We report electrically conductive tape (ECT) was characterized and used to assemble shingled cell strings at low temperature to achieve high reliability Pb- and Ag-free interconnections. The volume resistivity for two considered ECTs are 0.13 ± 0.06 mΩ·cm and 0.47 ± 0.20 mΩ·cm and specific contact resistances, 6.85± 2.00 mΩ·cm 2 and 6.30 ± 0.37 mΩ·cm 2 using the emerging IEC 62788-8-1 Technical Specification for assessment of electrically conductive adhesives (ECA). Durability and performance of the technology in glass–glass mini modules were evaluated with temperature cycling, damp heat testing, and combined-accelerated stress testing (CAST). Through temperature cycling (-40°C to 85°C) applying five times the mini module short-circuit current in forward bias and in the multi climate CAST protocol, there was negligible degradation of fill factor after replacing connectors at the modules' cable leads; however, CAST resulted in short circuit current loss attributed to degradation in light collection by the cells, not the ECT. The IEC 61215-2 85°C, 85% relative humidity damp heat testing showed susceptibility of the HJT cells to effects of humidity in the electroluminescence intensity around the module perimeter that degraded power performance by 4% (relative). Contrasting the IEC 61215-2 qualification testing-based damp heat testing with CAST, factors such as the optical stress of CAST may precipitate the degradation of the modules whereas the humidity levels and duration of IEC 61215-2 damp heat testing may lead to excessive levels of humidity diffused into the modules, potentially resulting in degradation that is unrepresentative of the field.

14 SOLAR ENERGY↗

DOE OSTI2020

Kirigami Engineering—Nanoscale Structures Exhibiting a Range of Controllable 3D Configurations

Abstract Kirigami structures provide a promising approach to transform flat films into 3D complex structures that are difficult to achieve by conventional fabrication approaches. By designing the cutting geometry, it is shown that distinct buckling‐induced out‐of‐plane configurations can be obtained, separated by a sharp transition characterized by a critical geometric dimension of the structures. In situ electron microscopy experiments reveal the effect of the ratio between the in‐plane cut size and film thickness on out‐of‐plane configurations. Moreover, geometrically nonlinear finite element analyses (FEA) accurately predict the out‐of‐plane modes measured experimentally, their transition as a function of cut geometry, and provide the stress–strain response of the kirigami structures. The combined computational–experimental approach and results reported here represent a step forward in the characterization of thin films experiencing buckling‐induced out‐of‐plane shape transformations and provide a path to control 3D configurations of micro‐ and nanoscale buckling‐induced kirigami structures. The out‐of‐plane configurations promise great utility in the creation of micro‐ and nanoscale systems that can harness such structural behavior, such as optical scanning micromirrors, novel actuators, and nanorobotics. This work is of particular significance as the kirigami dimensions approach the sub‐micrometer scale which is challenging to achieve with conventional micro‐electromechanical system technologies.

Zhang, Xu↗

DOE OSTI2020

Challenging a Global Land Surface Model in a Local Socio-Environmental System

Land surface models (LSMs) predict how terrestrial fluxes of carbon, water, and energy change with abiotic drivers to inform the other components of Earth system models. Here, we focus on a single human-dominated watershed in southwestern Michigan, USA. We compare multiple processes in a commonly used LSM, the Community Land Model (CLM), to observational data at the single grid cell scale. For model inputs, we show correlations (Pearson’s R) ranging from 0.46 to 0.81 for annual temperature and precipitation, but a substantial mismatch between land cover distributions and their changes over time, with CLM correctly representing total agricultural area, but assuming large areas of natural grasslands where forests grow in reality. For CLM processes (outputs), seasonal changes in leaf area index (LAI; phenology) do not track satellite estimates well, and peak LAI in CLM is nearly double the satellite record (5.1 versus 2.8). Estimates of greenness and productivity, however, are more similar between CLM and observations. Summer soil moisture tracks in timing but not magnitude. Land surface reflectance (albedo) shows significant positive correlations in the winter, but not in the summer. Looking forward, key areas for model improvement include land cover distribution estimates, phenology algorithms, summertime radiative transfer modelling, and plant stress responses.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

A Growing Freshwater Lens in the Arctic Ocean With Sustained Climate Warming Disrupts Marine Ecosystem Function

One of the most robust changes in the hydrological cycle predicted by Earth System Models (ESMs) during the remainder of 21st century is an increase in the difference between precipitation and evapotranspiration (P-E) in arctic and boreal regions. We explore the long-term consequences of this change for marine ecosystems in the Arctic Ocean using the Community Earth System Model forced with a business as usual scenario of future greenhouse gas concentrations. We find that by the year 2300 increases in freshwater delivery considerably reduce Arctic Ocean surface salinity, creating a freshwater lens that has far-reaching impacts on marine biogeochemistry. The expanding freshwater lens limits vertical nutrient supply into the euphotic zone by enhancing vertical stratification and accelerating surface lateral mixing with surface waters in the North Atlantic, which become increasingly nutrient depleted from weakening of the Atlantic Meridional Overturning Circulation (AMOC). The resulting increase in nutrient stress reduces marine export production in the Arctic Ocean by 53% in 2300 relative to the 1990s and triggers a shift in community composition with small phytoplankton replacing diatoms. At the same time, the seasonal timing of export production undergoes a 2-month forward shift, with the peak advancing from July to May. This suggests that the threat to food webs and higher trophic levels may intensify after the year 2100 as gains in productivity from sea ice loss saturate and freshwater impacts on nutrient stress continue to strengthen. Our analysis highlights the critical importance of changing terrestrial hydrology and land-ocean coupling as drivers of long-term biogeochemical change in the Arctic Ocean and the necessity of multi-century climate change projections.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

On the use of adjoints in the inversion of observed quasi-static deformation

An adjoint-based conjugate gradient algorithm provides an efficient means for imaging sources of deformation within the Earth, such as volume stresses associated with fluid flow in aquifers and reservoirs. For time intervals over which the overburden deforms elastically, one can calculate the gradient elements for a single model update using just two numerical simulations. The first is a forward run that is used to compute the residuals associated with the given iteration. The second simulation is to evaluate the application of the adjoint operator to the residuals. In this adjoint calculation, the residual displacements are applied as sources at the measurement locations, driving the deformation in the simulation. The volume stress on the source grid blocks, in response to the residual displacements, provide the gradient components. We apply this technique to satellite-based interferometric synthetic aperture radar (InSAR) line-of-sight displacements that were observed over an oil reservoir in California’s Central Valley. Furthermore, we find that the adjoint-based gradient estimates, requiring 18 CPU seconds, agree with conventional numerical calculations that take over 3700 CPU seconds to compute. Conjugate gradient algorithms utilizing the conventional approach and adjoint-based gradient computations give roughly the same reductions in misfit and similar final estimates of reservoir volume change.

58 GEOSCIENCES↗

DOE OSTI2024

Predicting Mechanical Properties from Microstructure Images in Fiber-Reinforced Polymers Using Convolutional Neural Networks

Evaluating the mechanical response of fiber-reinforced composites can be extremely time-consuming and expensive. Machine learning (ML) techniques offer a means for faster predictions via models trained on existing input–output pairs and have exhibited success in composite research. This paper explores a fully convolutional neural network modified from StressNet, which was originally used for linear elastic materials, and extended here for a non-linear finite element (FE) simulation to predict the stress field in 2D slices of segmented tomography images of a fiber-reinforced polymer specimen. The network was trained and evaluated on data generated from the FE simulations of the exact microstructure. The testing results show that the trained network accurately captures the characteristics of the stress distribution, especially on fibers, solely from the segmented microstructure images. The trained model can make predictions within seconds in a single forward pass on an ordinary laptop, given the input microstructure, compared to 92.5 h to run the full FE simulation on a high-performance computing cluster. These results show promise in using ML techniques to conduct fast structural analysis for fiber-reinforced composites and suggest a corollary that the trained model can be used to identify the location of potential damage sites in fiber-reinforced polymers.

Sun, Yixuan (ORCID:0000000311093380)↗

DOE OSTI2025

Thermally induced PtOx interfacial layer enhances stability of Pt/β-Ga2O3 vertical Schottky diodes

This study investigates the long-term stability of Pt/β-Ga2O3 field-plated Schottky barrier diodes at high temperatures, with extended thermal cycling and soaking stress. The device characteristics reveal a strong dependence on operating temperature, leading to an ON/OFF current ratio of ∼10× at ±3 V and 600 °C. Extensive thermal cycling (25 cycles over 100 h) between room temperature and 350 °C shows that leakage currents stabilize after the initial ten cycles. This stabilization is likely due to the formation of a thin PtOx layer at the Pt/β-Ga2O3 interface, as confirmed by high-resolution scanning transmission electron microscopy. Further exposure to a constant 350 °C environment for 10 h reveals a slight increase in the leakage current from 10−7 to 10−6 A at −5 V and degradation of the forward current, due to potential thermodynamic instability of the Ohmic contacts. This study provides insights into the changes in the Pt/β-Ga2O3 diode performance with thermal stress, offering a basis for predicting the device’s operational reliability at high temperatures for sensing and power applications.

08 HYDROGEN↗

DOE OSTI2026

Rates of Sea‐Level Rise Are Highly Sensitive to Ice Viscosity Parameters in Model Benchmarks

Glacier flow plays a major role in current and future rates of globally averaged sea-level rise. The viscosity of glacial ice, controlling the rate of flow, decreases as stress increases and is highly sensitive to the value of the stress exponent, $n$, in the constitutive equation for viscous flow. Glaciologists and climate modelers almost exclusively assume $n=3$ when modeling ice flow and projecting sea-level rise through forward modeling. However, recent work suggests that $n\approx 4$ better fits observations, prompting the question: How sensitive are projections of sea-level rise to the value of $n$? We use an established community ice flow model and standard benchmark experiments designed as an idealized representation of Pine Island Glacier, West Antarctica. While initializing an $n=3$ model to match observations of an $n=4$ ice sheet is possible, we find that incorrectly assuming $n=3$ when in fact $n=4$ dramatically underestimates rates of sea-level rise. The scale of this error grows nonlinearly with the magnitude of the climate forcing, acting to increase projection uncertainties. Additionally, we find that models often account for this stress-dependent rheology mismatch during model initialization in a way that masks this rheological effect in the short term while leaving model outputs vulnerable to larger biases in longer-term projections. Initializations to observations of Pine Island Glacier display similar rheology-mismatch fingerprints to our idealized example.

climate sensitivity↗

DOE OSTI2020

Model, Design, and Control for Power Conversion in Wave Energy Converter System

Wave energy, if all been harvested along the U.S. coastline, can power around 65% of the energy consumption in U.S.. Comparing to other renewable energy sources like solar or wind, ocean wave can provide up to 90% of steady uptime. With the high energy density (2-3 kW/m 2 ), it can produce more energy with the same amount of installation area comparing to the energy density of wind turbine (0.6 kW/m 2 ) and solar panel(0.2 kW/m 2 ). The predictability of wave provides advantages like planning installation, power dispatching, and maintenance activities. Although with all these advantages, wave energy converter system is still in the research stage due to its high system cost per electricity production. One of the challenges that need to be solved is the irregularity from the wave motion that leads to high instantaneous peak power into the wave energy converter, which usually reaches up to 10 - 20 times of the average power. The high peak power will not only bring high mechanical/electrical stress but also result in an overrating design of the components in the system. Another obstacle that prevents the wave energy system from moving forward is the high testing cost from the validations in wave-energy-test sites or tank-test sites. A high-fidelity multi-disciplinary system model, including hydrodynamics, mechanical dynamics, electromagnetics, and power electronics, is needed to predict the behavior of the system and reduce the cost of design validation.

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

Adhesion, structure, and mechanical properties of Cr HiPIMS and cathodic arc deposited coatings on SiC

Chromium deposited by high-power impulse magnetron sputtering (HIPIMS) versus cathodic arc (CA) processes exhibits very different mechanical properties. Combining the two can result in a single-phase with superior performance that can be tailored for use in coating SiC for advanced nuclear fuel cladding. Coating morphology, residual stress, elemental depth profiles, and mechanical testing by scratch, pull-off adhesion, and microcantilevers are shown for HiPIMS, CA, and combined coatings. CA coatings were likely to spall and had lower adhesion strength due to tensile residual stresses but had desirable material properties. Additionally, by depositing an initial layer of Cr by HiPIMS followed by a layer of Cr by CA, a more adherent coating was achieved and some of the stress issues with CA morphology were resolved. Combined coatings withstood at least 80 MPa in pull-off adhesion tests and had maximum failure stress values of 5GPa in microcantilever tests. These results were better than either individual deposition method and point to a hybrid approach being a path forward for a more robust coating.

36 MATERIALS SCIENCE↗

DOE OSTI2024

A Prefire Approach for Probabilistic Assessments of Postfire Debris‐Flow Inundation

Increases in wildfire activity and rainfall intensification are driving more postfire debris flows (PFDF) in many regions around the world. PFDFs are most common in the first postfire year and may even occur before a fire is fully controlled. This underscores the importance of assessing postfire hazards before a fire starts. Evaluation of PFDF hazards prior to fire can help strategize interventions lessening the negative effects of future fires. However, debris-flow runout and inundation analyses are not routine in PFDF hazard assessments, partially due to time constraints and substantial uncertainties in boundary conditions. Here, we propose a prefire PFDF inundation assessment framework using a debris-flow runout model based on the Herschel-Bulkley (HB) rheology (HEC-RAS v6.1). We constrain model inputs and parameters using Bayesian posterior analysis, rainfall-runoff simulations, and a debris-flow volume model. We use observations from recent PFDF incidents in northern Arizona, USA, to calibrate model components and then apply our prefire inundation assessment framework in a nearby unburned area. Specifically, we (a) identify yield stress as the most influential factor on inundation extent and arrival time in a HB model, (b) establish posterior distributions for model parameters suitable for forward modeling by leveraging uncertainties in field observations, and (c) implement a predictive forward analysis in an area that has not burned recently to evaluate PFDF inundation under several future fire scenarios. This study improves our ability to assess postfire debris-flow hazards before a fire begins and provides guidance for future applications of single-phase rheological models when assessing PFDF hazards.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Mechanism of the wurtzite to rocksalt phase transformation in cadmium sulfide single crystals shock compressed along the 𝑐-axis to elastic impact stresses of ∼ 5 GPa

Cadmium sulfide (CdS), which exhibits a wurzite (WZ) to rocksalt (RS) phase transformation at elevated stresses, is an ideal system to address the role of deformation on phase transformation mechanisms and kinetics. CdS has been shown to have very different elastic-inelastic behavior for shock propagation along the WZ 𝑐- and 𝑎-axes, and also exhibits significant differences in the time scale for the phase transformation when shocked along these different axes. As an important first step in examining the role of deformation in shock-induced phase transformations, here we present in situ, time-resolved x-ray diffraction (XRD) measurements in single-event, shock wave experiments on CdS single crystals shocked along the WZ 𝑐-axis to elastic impact stresses near or above ∼ 5 GPa, where a marked increase in the kinetics of this transformation has been reported. The XRD measurements are compared with forward diffraction simulations to evaluate different proposed phase transformation mechanisms and are shown to be consistent with a shearing mechanism that results in the RS [001] direction being aligned with the original WZ 𝑐-axis and the RS [110] direction being aligned with the original WZ 𝑎-axis. In order to reproduce all observed RS diffraction spots the forward diffraction simulations required three different RS crystalline domains, each with a [110] direction aligned with one of the three original WZ 𝑎-axes, and a significant mosaicity, particularly about the RS [001] direction (the direction of shock propagation). In conclusion, this large mosaicity is likely due to variations in the possible shearing mechanisms that connect the WZ and RS structures, which can create crystallites with up to ∼ ±10° of relative rotations about the RS [001] direction, as well as further rotation of these crystallites as they grow, merge, and coalesce.

Crystal structure↗

DOE OSTI2024

A Prefire Approach for Probabilistic Assessments of Postfire Debris-Flow Inundation

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

In-Situ Visualization of a Growing Brittle Crack in Aluminum Oxynitride Using Synchrotron X-Rays and the Double-Cleavage Drilled Compression Geometry

Brittle fracture is difficult to study in situ due to the speed of a growing crack and the often-catastrophic nature of failure in brittle materials. As a result, the influence of microstructural considerations, such as orientation, grain boundary locations, and strain field, on the crack path remains poorly understood. Presented in this study is a method addressing this knowledge gap, which utilizes the double-cleavage drilled compression geometry to achieve quasi-stable fracture in aluminum oxynitride (AlON). Synchrotron X-ray micro-computed tomography is used to characterize the crack shape and length, while high-energy diffraction microscopy provides information on the strains, orientations, and shapes of grains in the microstructure surrounding the crack tip. During testing, the crack grew in discrete and irregular jumps while the fracture toughness falls within reported ranges. The crack in AlON is found to have no greater tendency to crack intergranularly as compared to transgranularly, and grains which are cracked transgranularly do not display a trend in orientation or stress when compared to those around which the crack followed a grain boundary. The high resolution of the crack path and microstructural data provides a path forward for modeling and understanding 3D brittle fracture.

Gorske, Sara F.↗

DOE OSTI2022

Optimizing performance and yield of vertical GaN diodes using wafer scale optical techniques

Abstract To improve the manufacturing of vertical GaN devices for power electronics applications, the effects of defects in GaN substrates need to be better understood. Many non-destructive techniques including photoluminescence, Raman spectroscopy and optical profilometry, can be used to detect defects in the substrate and epitaxial layers. Raman spectroscopy was used to identify points of high crystal stress and non-uniform conductivity in a substrate, while optical profilometry was used to identify bumps and pits in a substrate which could cause catastrophic device failures. The effect of the defects was studied using vertical P-i-N diodes with a single zone junction termination extention (JTE) edge termination and isolation, which were formed via nitrogen implantation. Diodes were fabricated on and off of sample abnormalities to study their effects. From electrical measurements, it was discovered that the devices could consistently block voltages over 1000 V (near the theoretical value of the epitaxial layer design), and the forward bias behavior could consistently produce on-resistance below 2 mΩ cm 2 , which is an excellent value considering DC biasing was used and no substrate thinning was performed. It was found that high crystal stress increased the probability of device failure from 6 to 20%, while an inhomogeneous carrier concentration had little effect on reverse bias behavior, and slightly (~ 3%) increased the on-resistance (R on ). Optical profilometry was able to detect regions of high surface roughness, bumps, and pits; in which, the majority of the defects detected were benign. However a large bump in the termination region of the JTE or a deep pit can induce a low voltage catastrophic failure, and increased crystal stress detected by the Raman correlated to the optical profilometry with associated surface topography.

42 ENGINEERING↗