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DOE OSTI2023

Getting Technical: Introducing Students to Technical Concepts for Nuclear Science and Policy to Create and Encourage Diversity in the Nuclear Field

When discussing diversity, it is important to consider the many of the types of diversity: gender diversity, racial diversity, religious diversity, cultural diversity, and diversity in abilities. The nuclear field has recently seen a surge in the diversity within the entire industry, but there is still room for the industry to grow in those areas. Where does that begin? How does that develop? When is the right time to engage the next generation of nuclear professionals? What topics should be introduced to encourage and foster excitement in the nuclear field? These questions are all certainly important but narrowing in on the topics that should be introduced might prove to be a very effective way to grow excitement in and, then, diversity in the nuclear field. Students at all socioeconomic levels should be introduced to various technical concepts that correspond to the stage and level of education that is appropriate for those students. Oftentimes there may be a speaker at a school for certain ages that will provide an overview of the nuclear industry as a whole, or perhaps even specifics on what that person does, but rarely is the interaction carried on over a long period of time and rarely do presentations for these students introduce technical concepts. Creating new, effective volunteer programs in a wide range of schools in local areas where nuclear sciences are supported would allow professionals in the nuclear field to identify and focus on students whose aptitude might lean them towards future careers in the nuclear field. This paper will focus on potential, effective ways to start these programs, and it will identify a range of technical concepts that might be considered as age-appropriate or that can be molded to fit individual schools and would, in turn, begin to develop a diverse base of students to grow and enter the nuclear field.

Loftin, Bradley↗

DOE OSTI2023

ADVANCED TECHNIQUES FOR ENERGY INPUT REDUCTION IN GYPSUM WALLBOARD DRYING

Gypsum has been used for thousands of years in building and construction applications, starting with the pyramids in ancient Egypt, to “Plaster of Paris” in the midcenturies, and to the now-ubiquitous drywall in modern-day houses. Production of gypsum drywall boards takes several steps with high energy and water consumption. The current state of the art in industry is a process that begins by mining gypsum and reducing its particle size by milling. These gypsum particles undergo calcination to convert the gypsum (calcium sulfate dihydrate) into stucco (calcium sulfate hemihydrate). The stucco is mixed with additives and enough water to form a slurry that can be poured onto a conveyor belt and molded into the desired geometry. The stucco reacts with the water, converting back into gypsum. The remaining water is then dried from the board to form the final product. While only ~20 wt. % of water is needed for the conversion of stucco to gypsum, significant excess water is needed to ensure sufficient fluidity of the slurry for processibility. This is due to the low quality of the stucco particles produced in high throughput calcination units, which disintegrate upon mixing with water, thereby reducing the fluidity and processability of the slurry. This project aims to produce high-quality stucco particles by dielectric calcination. In doing so, particle integrity can be maintained through the slurry formulation step, and particle size distribution of the stucco can be adjusted to increase fluidity with less excess water. With less water remaining unreacted in the board, significant energy can be saved in drying the product. The project aims to 1) develop a dielectric calcination method to TRL 3, 2) determine optimal and practical particle size distributions to minimize excess water in the slurry, and 3) reduce the energy consumption of the drying process.

Conforti, Kameron↗

DOE OSTI2025

Development of novel techniques for non-invasive air leakage and moisture detection in building envelopes

Unwanted air leakage and moisture in building envelopes can cause high energy consumption, detrimental indoor air quality, poor occupant comfort, and reduction in building material durability. High moisture can cause rot and mold, leading to costly and time-consuming repairs that add to the carbon burden of the building envelope. Novel detection techniques for locating and measuring air leakage flow and areas of high moisture in building envelopes will be presented. The techniques are easy, fast, and non-destructive which can enable quick building envelope assessment, foster retrofits, and lead to energy savings and carbon emission reduction.

Boudreaux, Philip [ORNL] (ORCID:0000000229564665)↗

DOE OSTI2025

Development of a second COMB dipole magnet with STAR wires

Rare-Earth Barium Copper Oxide (REBCO) coated conductors are an attractive option for application in high-field accelerator magnets due to their high critical field and the convenience of fabrication without heat treatment compared to some other superconductors. Fermilab plays a vital role in superconducting accelerator magnet R&D under the framework of the U.S. Magnet Development Program. An integral part of that program is the accelerator magnet development based on REBCO conductors to demonstrate self-fields of 5 T or greater compatible with operation in hybrid configurations to generate fields beyond 16 T for future High Energy Physics (HEP) applications. A small, two-layer REBCO dipole magnet based on the Conductor on Molded Barrel (COMB) magnet technology, developed at Fermilab with Symmetric Tape Round (STAR®) wires from AMPeers LLC was recently fabricated and tested in liquid helium, demonstrating the design feasibility. A second dipole magnet based on the same technology is currently under development at Fermilab. The coil has a 60-mm clear bore and a 120-mm OD and consists of six layers of STAR® conductor, which allows to significantly increase the magnetic field compared to the previous design, and potentially probe the 5 T self-field target. This presentation reports the progress in the magnet development.

Kashikhin, Vadim [Fermilab]↗

DOE OSTI2025

Machine Learning-Driven Optimization of Building Enclosures for Moisture Durability and Thermal Performance

The design of moisture-durable building enclosures with low embodied carbon often involves an iterative process of selecting the materials for the specific exposure conditions to meet the performance requirements. While hygrothermal simulations are commonly used to evaluate moisture durability, they often require advanced expertise for proper implementation. Machine learning (ML) provides a promising alternative by streamlining the design process and minimizing the reliance on complex simulations. This study presents a machine learning-based approach for predicting moisture durability in residential wall assemblies. The ML model was trained to estimate the mold index and maximum moisture content of various layers under typical exposure conditions. The model achieved a high predictive accuracy, with a coefficient of determination (R²) exceeding 0.90 when compared to traditional hygrothermal simulations on materials that were not part of training the ML model. Building on these results, the ML model was developed into a practical tool for optimizing wall assembly designs. This tool allows users to automatically optimize material selections based on energy, moisture, and carbon performance criteria. By incorporating multi-objective optimization, the tool identifies configurations that minimize embodied carbon while maintaining moisture safety and code-compliant thermal performance. Additionally, it provides insights into how material choices influence assembly durability, energy efficiency, and carbon reduction. The tool will be implemented in the Building Science Advisor (BSA) to enhance its performance and provide more granularity on the results. This research highlights the potential for ML-driven tools to simplify the design of high-performance building enclosures, offering architects and engineers a faster, more efficient way to balance critical performance factors.

Salonvaara, Mikael [ORNL] (ORCID:0000000318991554)↗

DOE OSTI2025

Next generation retrofit wall panels with integrated vacuum insulation panels

Approximately two-thirds of residential buildings in the United States were constructed before the Department of Energy established energy conservation measures. These buildings present major opportunities for improving energy efficiency, though retrofitting them remains technically and economically challenging. This study presents the development and the durability evaluation of an innovative retrofit panel system that integrates vacuum insulation panels (VIP) with a nail-base panel (called a retrofit insulated panel) to enhance thermal performance with minimal disruption to occupants and without altering standard nail-based panel installation practices. Hygrothermal simulations were conducted to assess the moisture behavior of wall assemblies before and after retrofit installation under varying water vapor control strategies and climate conditions. Results indicate that, with appropriate moisture control strategy, the retrofit system effectively prevents moisture accumulation, keeping mold index values and relative humidity levels below critical thresholds. Additionally, Guarded Hot Box testing was performed to compute the effective R-value of the panel under different coverage areas that demonstrates its effectiveness in enhancing both thermal and moisture performance in existing residential buildings.

Iffa, Emishaw [ORNL]↗

DOE OSTI2025

Method of manufacturing monolithic optical systems

Disclosed are monolithic optical systems using an aerogel molded around a mandrel. A method of manufacturing an optical system includes applying a reflective coating to at least a portion of a surface of a mandrel, placing the mandrel in a tank and subsequently filling the tank with aerogel to a predetermined depth below a top of the mandrel. The method includes adding a separation layer to the tank on top of the aerogel at the predetermined depth, catalyzing the separation layer into a solid, and adding aerogel on top of the separation layer filling the tank with aerogel above a height of the mandrel, and removing the aerogel and mandrel from the tank, drying the aerogel into a solid aerogel structure, catalyzing the reflective coating to bond the reflective coating with the aerogel, and removing the mandrel from the aerogel structure to produce the aerogel structure having a hollowed-out interior.

Ravizza, Frank↗

DOE OSTI2026

Durable Thin‐Film Porous Transport Electrodes for High Current Density PEM Water Electrolysis

Proton exchange membrane water electrolyzers rely on relatively expensive Ir-based catalysts for efficient and durable hydrogen production. To reduce system costs, Ir loadings can be reduced if performance and durability are maintained. Sputter deposition is a readily scalable method to synthesize uniform, low-loading catalyst layers with controlled composition. A catalyst applied directly to the porous transport layer can have advantages for performance, manufacturing simplicity, and catalyst recovery. Suitable porous transport layer porosity can minimize activity losses when reducing loadings. Here, methods are presented to deposit metallic Ir as well as amorphous and rutile Ir oxides. The activity and durability of these materials in the porous transport electrode architecture is evaluated. The metallic and amorphous forms have better initial activity, however, operation at 3 A cm −2 with 0.1 mg Ir cm −2 shows that only rutile IrO 2 maintains performance beyond 100 h with a 50 mV improvement after 700 h. A >10x reduced dissolution rate is shown for rutile IrO 2 . With a low-porosity transport layer and 0.4 mg Ir cm −2 , a steady-state voltage decay rate of 6 µV h −1 is achieved. The results demonstrate that sputter-deposited rutile IrO 2 porous transport electrodes with low Ir loading can be operated at high current density to reduce hydrogen production costs.

08 HYDROGEN↗

DOE OSTI2020

Hybrid fiber metal composite laminate interlaminar reinforcement through metal interlocks

Aircraft and automobile industries are continually seeking high-performance and lightweight solutions. Fiber-reinforced composites in conjunction with metals are being considered in the form of hybrid materials. There is a continuous need for improvement of interfacial bonding between composite layers and metal constituents. In this study, an innovative hybrid fiber interlocking metal hooks laminate (FIMHL) system was developed in which fiber-reinforced thermoset composite, and metal sheets are mechanically bonded together using out of plane hooks stamped in the metal. Process optimization was performed to gain the full benefit of the through-thickness reinforcement. Microstructural analysis showed improved interaction between the metal hooks and the fiber layers which reduced porosity and resin richness. This was reflected in mechanical properties, as tensile and flexural strength of FIMHL was enhanced by 38.5 and 18.8%, respectively, after process optimization. Furthermore, normalized weight fraction (76.4%) properties of FIMHL also confirmed that the increase in mechanical properties of optimized panel were not only due to increased reinforcement (glass fiber + aluminum) volume fraction but also because of improved metal hooks and fibers interaction. There was no significant effect on lap shear and fracture toughness, as they depend on bend back behavior of the hooks. A bilinear traction-separation model was used to characterize mode-I interlaminar fracture toughness properties, and 4.5% variation was recorded when modeling and experimental values were compared.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Enhanced ductility in in-layer glass-carbon fiber/epoxy hybrid composites produced via tailored fiber placement

Experimental mechanical property results of composite materials with hybrid reinforcements (commingled glass and carbon fibers) are detailed and compared with single-fiber composite properties. In-layer hybrid materials, with carbon and glass fiber tows laid side-by-side, were produced via tailored fiber placement (TFP) technology. Detailed experiments showed a phenomenon of “enhanced ductility” of carbon fiber in the hybrid composites of 12–24% relative to an all-carbon fiber composite and multiple stress–strain peaks were observed. Here, this enhanced ductility was hypothesized to be due to the glass fibers mitigating the shock waves arising from the initial failures of carbon fibers, and preventing the premature failure of the remaining carbon fibers. A novel way to engineer the stress–strain behavior of a hybrid composite to achieve a metal-like ductile response (plateau of stress–strain behavior, often termed “elastic–plastic deformation”) was demonstrated by carefully selecting the type and composition of carbon and glass fiber materials.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Real-time cure monitoring of fiber-reinforced polymer composites using infrared thermography and recursive Bayesian filtering

Despite the desirable characteristics of fiber-reinforced polymer (FRP) composites, their utilization in high volume production industries is limited by a lack of efficient manufacturing techniques. Monitoring the curing process of these composites can help with improving the quality and efficiency of the manufacturing process. This article discusses a method that uses Kalman-filter-based fusion of the information obtained from infrared thermography (surface temperature measurements) and a heat conduction model to estimate degrees of cure and internal temperatures of curing FRP composite parts in real time. The effectiveness of the methodology is demonstrated by successfully monitoring the curing of an FRP composite part in a laboratory experiment. Finally, the proposed methodology is a crucial step towards identifying anomalies in the curing process that negatively impact the quality of FRP composite parts.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Preservation of erniettomorph fossils in clay-rich siliciclastic deposits from the Ediacaran Wood Canyon Formation, Nevada

Three-dimensionally preserved Ediacaran fossils occur globally within sandstone beds. Sandy siliciclastic deposits of the Ediacaran Wood Canyon Formation (WCF) in the Montgomery Mountains, Nevada, contain two fossil morphologies with similar shapes and sizes: one exhibits mm-scale ridges and a distinct lower boundary and the other is devoid of these diagnostic features. We interpret these as taphomorphs of erniettomorphs, soft-bodied organisms with uncertain taxonomic affinities. We explore the cast-and-mould preservation of both taphomorphs by petrography, Raman spectroscopy, X-ray fluorescence microprobe and X-ray diffraction. All fossils and the surrounding sedimentary matrix contain quartz grains, iron-rich chlorite and muscovite. The ridged fossils contain about 70% larger quartz grains compared to the ridgeless taphomorph, indicating a lower abundance of clay minerals in the ridged fossil. Chlorite and muscovite likely originated from smectite and kaolinite precursors that underwent lower greenschist facies metamorphism. Kaolinite and smectite are inferred to have been abundant in sediments around the ridged fossil, which enabled the preservation of a continuous, distinct, clay- and kerogen-rich bottom boundary. The prevalence of quartz in the ridged fossils of the WCF and in erniettomorphs from other localities also suggests a role for this mineral in three-dimensional preservation of erniettomorphs in sandstone and siltstone deposits.

58 GEOSCIENCES↗

DOE OSTI2020

Thermal Image Processing for Feature Extraction from Encapsulated Phase Change Materials

Encapsulated inorganic particles with high melting points (>300 °C) are desired as high-temperature Phase Change Materials (PCMs) for next-generation Latent Heat Thermal Energy Storage (LHTES) systems. One of the many challenges during the development of PCMs is to achieve a high throughput that in turn depends on accurately modeling the relation between process parameters and geometric & thermal properties of the PCMs particle. During the production of the PCMs, a high-speed infrared camera is used to acquire images of the encapsulated material under controlled illumination conditions. This research article focuses on the development of image processing techniques for both geometric and thermal feature extraction during the development of the PCMs. A user-friendly GUI has been designed in MATLAB and preliminary experimental results have demonstrated that the method is fast, accurate and reliable for a high throughput production. The extracted features will be used to develop Machine Learning (ML) models to predict the geometric and thermal properties of the PCM based on the process parameter settings. The ML model will accelerate the search for the optimized process settings to boost the throughput of the production.

25 ENERGY STORAGE↗

DOE OSTI2024

Development of an immersion fiber optic Raman probe for real-time analysis of molten materials

This study presents an advancement in high-temperature Raman spectroscopy, specifically for analyzing molten materials. It introduces an approach by integrating a fiber-optic Raman probe with a copper block protection system designed to endure extreme thermal conditions. The copper block features an open port designed to accommodate an external telescope with a 3 cm focal length, enabling Raman spectra collection in challenging high-temperature environments. A built-in gas channel ensures a continuous flow of argon gas to prevent flux intrusion. The robust copper block acts as a reliable shield, safeguarding the fiber-optic Raman probe within molten materials. This enhancement maintains the probe's integrity and significantly improves its resilience, making it ideal for rigorous investigations of molten substances. This advancement is particularly relevant in metallurgy, where flux materials impact production quality and efficiency. The ability to acquire Raman signals under elevated thermal conditions offers opportunities for studying molecular dynamics, compositional changes, and chemical interactions within molten substances. This introduced direct immersion probing technique has implications, benefiting both scientific and industrial fields. It holds promise for advancing research and exploration in various contexts, from fundamental scientific inquiries to practical applications in metallurgical processes, where flux materials are critical for optimizing production quality and efficiency. Furthermore, this approach enhances the capabilities of high-temperature Raman spectroscopy, making it a valuable tool for investigating molten materials and their properties in diverse settings.

Argon↗

DOE OSTI2021

Closing the Loop on Automotive Carbon Fiber Prepreg Manufacturing Scrap

The project demonstrated how to “close the loop” on carbon fiber by integrating industrial carbon fiber scrap into new functional components in an automotive lightweighting application. The project serves as a validation of discontinuous recycled carbon fiber in a commercial context, while generating comprehensive material data throughout the production chain.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Living Filter Designs for In-Line Recovery and Sorting of Critical materials

This project explored “bio-mining” of critical materials from electronic waste (E-waste) streams by developing living filters arrays capable of recovering these materials, focusing on the platinum group metals (PGMs) and rare earth elements (REEs). While highly toxic, E-waste is considered a valuable “urban mine” as it contains critical materials such as PGMs and REEs with orders of magnitude higher purity than the richest ores. The aim of the project was to: (1) develop mechanically robust, silk-based biomaterial filtration membranes that can capture REEs from dilute aqueous waste; (2) design and build 3D bioprinted living filters containing encapsulated electrochemically active bacteria (EAB) capable of bio-reducing PGMs and recovering them from waste streams; and (3) constructing combined living filter arrays using both components to efficiently capture REE and PGM from the same waste stream. The developed silk-based filtration membranes were self-assembled using silk-nanofibrils (SNFs) derived from silkworm (Bombyx mori) cocoons in conjunction with recombinant silk-elastin-like proteins (SELPs), which contained lanthanide-binding peptide tags (LBTs) with a high affinity and specificity towards REEs. These 100% biodegradable protein-based membranes were capable of recovering up to 85% of model REE ions (Tb 3+ ) filtered through the membrane, with ~50% recovery achieved in the presence of high concentrations (100X) of common interfering metals (Ca 2+ , Cu 2+ , Fe 3+ , Zn 2+ ). REE captured by the membranes were easily recovered by applying a low pH desorption buffer. The membranes also demonstrated substantial reusability, with only a 30% loss in binding capacity after 4 cycles of REE binding and recovery. To recover the PGMs, we created a bottom-up assembling strategy to construct a living hydrogel composed of a seamlessly integrated living catalyst, Shewanella loihica PV-4 (PV-4), for metal reduction, and their structural and functional linkers, bio-reduced graphene oxide (B-rGO). This hydrogel demonstrated a close to 90% recovery of model metal ions, Pd, from a simulated e-waste leaching stream with minimum-to-no biomass production. It’s also worth noting that the Pd recovery is initiated immediately after the introduction of living hydrogel, compared to conventional biocarriers that required start-up times within hours to days. Overall, these living hydrogels demonstrated superior bioactivity, structural integrity, and agility over existing biocarriers, which offers extensive opportunities to advance the biological metal recovery with unparallel efficiency, reduced energy/material consumption, and minimal environmental impact.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Next Gen High Efficiency Boosted Engine Development

This work represents an advanced engineering research project partially funded by the U.S. Department of Energy (DOE). Ford Motor Company, FEV North America, and Oak Ridge National Laboratory collaborated to develop a next generation boosted spark ignited engine concept. The project goals, specified by the DOE, were 23% improved fuel economy and 15% reduced weight relative to a 2015 or newer light-duty vehicle. The fuel economy goal was achieved by designing an engine incorporating high geometric compression ratio, high dilution tolerance, low pumping work, and low friction. The increased tendency for knock with high compression ratio was addressed using early intake valve closing (EIVC), cooled exhaust gas recirculation (EGR), an active pre-chamber ignition system, and careful management of the fresh charge temperature. Engine weight reduction measures were implemented throughout the engine system making use of composite materials, advanced manufacturing techniques, and architectural choices. This report outlines the analytical, design, fabrication, and test work conducted for the duration of the project. The combustion system stability, EGR tolerance, and knock resistance were validated on a single cylinder engine. An inline six-cylinder engine was then designed targeting application in the Ford F150. Multi-cylinder engines were produced and tested achieving the target vehicle fuel economy improvement of 23% assessed using measured engine fuel consumption combined with a vehicle drive cycle simulation. Actions were identified and designs were demonstrated to achieve the 15% weight reduction target. This project included items covering a range of technology readiness levels. Some of the technologies explored are production ready, while others were investigated to understand the limitations for what can be achieved in a stoichiometric, gasoline-fueled, spark-ignited internal combustion engine.

42 ENGINEERING↗

DOE OSTI2022

SMC Reinforced by Recycled or Textile Carbon Fiber

There is a significant need to expand material options for SMC that has traditionally used glass fibers for decades. There are several integral issues related to chopping and conveying a range of materials including glass, carbon, basalt, thermoplastic tapes, and recycled fibers. These are in a variety of forms including continuous tows, discontinuous agglomerates such as pyrolyzed carbon fibers that could be used to produce a range of SMC intermediates. Standard/conventional SMC processing is limited to cutting rotors specifically for glass and compounding with thermoset polyesters and some epoxies. The multi-material, multi-format line developed in this project is flexible to enable custom conveying and uses an interchangeable rotor dedicated for specific material types. The overall tasks undertaken in this project included: evaluation of the fiber feed mechanism, effect of textile grade carbon, evaluating servo motor controlling of conveyor, evaluate doctor box resin feed, evaluate compaction unit, evaluation of different formulations, and develop automation such as PLC programming. The new multi-material SMC line Version 2 (SCM-V2) incorporated servo motors over induction motors which gave the overall cutter system precision control and made it quiet. The addition of a 14-roll compaction unit at the end of the line in SMC-V2 enabled higher material wet out which was a limitation in the SMC Version 1 (SMC-V1). The cutters were further updated to reduce the cantilever overhang of the fiber which enabled more uniform cut lengths for glass, carbon, and basalt fibers. The overall instrumentation and system control including a remote control operation was enabled in the SMC-V2. The line speed is capable of 10-20 ft/minute. The cutting modules were designed and engineered for cutting glass, basalt and textile grade carbon in 300k and 450-600k format widths. The cutting trials were established for a range of fiber types. The study also demonstrated the utility of the line to cut and produce basalt fiber SMC. Initial trials were conducted on the properties from recycled carbon fiber (rCF) mats in epoxy resin. Overall, the Covid19 situation constrained the team from accessing the SMC line for over 18 months. Despite this challenge major advancements were made.

36 MATERIALS SCIENCE↗