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DOE OSTI2026

Reduced-order CFD modeling of cryogenic hydrogen isotope extrusion for pellet fueling

This study presents a reduced-order model (ROM) for computational fluid dynamics (CFD) simulations of cryogenic hydrogen isotope extrusions, focusing on protium (H₂) and deuterium (D₂) piston extruders. Using a 2D axisymmetric ROM in ANSYS-Polyflow, significant computational savings were achieved (runtime reduced from 9∼24 h to 3∼5 min), with extrusion force discrepancies between the 2D ROM and 3D models being on the order of 1%. Parametric studies identified optimal cutoff shear rates in the viscosity model (0.01/s for H₂ and 0.001/s for D₂), providing recommendations for future simulations. Finally, a comprehensive comparison of ROM results with experimental data was performed across varying geometries, cryogenic materials, temperatures, extrusion lengths, and piston velocities. Predictions at low extrusion temperatures met the objective of providing quick and efficient solutions with an acceptable extrusion force error of approximately 10% or less, validating the effectiveness of the 2D ROM approach. However, at high temperatures closer to the triple point, extrusion force error grows, which necessitates developing an improved model that accounts for temperature effects, e.g. melting. Nevertheless, the findings still represent a significant improvement in efficiency of CFD modeling of cryogenic hydrogenic extrusion. The ROM framework can also be extended to tritium (T2) and screw extruders, which will ultimately provide a fast and effective tool for optimizing pellet injector design for ITER and future reactor systems.

Fan, Joy [ORNL] (ORCID:0000000229751735)↗

DOE OSTI2025

AI-Optimized Polarization at Jefferson Lab

The AI-Optimized Polarization project seeks to develop experimental control applications for polarized targets and beams at Jefferson Lab using AI/ML. This paper will focus on two ongoing efforts involving a cryogenic polarized target and a linearly-polarized photon beam. Firstly, cryogenic targets, such as those used in Halls B and C (and approved for Hall D), are complex systems that are sensitive to a number of factors, including the temperature, beam currents, and the microwave and NMR apparatus. Secondly, the Hall D photon beam polarization depends on the optimal orientation of a diamond radiator, which produces coherent bremsstrahlung radiation from the electron beam incident upon it. Manual operation of both systems is tedious and error prone; implementing well-designed, interpretable control systems that incorporate AI is expected to lead to improved real-time polarization. AI optimization of nuclear physics experiments will lead, not just to cost-savings, but also to more efficient and higher-quality data, and this project will help to lay the foundation for future autonomous experiments.

Moran, Patrick [College of William and Mary, Willi↗

DOE OSTI2026

Co-sputter deposition of Nb₃Sn layer into SRF cavity using Nb-Sn composite target

Nb₃Sn, with its superior superconducting critical temperature (Tc ~18.3 K) and superheating field (Hsh ~400 mT), is considered a promising material for superconducting radiofrequency (SRF) cavities, offering enhanced cryogenic performance compared to bulk niobium cavities. A Nb₃Sn coating technique has been developed for Nb SRF cavities using co-sputtering of Nb-Sn composite target in a DC cylindrical magnetron sputtering system. The composite target configuration and discharge conditions for co-sputtering were optimized to deposit Nb-Sn films on flat Nb substrates, followed by annealing to form Nb₃Sn. Multiple strategies have been explored to improve the surface homogeneity of the Nb₃Sn coating, including optimizing a two-step annealing process, annealing in Sn vapor, and a light Sn recoating process. A 1.5 µm Nb-Sn co-sputtered film was deposited on the interior of a 2.6 GHz Nb SRF cavity and annealed at 600 °C for 6 h, followed by 950 °C for 1 h. Cryogenic RF testing of the annealed cavity demonstrated a Tc of 17.8 K, confirming the formation of Nb₃Sn. Then, the annealed cavity underwent a light recoating treatment and attained a quality factor (Q0) of 8.5E+08 at 2.0 K.

Accelerator Physics↗

DOE OSTI2023

Optimal Binding Affinity for Sieving Separation of Propylene from Propane in an Oxyfluoride Anion-Based Metal–Organic Framework

Highly efficient adsorptive separation of propylene from propane offers an ideal alternative method to replace the energy-intensive cryogenic distillation technology. Molecular sieving-type separation via high-performance adsorbents is targeted for superior selectivity, but the limit in adsorption capacity remains a great challenge. Here, we report an oxyfluoride-based ultramicroporous metal–organic framework UTSA-400, [Ni(WO 2 F 4 )(pyz) 2 ] (pyz = pyrazine), featuring one-dimensional pore channels that can accommodate the propylene molecules with optimal binding affinity while specifically excluding the propane molecules. The exposed oxide/fluoride pairs in UTSA-400 serve as strong functional sites for strengthened propylene–host interactions, accounting for a significantly enhanced propylene uptake, while the propane molecules are excluded due to the regulated host framework dynamics. The strong propylene binding enables near-saturation of propylene in the pore confinement at ambient conditions, leading to full utilization of pore space and superior packing density. Combined in situ infrared spectroscopy measurements and dispersion-corrected density functional theory calculations clearly unveil the nature of boosted host–guest binding. Direct production of polymer-grade (>99.5%) propylene with remarkable dynamic productivity is demonstrated by column breakthrough experiments. Furthermore, this work presents an example of pore engineering with atomic precision to break the trade-off in adsorptive separation through guest binding optimization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Revealing the Crystalline Architecture of Semicrystalline Ion Exchange Membranes for the Design of Conductive and Durable Alkaline Anion Exchange Membranes

Alkaline anion exchange membrane (AAEM) fuel cells offer a cost-effective alternative to proton exchange membrane (PEM) fuel cells by eliminating the need for expensive precious metal catalysts. In both PEMs and AAEMs, semicrystalline polymers are a common choice, as the crystalline domains can act as mechanical reinforcements that limit swelling and promote mechanical durability in the material. However, spatially resolved characterization of crystalline organization in ion exchange membranes beyond ensemble-averaged X-ray scattering is underrepresented, likely in part due to ionization damage limitations in soft materials. Here, in this study, we resolve the nanometer-size crystallites in semicrystalline ion exchange membranes by applying cryogenic four-dimensional scanning transmission electron microscopy (cryo-4D-STEM) along with data-processing algorithms designed to optimize signals at a low dose to minimize radiation damage. We investigate the effects of synthesis components, including molecular weight and thermal treatment, on a model system of AAEMs in comparison to Nafion, the most commonly used and commercially successful PEM today. We find that excess water uptake in polymer membranes, a property directly associated with weak mechanical durability and with possible negative impacts on ion conductivity, can be reduced by over 30% by varying the polymer's crystalline morphology through changes in synthesis parameters such as molecular weight and thermal history. Our results indicate that this improvement is correlated with smaller crystalline domains with a more homogeneous distribution. More broadly, these results demonstrate how the crystalline architecture of polymer membranes can be tuned through their chemistry and thermal treatment in order to improve their conductivity and durability for commercial fuel cell performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

PIP-II Linac Cryogenic Distribution System Design Challenges

The PIP-II linac Cryogenic Distribution System (CDS) is characterized by extremely small heat inflows and robust mechanical design. It consists of a Distribution Valve Box (DVB), Intermediate Transfer Line, Tunnel Transfer Line, comprising 25 Bayonet Cans, and ends with a Turnaround Can. Multiple helium streams, each characterized by distinct helium parameters, flow through each of these elements. The CDS geometry allows maintaining an acceptable pressure drop for each helium stream, considering the planned flows and helium parameters in different operation modes. This is particularly crucial for the return line of helium vapors, which return from cryomodules to the cold compressors and thus have very restrictive pressure drop requirements. On both sides of the DVB there are fixed supports for process pipes. One of the DVB design challenges was to route the process pipes in such a way that their shape provided sufficient compensation for thermal shrinkage. This ensures th at the forces resulting from thermal shrinkage acting on the cryogenic valves remain at a level acceptable to the manufacturer. The required thermal budget of the CDS was achieved by thermo-mechanical optimization of its components, like process pipes fixed supports in Bayonet Cans.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Design and optimization of higher order mode couplers for the superconducting cavities of the PERLE energy recovery linac

The Powerful Energy Recovery Linac for Experiments (PERLE) is an energy recovery linac (ERL) facility based on superconducting radio-frequency (SRF) technology to be hosted at the Laboratoire de Physique des 2 Infinis Irène Joliot-Curie (IJCLab) in France. With a target beam power of 10 MW, PERLE aims to demonstrate the high-current, continuous wave, multi-pass operation to validate options for future high-energy machines, such as the 50 GeV ERL proposed for the Large Hadron electron Collider (LHeC) and the Future Circular electron-hadron Collider (FCC-eh), and host dedicated particle physics and nuclear experiments. In high-current ERLs, the regenerative Beam Breakup (BBU), emerging from the beam and cavity Higher Order Modes (HOMs) interaction, is a major concern for their stable operation. Beam-induced HOMs can increase the cavity heat load at cryogenic temperature and cause beam instabilities. HOM couplers are installed in the cavity beam pipes to absorb HOM energy and mitigate these effects. This thesis presents the design and optimization of several coaxial HOM couplers for the 5-cell 801.58 MHz elliptical Nb cavities of the 500 MeV PERLE ERL configuration. The RF transmission of the HOM couplers was optimized to enhance the damping of the most dangerous HOMs. The optimized HOM couplers were integrated into endgroups to simulate their damping performance and thermal behavior. The optimized HOM couplers were 3D-printed in epoxy and copper-coated. Low-power RF measurements were conducted on the produced HOM couplers installed in copper PERLE-type cavities to validate their damping performance and propose several endgroups for the PERLE 5-cell cavity to mitigate HOMs below the BBU instability limits.

Barbagallo, Carmelo↗

DOE OSTI2022

Optimization of gold germanium (Au 0.17 Ge 0.83 ) thin films for high sensitivity resistance thermometry

Gold–germanium (Au x Ge 1–x ) solid solutions have been demonstrated as highly sensitive thin film thermometers for cryogenic applications. However, little is known regarding the performance of the films for thicknesses less than 100 nm. In response, here we report on the resistivity and temperature coefficient of resistance (TCR) for sputtered films with thicknesses ranging from 10 to 100 nm and annealed at temperatures from 22 to 200°C. The analysis is focused upon composition x=0.17, which demonstrates a strong temperature sensitivity over a broad range. The thinnest films are found to provide an enhancement in TCR, which approaches 20% K –1 at 10 K. Furthermore, reduced anneal temperatures are required to crystallize the Ge matrix and achieve a maximum TCR for films of reduced thickness. These features favor the application of ultra-thin films as high-sensitivity, on-device thermometers in micro- and nanolectromechanical systems.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

THESEUS: A techno-economic design, integration and downselection framework for energy storage

Optimal selection of energy storage technologies is critical to ensure reliable integration of intermittent and often uncertain renewable energy in electricity grids. The consideration of a diverse set of energy storage technologies is required for a more sustainable deployment of energy storage. We present THESEUS (TecHno-Economic framework for Systematic Energy storage Utilization and downSelection), which is a comprehensive framework for the optimal selection, design and operation of energy storage systems. THESEUS includes rigorous models of major energy storage technologies at different maturity levels, such as thermal storage using phase-change materials or molten salt, cryogenic storage, mechanical storage in the form of compressed air and pumped hydro storage, chemical storage using hydrogen, and electrochemical storage in the form of lithium-ion, sodium sulfur and vanadium flow batteries. An illustrative case study on state-wide prospective energy storage shows that storage integration with fossil power plants could reduce the cost of meeting the grid energy demand by 20%, with mechanical storage as the best suited technology. Although high-temperature thermal storage has low storage efficiency, it is optimal for integration with renewable energy plants. In addition, Li-ion batteries are optimal for high ramping but low storage duration requirements. Furthermore, such insights can enable the deployment of both existing and emerging energy storage technologies to facilitate a smooth transition to a clean energy future.

25 ENERGY STORAGE↗

DOE OSTI2024

Exergetic design and analysis of a freeze-out heat exchanger for helium purification

The freeze-out purification process is very effective in removing moisture contamination and can be utilised for purification of helium gas in cryogenic applications. A process model for a freeze-out helium purifier (up to 30 g/s of contaminated helium at 10 ppmv) with a coiled finned-tube heat exchanger is developed. Furthermore, an extensive 1st and 2nd law (exergy) analysis is carried out and the exergetically optimal heat exchanger configuration (diameter and number of flow passes) for a given heat exchanger surface area ranging from 42.5 m 2 to 57.5 m 2 are found.

cryogenics↗

DOE OSTI2026

Reconstruction of cosmic-ray muon events with CUORE

We report the in-situ 3D reconstruction of through-going muons in the CUORE experiment, a cryogenic calorimeter array searching for neutrinoless double beta (0vββ) decay, leveraging the segmentation of the detector. Due to the slow time response of the detector, time-of-flight estimation is not feasible. Therefore, the track reconstruction is performed using a multi-objective optimization algorithm that relies on geometrical information from the detector as a whole. We measure the integral flux of cosmic-ray muons underground at the Laboratori Nazionali del Gran Sasso, and find our value to be in good agreement with other experiments that have performed a similar measurement. To our knowledge, this work represents the first demonstration of 3D particle tracking and reconstruction of through-going muons with per-event angular determination in a millikelvin cryogenic detector array. The analysis performed for this work will be critical for validating the muon-related background in CUPID, a next-generation 0vββ experiment, and for follow-up studies on detector response and on delayed products induced by cosmic-ray muons.

Adams, D. Q. [University of South Carolina]↗

DOE OSTI2023

Selective and Scalable Control of Spin Quantum Memories in a Photonic Circuit

A central goal in many quantum information processing applications is a network of quantum memories that can be entangled with each other while being individually controlled and measured with high fidelity. This goal has motivated the development of programmable photonic integrated circuits (PICs) with integrated spin quantum memories using diamond color center spin-photon interfaces. However, this approach introduces a challenge into the microwave control of individual spins within closely packed registers. Here, we present a quantum memory-integrated photonics platform capable of (i) the integration of multiple diamond color center spins into a cryogenically compatible, high-speed programmable PIC platform, (ii) selective manipulation of individual spin qubits addressed via tunable magnetic field gradients, and (iii) simultaneous control of qubits using numerically optimized microwave pulse shaping. The combination of localized optical control, enabled by the PIC platform, together with selective spin manipulation opens the path to scalable quantum networks on intrachip and interchip platforms.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

The 8RH 2 Process for Producing Clean Hydrogen with Autothermal Reforming and Carbon Capture

The primary objective of this project is to demonstrate the commercial viability and environmental benefits of an 8 Rivers Hydrogen (8RH 2 ) process, a proprietary technology developed to optimally produce high-purity blue H 2 with up to 99% carbon capture. This 8RH 2 process is particularly notable for its integration of a low-energy cryogenic CO 2 separation system that not only maximizes hydrogen recovery but also minimizes the carbon footprint of the operation. This aligns with global environmental goals and supports the United States' push toward energy sustainability and independence.

03 NATURAL GAS↗

DOE OSTI2025

Helium recovery system at IB3A

The growing demand for sustainable cryogenic operations at Fermilab has underscored the need to improve helium management, particularly at the Industrial Building 3A (IB3A) test facility. IB3A characterizes and tests superconductors, cables, and coils for projects such as the HL-LHC AUP and Mu2e, yet currently relies on 500 L Dewars whose boil-off is vented to atmosphere, wasting a critical, non-renewable resource and increasing the cost of testing. A project is therefore under way to link IB3A to an existing purification and liquefaction station in a neighboring building through a dedicated pipeline. Captured helium will be transferred, purified, reliquefied, and returned for reuse, cutting losses and operating costs. This paper details the first two project phases: "Design and Engineering" and "Procurement and Installation." The design phase finalizes pipeline specifications, establishes flow-control requirements, and resolves integration challenges with existing cryogenic infrastructure. The procurement and installation phase covers material sourcing, pipeline construction, and deployment of control and monitoring systems to assure reliable, efficient operation. Key technical hurdles-route optimization, pressure drop mitigation, and interface compatibility-are discussed alongside implemented solutions. Implementing the pipeline and upgrading IB3A will dramatically reduce helium consumption and therefore testing cost, strengthening Fermilab's capacity to support frontier science far into the future.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗

DOE OSTI2024

Optimizing the Heisenberg Vortex Tube for Hydrogen Cooling (Final Technical Report)

Hydrogen utilization at Plug Power sites ranges between 70-93% with the remainder vented and lost to the atmosphere. The goal of this project was to improve hydrogen utilization at Plug Power fulfillment centers via the patented Heisenberg vortex tube (HVT). The HVT combines conventional counterflow vortex tubes with para-orthohydrogen conversion catalyst to allow the cooling of hydrogen flows with no moving parts or external energy inputs. In year 1 of this project the HVT was evaluated to improve hydrogen utilization via the following concepts: 1) increasing liquid hydrogen pump volumetric efficiency by 20% through vapor separation and subcooling of the liquid, 2) reducing liquid hydrogen storage tank boil-off losses by 20% through thermal vapor shielding (TVS), and 3) increase isentropic efficiency of supercritical hydrogen expansion at 40-50 K, from 31% to over 40%. The TVS concept was selected as the most favorable application for further development. While the conceptual analysis was underway, the cryocatalysis hydrogen experiment facility (CHEF) was retrofitted with a new cryocooler, higher pressure condenser tanks, and in-situ fiber-optic Raman probes for ortho-parahydrogen composition analysis at the inlets and outlets of the HVT. To our knowledge this is the first in-situ implementation of cryogenic Raman probes for ortho-parahydrogen analysis. Subsequent testing of catalyzed and non-catalyzed HVT identified a low flow rate, high-conversion efficacy regime well suited for TVS development. Computational fluid dynamics (CFD), Reduced order modeling (ROM), and quantum Monte Carlo atomistic simulations were applied to optimize the design of the HVT implemented for TVS. The simulations and analysis identified a ruthenium-based catalyst as the most optimal for high conversion with little pressure losses and was matched to experimental measurements. These results indicated the design could achieve the 20% boil-off reduction target. An HVT field-trial was designed and constructed by Plug Power and implemented at a customer site. However, budget limitations reduced the amount of catalyst that could be applied to the HVT. With the reduced amount of catalyst, CFD analysis estimated about 3% reduction in boil-off. A similar amount of boil-off reduction was observed during preliminary measurements during tank commissioning. However, the results have a large margin for error and were operated at relatively low tank temperatures when the HVT has the lowest potential for improvement. This project demonstrated the use of para-orthohydrogen catalysis for reducing liquid hydrogen tank boil-off losses. The field trial system is anticipated to provide long-term experimental measurements on tank operational performance that will allow Plug Power to instrument additional tanks in the future. Recommendations for future work include the development of higher activity, lower cost para-orthohydrogen conversion catalyst for use in the HVT. Tank process optimizations could maximize the efficacy of the HVT and further improve hydrogen utilization.

08 HYDROGEN↗

DOE OSTI2022

Strong and ductile FeNiCoAl-based high-entropy alloys for cryogenic to elevated temperature multifunctional applications

The highly tunable properties of multi-principal element alloys, commonly known as high-entropy alloys (HEAs), provide a remarkable potential for the development of superior materials for critical structural applications that involve extreme conditions. However, the optimization of the properties of HEAs has been primarily limited to behavior at either low or high temperatures. We report on a non-equiatomic, heterostructured, high-entropy alloy FeNiCoAlTaB which possesses remarkable combinations of mechanical properties across a wide range of temperatures from 77 K to 1073 K. The current metastable alloy presents good ductility and superior engineering tensile strengths of 2.2 GPa, 1.4 GPa, 800 MPa, and 500 MPa at 77 K, 298 K, 873 K, and 1073 K, respectively. This behavior is achieved by a synergic sequence of individual mechanisms that are activated at different temperatures. The alloy even displays pseudoelasticity at 77 K with an applied load up to 2 GPa. This work provides a methodology for tailoring structural heterogeneity and metastability in the design and fabrication of multifunctional HEAs that will outperform known metals and alloys over a wide range of temperatures.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Extracellular filaments revealed by affinity capture cryogenic-electron tomography

Cryogenic-electron tomography (cryo-ET) has provided an unprecedented glimpse into the nanoscale architecture of cells by combining cryogenic preservation of biological structures with electron tomography. Micropatterning of extracellular matrix proteins is increasingly used as a method to prepare adherent cell types for cryo-ET as it promotes optimal positioning of cells and subcellular regions of interest for vitrification, cryo-focused ion beam (cryo-FIB) milling, and data acquisition. Here we demonstrate a micropatterning workflow for capturing minimally adherent cell types, human T cells and Jurkat cells, for cryo-FIB and cryo-ET. Our affinity capture system facilitated the nanoscale imaging of Jurkat cells, revealing extracellular filamentous structures. It improved workflow efficiency by consistently producing grids with a sufficient number of well-positioned cells for an entire cryo-FIB session. Affinity capture can be extended to facilitate high-resolution imaging of other adherent and non-adherent cell types with cryo-ET.

Biochemistry↗

DOE OSTI2024

Conceptual Structural Design and Analysis of a 20 T Hybrid Cos Dipole for Future Particle Colliders

Here, to reach high collision energy for future high-energy particle colliders, like the Future Circular Collider (FCC) or the Muon Collider, it is required to achieve high field strength of the bending dipoles. Currently, the practical limit for Nb$_{\text{3}}$ Sn technology is around 16 T and, in order to further increase the magnetic field, the superconducting magnet community is considering High Temperature Superconductors (HTS), in particular Bi-2212 and REBCO conductors. However, their relevant higher cost has led the community to consider a hybrid approach where HTS materials are used in the high field region of the coils with so-called insert coils, and Low Temperature Superconductors are involved in the lower field part ($< $ 16 T) with so-called outsert coils. This paper describes the conceptual mechanical design of a 20 T hybrid cos$\theta$ dipole configuration. The high stress levels that the structure is facing due to the high magnetic field are discussed. Moreover, it presents the results of the optimization analysis of the shell-based support structure based on the key-and-bladder technology that provides the azimuthal pre-stress during room temperature assembly and cooldown to cryogenic temperatures. The aim of this work is to present a feasible design that satisfies the stress requirements.

D'Addazio, Marika [Politecnico di Torino (Italy); ↗