Results for “robust parameter design” — Page 3

DOE OSTI2022

Designer Metasurfaces for Antireflective Applications Enabled by Advanced Nanoparticle Technology

Optic processing advances have shifted system limitations, with current constraints consisting of antireflective (AR) coatings applied to optics and the inability to reduce size, weight, and price. Metasurfaces, and more broadly metaoptics, provide an avenue to overcome these limitations. The ability to generate substrate-engraved metasurfaces that can be tailored is demonstrated within a broad design space to satisfy large-area AR applications for bandpass or broadband needs, demonstrating an optically equivalent surface roughness standard deviation of only 5 Å. Using an advanced nanoparticle masking approach, two metasurfaces are fabricated: 1) vertical sidewall nanofeature metasurface (MS) for AR applications at 351 nm, and 2) sloped sidewall MS designed for broadband AR applications. For the 351 nm MS, the reflectance is measured to be 0.127%. In the case of the sloped sidewall MS, the reflectance is measured to be <0.25% over 400–700 nm and <1% over 400–1100 nm. To the best of the authors’ knowledge, this is the first demonstration of a broadband AR capable of this performance. The tunability of these structures, with a parameter space spanning even more remarkable designs such as broader bands and acceptance angles, coupled with high laser-induced damage durability and mechanical robustness, displays the strength of metasurfaces for AR applications.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Absolute Neutron Rate Measurement and Non-Thermal/Thermonuclear Fusion Differentiation

The goal of fusion energy is to produce significantly more energy from fusion reactions than is input into the device. One of the products of fusion reactions is neutrons, which, due to their lack of charge, provide a unique view into the parameters of the device. Lawrence Livermore National Laboratory (LLNL) in collaboration with the University of California, Berkeley (UCB) have designed, assembled, and fielded a robust and portable neutron detection system known as PANDA (Portable and Adaptable Neutron Diagnostics for ARPA-E). This detector suite consists of three LaBr activation detectors that are calibrated to give a total neutron yield on shot, and twenty-four scintillators coupled to photo-multiplier tubes (SPMT). The SPMTs can be configured to attain spatial, temporal and/or energy information from fusion neutrons. The system was designed to be portable and is compartmentalized so that individual components can be used at different fusion facilities. During the duration of this work, part of the system was installed at the FuZE facility, a part of Zap Energy. Another component was installed that the CESZAR facility at the University of California, San Diego (UCSD) to support experiments by Magneto-Inertial Fusion Technologies, Inc. (MIFTI). The diagnostics were successful at both locations and the LLNL/UCB team supported the data analysis by creating and running analysis scripts and Monte-Carlo calculations. At Zap Energy the diagnostics demonstrated that the fusion from the FuZE device is thermonuclear in nature, a result that resulted in an invited talk at the American Physical Society Division of Plasma Physics and an invited paper. Additionally, temporal and spatial data was taken using the SPMTs to understand the duration and length of fusion production. At UCSD the neutron yield from the diagnostics was used to show improvements to fusion yields on their gas puff Z-pinch when using a gas shell surrounding the fuel. The success in this diagnostic has led to continued work at both Zap Energy and MIFTI, as well as follow on funding and interest at other fusion energy companies.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Enhancing Sterile Neutrino Oscillation Sensitivities using SBND-PRISM at the Short-Baseline Neutrino Programme

The Short-Baseline Neutrino (SBN) Programme at Fermilab is comprised of two detectors, SBND and ICARUS, placed at $110$\,m and $600$\,m along the Booster Neutrino Beam at Fermilab. The key physics aim of the programme is to definitively test the sterile neutrino hypothesis, a proposed fourth flavour of neutrino that may explain certain experimental anomalies seen regarding standard model neutrino oscillations. To be able to detect the existence of sterile neutrinos, the uncertainties of the programme must be well constrained. To enable this, a robust analysis must be constructed that can consistently identify the correct values of systematic parameters and generate accurate predictions of what the neutrino energy spectrum at ICARUS should look like. SBND's design allows for the introduction of a technique called PRISM. In PRISM, the detector is divided into regions of different off axis angles from the beam, forming different samples where systematics impact each one in a distinct way. This allows any fits performed to obtain a better understanding of the correct value of the systematic parameters. The first analysis included in this thesis focuses on the improvements seen to the sensitivity of SBN to sterile oscillation parameters when using a PRISM configuration instead of treating SBND as a single whole. Focusing on the $5\sigma$ exclusion contour from the $\numu$ disappearance channel using three PRISM samples, an improvement on the order of $30$\,\% is seen, extending the parameter space for which the null hypothesis can be excluded. This thesis also presents a series of mock data studies comparing the abilities of SBND and PRISM analyses, concluding that in the case of simple changes between Monte Carlo (MC) and data, PRISM produces predictions of the ICARUS event rate spectrum that are more accurate and have smaller uncertainties. When moving to more realistic mock data, using different models to create the mock data than were used for the MC, the postfit predictions at ICARUS had a smaller difference between the postfit and mock data reconstructed energy spectra across all mock data samples tested. Finally, a covariance matrix defined by the maximum discrepancy between the postfit and mock data spectra at ICARUS from each of the SBND and PRISM fits across all the samples was constructed. The resultant $1\sigma$ fractional error induced by this bias systematic on the postfit spectrum has a smaller magnitude for PRISM than SBND, with the improvements ranging from $2.21$\,\% to $6.26$\,\% depending on the mock data samples. This summarises the reduction in systematic error when using PRISM instead of treating SBND as a single detector. *************************************** AUTHOR = Slater, Bethany University of Liverpool b.slater2@liverpool.ac.uk TITLE = Enhancing Sterile Neutrino Oscillation Sensitivities using SBND-PRISM at the Short-Baseline Neutrino Programme PAGES = 218 NOTE = Ph.D. University of Liverpool March 2026 ABSTRACT = The Short-Baseline Neutrino (SBN) Programme at Fermilab is comprised of two detectors, SBND and ICARUS, placed at $110$\,m and $600$\,m along the Booster Neutrino Beam at Fermilab. The key physics aim of the programme is to definitively test the sterile neutrino hypothesis, a proposed fourth flavour of neutrino that may explain certain experimental anomalies seen regarding standard model neutrino oscillations. To be able to detect the existence of sterile neutrinos, the uncertainties of the programme must be well constrained. To enable this, a robust analysis must be constructed that can consistently identify the correct values of systematic parameters and generate accurate predictions of what the neutrino energy spectrum at ICARUS should look like. SBND's design allows for the introduction of a technique called PRISM. In PRISM, the detector is divided into regions of different off axis angles from the beam, forming different samples where systematics impact each one in a distinct way. This allows any fits performed to obtain a better understanding of the correct value of the systematic parameters. The first analysis included in this thesis focuses on the improvements seen to the sensitivity of SBN to sterile oscillation parameters when using a PRISM configuration instead of treating SBND as a single whole. Focusing on the $5\sigma$ exclusion contour from the $\numu$ disappearance channel using three PRISM samples, an improvement on the order of $30$\,\% is seen, extending the parameter space for which the null hypothesis can be excluded. This thesis also presents a series of mock data studies comparing the abilities of SBND and PRISM analyses, concluding that in the case of simple changes between Monte Carlo (MC) and data, PRISM produces predictions of the ICARUS event rate spectrum that are more accurate and have smaller uncertainties. When moving to more realistic mock data, using different models to create the mock data than were used for the MC, the postfit predictions at ICARUS had a smaller difference between the postfit and mock data reconstructed energy spectra across all mock data samples tested. Finally, a covariance matrix defined by the maximum discrepancy between the postfit and mock data spectra at ICARUS from each of the SBND and PRISM fits across all the samples was constructed. The resultant $1\sigma$ fractional error induced by this bias systematic on the postfit spectrum has a smaller magnitude for PRISM than SBND, with the improvements ranging from $2.21$\,\% to $6.26$\,\% depending on the mock data samples. This summarises the reduction in systematic error when using PRISM instead of treating SBND as a single detector.

Slater, Bethany [Liverpool U.]↗

DOE OSTI2026

Enhancing Sterile Neutrino Oscillation Sensitivities using SBND-PRISM at the Short-Baseline Neutrino Programme

The Short-Baseline Neutrino (SBN) Programme at Fermilab is comprised of two detectors, SBND and ICARUS, placed at $110$\,m and $600$\,m along the Booster Neutrino Beam at Fermilab. The key physics aim of the programme is to definitively test the sterile neutrino hypothesis, a proposed fourth flavour of neutrino that may explain certain experimental anomalies seen regarding standard model neutrino oscillations. To be able to detect the existence of sterile neutrinos, the uncertainties of the programme must be well constrained. To enable this, a robust analysis must be constructed that can consistently identify the correct values of systematic parameters and generate accurate predictions of what the neutrino energy spectrum at ICARUS should look like. SBND's design allows for the introduction of a technique called PRISM. In PRISM, the detector is divided into regions of different off axis angles from the beam, forming different samples where systematics impact each one in a distinct way. This allows any fits performed to obtain a better understanding of the correct value of the systematic parameters. The first analysis included in this thesis focuses on the improvements seen to the sensitivity of SBN to sterile oscillation parameters when using a PRISM configuration instead of treating SBND as a single whole. Focusing on the $5\sigma$ exclusion contour from the $\numu$ disappearance channel using three PRISM samples, an improvement on the order of $30$\,\% is seen, extending the parameter space for which the null hypothesis can be excluded. This thesis also presents a series of mock data studies comparing the abilities of SBND and PRISM analyses, concluding that in the case of simple changes between Monte Carlo (MC) and data, PRISM produces predictions of the ICARUS event rate spectrum that are more accurate and have smaller uncertainties. When moving to more realistic mock data, using different models to create the mock data than were used for the MC, the postfit predictions at ICARUS had a smaller difference between the postfit and mock data reconstructed energy spectra across all mock data samples tested. Finally, a covariance matrix defined by the maximum discrepancy between the postfit and mock data spectra at ICARUS from each of the SBND and PRISM fits across all the samples was constructed. The resultant $1\sigma$ fractional error induced by this bias systematic on the postfit spectrum has a smaller magnitude for PRISM than SBND, with the improvements ranging from $2.21$\,\% to $6.26$\,\% depending on the mock data samples. This summarises the reduction in systematic error when using PRISM instead of treating SBND as a single detector. *************************************** AUTHOR = Slater, Bethany University of Liverpool b.slater2@liverpool.ac.uk TITLE = Enhancing Sterile Neutrino Oscillation Sensitivities using SBND-PRISM at the Short-Baseline Neutrino Programme PAGES = 218 NOTE = Ph.D. University of Liverpool March 2026 ABSTRACT = The Short-Baseline Neutrino (SBN) Programme at Fermilab is comprised of two detectors, SBND and ICARUS, placed at $110$\,m and $600$\,m along the Booster Neutrino Beam at Fermilab. The key physics aim of the programme is to definitively test the sterile neutrino hypothesis, a proposed fourth flavour of neutrino that may explain certain experimental anomalies seen regarding standard model neutrino oscillations. To be able to detect the existence of sterile neutrinos, the uncertainties of the programme must be well constrained. To enable this, a robust analysis must be constructed that can consistently identify the correct values of systematic parameters and generate accurate predictions of what the neutrino energy spectrum at ICARUS should look like. SBND's design allows for the introduction of a technique called PRISM. In PRISM, the detector is divided into regions of different off axis angles from the beam, forming different samples where systematics impact each one in a distinct way. This allows any fits performed to obtain a better understanding of the correct value of the systematic parameters. The first analysis included in this thesis focuses on the improvements seen to the sensitivity of SBN to sterile oscillation parameters when using a PRISM configuration instead of treating SBND as a single whole. Focusing on the $5\sigma$ exclusion contour from the $\numu$ disappearance channel using three PRISM samples, an improvement on the order of $30$\,\% is seen, extending the parameter space for which the null hypothesis can be excluded. This thesis also presents a series of mock data studies comparing the abilities of SBND and PRISM analyses, concluding that in the case of simple changes between Monte Carlo (MC) and data, PRISM produces predictions of the ICARUS event rate spectrum that are more accurate and have smaller uncertainties. When moving to more realistic mock data, using different models to create the mock data than were used for the MC, the postfit predictions at ICARUS had a smaller difference between the postfit and mock data reconstructed energy spectra across all mock data samples tested. Finally, a covariance matrix defined by the maximum discrepancy between the postfit and mock data spectra at ICARUS from each of the SBND and PRISM fits across all the samples was constructed. The resultant $1\sigma$ fractional error induced by this bias systematic on the postfit spectrum has a smaller magnitude for PRISM than SBND, with the improvements ranging from $2.21$\,\% to $6.26$\,\% depending on the mock data samples. This summarises the reduction in systematic error when using PRISM instead of treating SBND as a single detector.

Slater, Bethany [Liverpool U.]↗

DOE OSTI2026

Enhancing Sterile Neutrino Oscillation Sensitivities using SBND-PRISM at the Short-Baseline Neutrino Programme

The Short-Baseline Neutrino (SBN) Programme at Fermilab is comprised of two detectors, SBND and ICARUS, placed at $110$\,m and $600$\,m along the Booster Neutrino Beam at Fermilab. The key physics aim of the programme is to definitively test the sterile neutrino hypothesis, a proposed fourth flavour of neutrino that may explain certain experimental anomalies seen regarding standard model neutrino oscillations. To be able to detect the existence of sterile neutrinos, the uncertainties of the programme must be well constrained. To enable this, a robust analysis must be constructed that can consistently identify the correct values of systematic parameters and generate accurate predictions of what the neutrino energy spectrum at ICARUS should look like. SBND's design allows for the introduction of a technique called PRISM. In PRISM, the detector is divided into regions of different off axis angles from the beam, forming different samples where systematics impact each one in a distinct way. This allows any fits performed to obtain a better understanding of the correct value of the systematic parameters. The first analysis included in this thesis focuses on the improvements seen to the sensitivity of SBN to sterile oscillation parameters when using a PRISM configuration instead of treating SBND as a single whole. Focusing on the $5\sigma$ exclusion contour from the $\numu$ disappearance channel using three PRISM samples, an improvement on the order of $30$\,\% is seen, extending the parameter space for which the null hypothesis can be excluded. This thesis also presents a series of mock data studies comparing the abilities of SBND and PRISM analyses, concluding that in the case of simple changes between Monte Carlo (MC) and data, PRISM produces predictions of the ICARUS event rate spectrum that are more accurate and have smaller uncertainties. When moving to more realistic mock data, using different models to create the mock data than were used for the MC, the postfit predictions at ICARUS had a smaller difference between the postfit and mock data reconstructed energy spectra across all mock data samples tested. Finally, a covariance matrix defined by the maximum discrepancy between the postfit and mock data spectra at ICARUS from each of the SBND and PRISM fits across all the samples was constructed. The resultant $1\sigma$ fractional error induced by this bias systematic on the postfit spectrum has a smaller magnitude for PRISM than SBND, with the improvements ranging from $2.21$\,\% to $6.26$\,\% depending on the mock data samples. This summarises the reduction in systematic error when using PRISM instead of treating SBND as a single detector. *************************************** AUTHOR = Slater, Bethany University of Liverpool b.slater2@liverpool.ac.uk TITLE = Enhancing Sterile Neutrino Oscillation Sensitivities using SBND-PRISM at the Short-Baseline Neutrino Programme PAGES = 218 NOTE = Ph.D. University of Liverpool March 2026 ABSTRACT = The Short-Baseline Neutrino (SBN) Programme at Fermilab is comprised of two detectors, SBND and ICARUS, placed at $110$\,m and $600$\,m along the Booster Neutrino Beam at Fermilab. The key physics aim of the programme is to definitively test the sterile neutrino hypothesis, a proposed fourth flavour of neutrino that may explain certain experimental anomalies seen regarding standard model neutrino oscillations. To be able to detect the existence of sterile neutrinos, the uncertainties of the programme must be well constrained. To enable this, a robust analysis must be constructed that can consistently identify the correct values of systematic parameters and generate accurate predictions of what the neutrino energy spectrum at ICARUS should look like. SBND's design allows for the introduction of a technique called PRISM. In PRISM, the detector is divided into regions of different off axis angles from the beam, forming different samples where systematics impact each one in a distinct way. This allows any fits performed to obtain a better understanding of the correct value of the systematic parameters. The first analysis included in this thesis focuses on the improvements seen to the sensitivity of SBN to sterile oscillation parameters when using a PRISM configuration instead of treating SBND as a single whole. Focusing on the $5\sigma$ exclusion contour from the $\numu$ disappearance channel using three PRISM samples, an improvement on the order of $30$\,\% is seen, extending the parameter space for which the null hypothesis can be excluded. This thesis also presents a series of mock data studies comparing the abilities of SBND and PRISM analyses, concluding that in the case of simple changes between Monte Carlo (MC) and data, PRISM produces predictions of the ICARUS event rate spectrum that are more accurate and have smaller uncertainties. When moving to more realistic mock data, using different models to create the mock data than were used for the MC, the postfit predictions at ICARUS had a smaller difference between the postfit and mock data reconstructed energy spectra across all mock data samples tested. Finally, a covariance matrix defined by the maximum discrepancy between the postfit and mock data spectra at ICARUS from each of the SBND and PRISM fits across all the samples was constructed. The resultant $1\sigma$ fractional error induced by this bias systematic on the postfit spectrum has a smaller magnitude for PRISM than SBND, with the improvements ranging from $2.21$\,\% to $6.26$\,\% depending on the mock data samples. This summarises the reduction in systematic error when using PRISM instead of treating SBND as a single detector.

Slater, Bethany [Liverpool U.]↗

DOE OSTI2023

Numerical study of proppant transport and settling processes in fractures

Reservoir stimulation by creating hydraulically conductive fractures is the key step for enabling enhanced geothermal systems (EGS). The effectiveness of stimulation is significantly influenced by the deposition of proppant inside induced fractures. The transportation and settling of proppant in a propagating fracture is controlled by a multitude of operational and physical parameters, including the fracturing fluid rheology, injection rate, proppant concentration, fracture length/aperture evolution, proppant size/density/shape, etc. A numerical tool that robustly and efficiently accounts for all important attributes can facilitate the design and optimization of reservoir stimulation. This study presents the novel computational tool ELK (ELectrical fracKing) developed for the numerical simulation of proppant-fluid mixture circulation in a fractured geothermal reservoir. We enriched the MOOSE-based PorousFlow module with a suite of equations to consider the fluid-proppant mixture with particle-particle/fluid interactions, which include gravitational settling, particle convection, particle hampering, and strong density and viscosity contrasts. The computational tool is validated by comparing the predicted proppant bed evolution against two different laboratory scale experiments of proppant transport in a fixed aperture channel. Further parameter studies were performed, and the modeling results show that the proppant deposition is determined by the mixing characteristics and settling of the particles from the slurry. Concentration-dependent density and viscosity lead to an inhomogeneous distribution of the proppant, particle collision, and enhanced settling at the bottom of the fractures. Preliminary coupling with dynamic fracture propagation shows promising results and will be further developed to simulate hydraulic stimulation at high fidelity.

15 GEOTHERMAL ENERGY↗

DOE OSTI2026

A robust alloy design (RAD) strategy for next-generation (IV) nuclear fission reactors

Next-generation nuclear reactors demand structural materials capable of withstanding extreme conditions, including high temperatures, intense neutron flux, and corrosive environments. Multi-Principal Element Alloys (MPEAs) have emerged as promising candidates due to their exceptional radiation tolerance, thermal stability, and compositional flexibility. This study introduces a versatile and customizable Robust Alloy Design (RAD) strategy for systematically designing MPEAs for GEN-IV reactor fuel cladding. The RAD framework integrates nuclear-relevant selection criteria, empirical parameter assessments, and high-throughput CALPHAD simulations to efficiently narrow compositional space and identify stable alloys. A unified RAD score developed for the first time, combines key performance metrics, including fuel-clad chemical interaction (FCCI), neutron absorption cross-section (NAC), valence electron configuration (VEC), and melting point factor (MPF), into a flexible ranking system adaptable to reactor-specific priorities. Among 724 candidates, V555(5Al–5Cr–5Fe–85V) emerged as the top alloy, validated experimentally with a homogeneous single-phase BCC microstructure and superior mechanical properties (nano-indentation: 3.389 ± 0.258 GPa; Vickers hardness: 240 ± 6.7 HV), significantly outperforming Zircaloy-4 and V-4Cr-4Ti. Importantly, the RAD strategy is not limited to nuclear applications; its customizable weighting system enables scalability to other extreme environments. This adaptability positions RAD strategy as a versatile tool for advanced materials design across multiple industries.

Alloy design↗

DOE OSTI2022

Optimized Test Section for Helium Flow Loop Experiment

Phase 3 of this project uses the knowledge and techniques gained from Phase 1 and Phase 2. The first outcome of Phase 3 is a new test section which can be manufactured and tested in the Helium Flow Loop Experiment to verify the results of the optimization study. The second outcome of Phase 3 is analyzing the features of this design and determining its performance under simulated TBM conditions: heat flux, pressure, mass flow rate, one-sided and volumetric heating. This will be accomplished by first using the results from the Phase 1 analyses and then applying the optimization strategy from Phase This phase uses the STAR-CCM+ Design Manager tool to apply the optimization strategy to the Helium Flow Loop Experiment (HFLE). The optimization algorithm used by the Design Manager tool is Simultaneous Hybrid Exploration that is Robust, Progressive, and Adaptive (SHERPA search algorithm). In addition to demonstrating the optimization features, a simple parameter sweep is also included in this phase. This report details the applied single objective optimization.

42 ENGINEERING↗

DOE OSTI2024

Human-Machine Shared Control for Path Following Considering Driver Fatigue Characteristics

Fatigue driving has been regarded as one of the most important factors that cause traffic accidents. This paper proposes a robust human-machine shared control strategy to improve the vehicle performance for different driver fatigue states. Firstly, the time-varying driver steering model is proposed to address the model mismatch caused by fatigue driving. And the driver fatigue evaluation system is established based on facial features to quantify driver fatigue levels. Based on the quantified fatigue levels, a novel strategy for allocating authorities of the driver and controller is developed for building the driver-vehicle interaction system. Then, to weaken the influence of parameter perturbations caused by the time-varying driver states, we design a fatigue-based shared controller through state feedback. The actuator saturation and system constraints are considered in the controller design through the robust set-invariance property to improve vehicle safety and driving comfort. The driver-in-the-loop platform is conducted to validate the effectiveness of the proposed shared steering controller. In conclusion, the experimental results show that the proposed strategy can adaptively optimize the human-machine authorities according to fatigue states and comprehensively improve vehicle performance.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Mitigating the Impacts of Uncertain Geomagnetic Disturbances on Electric Grids: A Distributionally Robust Optimization Approach

Severe geomagnetic disturbances (GMDs) increase the magnitude of the electric field on the Earth’s surface (E-field) and drive geomagnetically-induced currents (GICs) along the transmission lines in electric grids. These additional currents can pose severe risks, such as current distortions, transformer saturation and increased reactive power losses, each of which can lead to system unreliability. Today several mitigation actions (e.g., changing grid topology) exist that can reduce the harmful GIC effects on the grids. Making such decisions can be challenging, however, because the magnitude and direction of the E-field are uncertain and non-stationary. In this paper, we model uncertain E-fields using the distributionally robust optimization (DRO) approach that determines optimal transmission grid operations such that the worst-case expectation of the system cost is minimized. We also capture the effect of GICs on the nonlinear AC power flow equations. For solution approaches, we develop an accelerated column-and-constraint generation (CCG) algorithm by exploiting a special structure of the support set of uncertain parameters representing the E-field. Extensive numerical experiments based on “epri-21” and “uiuc-150” systems, designed for GMD studies, demonstrate (i) the computational performance of the accelerated CCG algorithm, (ii) the superior performance of distributionally robust grid operations that satisfy nonlinear, nonconvex AC power flow equations and GIC constraints, in comparison with standard stochastic programming-based methods during the out-of-sample testing.

42 ENGINEERING↗

DOE OSTI2022

Compressive properties of silicone Bouligand structures

Abstract This article presents an examination of silicone, Bouligand lattices in compression. Appearing frequently in biological organisms and manufacturing design, Bouligand structures comprise layers of parallel strands or fibers oriented in a helical fashion. They can exhibit exceptional fracture resistance when composed of rigid or composite materials. The behavior of elastomeric Bouligand structures, however, is less well understood. Additively manufactured (AM) elastomeric lattices have applications in stress mitigation, medical devices, and soft robotics. This article demonstrates that Bouligand structures are a useful addition to the design space of AM elastomers. By adjusting the layer-rotation parameters, lattice stress can increase by more than 300% without altering the porosity. Additionally, we introduce path length metrics that help explain the observed relationship between layer rotation and compression response. Impact statement Additive manufacturing (AM) continues to push the boundary of manufacturable structures and enhance the ability to robustly design for specific properties and behaviors. The more we understand the design space of a novel AM microstructure, the greater its application range. In this article, we describe the mechanical behavior of helicoidal, elastomeric lattices and introduce path length metrics to help explain their stress response. We show that these structures can exhibit a large range of mechanical behaviors in compression, making them well suited for applications such as stress mitigation and impact absorption. Additionally, the path length metrics could become useful design tools and may be applicable to a larger set of cellular structures. These findings expand our ability to rapidly design materials with highly specific and customizable properties to meet the needs of modern engineering challenges. Graphical abstract

Van Meerbeek, I. M. (ORCID:000000021258132X)↗

DOE OSTI2022

Implementation of a Model Predictive Control Strategy to Regulate Temperature Inside Plug-Flow Solar Reactor With Countercurrent Flow

Abstract Solar-driven thermochemical energy storage systems are proven to be promising energy carriers (solar fuels) to utilize solar energy by using reactive solid-state pellets. However, the production of solar fuel requires a quasi-steady-state process temperature, which represents the main challenge due to the transient nature of solar power. In this work, an adaptive model predictive controller (MPC) is presented to regulate the temperature inside a tubular solar reactor to produce solid-state solar fuel for long-term thermal storage systems. The solar reactor system consists of a vertical tube heated circumferentially over a segment of its length by concentrated solar power, and the reactive pellets (MgMn2O4) are fed from the top end and flow downwards through the heated tube. A countercurrent flowing gas supplied from the lower end interacts with flowing pellets to reduce it thermochemically at a temperature range of 1000—1500 °C. A low-order physical model was developed to simulate the dynamics of the solar reactor including the reaction kinetics, and the proposed model was validated numerically by using a 7-kW electric furnace. The numerical model then was utilized to design the MPC controller, where the control system consists of an MPC code linked to an adaptive system identification code that updates system parameters online to ensure system robustness against external disturbances (sudden change in the flow inside the reactor), model mismatches, and uncertainty. The MPC controller parameters are tuned to enhance the system performance with minimum steady-state error and overshoot. The controller is tested to track different temperature ranges between 500 °C and 1400 °C with different particles/gas mass flowrates and ramping temperature profiles. Results show that the MPC controller successfully regulated the reactor temperature within ± 1 °C of its setpoint and maintained robust performance with minimum input effort when subjected to sudden changes in the amount of flowing media and the presence of chemical reaction.

Engineering↗

DOE OSTI2026

Robustness of inertial fusion energy relevant implosions to low-mode asymmetries

Inertial confinement fusion implosions for power production need to be robust. Degradation sources need to be understood and considered for an economic power plant. In this work, the impact of low-mode asymmetries on yield is studied using 2D radiation hydrodynamics simulations for inertial fusion energy relevant implosions. First, a high-gain indirectly driven capsule design is developed. This design is subsequently degraded with low-mode drive asymmetries. The results show that yield is constant with increasing amounts of asymmetry until a cliff is reached where the yield quickly drops below ignition. Robustness arises because the degraded hotspot still has enough time to get to ignition before capsule decompression. This robustness occurs even though the asymmetry couples less energy to the hotspot and causes decompression to occur sooner. The robustness is linked to the generalized Lawson parameter, χ⁠. The value of χ steadily decreases with increasing asymmetry. Once χ is close to one, the hotspot is no longer able to ignite before the capsule decompresses. A simple piston model is used to predict where the robustness cliff is for any design. The trade-off between yield and robustness is also demonstrated.

Physics - Plasma physics↗

DOE OSTI2024

Control, Fault Management, and Grid Support Functionality of an MV AC-DC Solid State Transformer based EV Extreme Fast Charging Station

Electric vehicles (EVs) have become increasingly popular in recent times while revolutionizing the consumer and commercial transportation market. The development of charging infrastructure has become one of the priorities for increasing the adoption of EVs. Extreme fast charging (XFC) technology can reduce the so-called ’range anxiety’ of consumers as they significantly reduce the charging time. With the advent of wide band-gap (WBG) power devices and improvement in power electronic converters, medium voltage (MV) solid state transformer (SST) based XFC system has the potential to replace the traditional XFC stations because of the lower footprint, ease of installation, enhanced control feature, and better system efficiency. The control system design is one of the critical aspects of the SST development process. Careful consideration and detailed analysis are required to find out suitable control method for the SST based on its topology among different centralized and decentralized control architectures. Also, the control parameters selection and potential improvement to the transient response of the controller ought to be investigated. Another major concern of the SST is different types of internal fault which reduces the overall reliability of the XFC system. As a result, designing a robust protection system is essential. Among different fault modes, open circuit switch faults have received significant attention as an active research area because of their likelihood and severe effects on converters. Therefore, the power stages used in the XFC system require functional and accurate open circuit switch fault management methods. An equally significant aspect of this SST based XFC is its compatibility in a microgrid where there is no synchronous generator present. When the grid is not available, the XFC SSTs can provide grid forming capability and continue supplying the critical loads in islanded mode. The transition between grid connected and islanded mode, especially the grid resynchronization process has to be carefully performed for the safety of the microgrid components. The challenges posed by the aforementioned issues have inspired the work done in this dissertation. Here, a 13.2 kV, 1 MVA, AC/DC SST for the XFC system is examined and a comparative analysis is conducted to select the control architecture based on feasibility of implementation and performance. A detailed control parameter design process is demonstrated considering the sensor dynamics and delay. The selected decentralized control method is augmented by introducing a novel sensor-less load current feedforward method to provide better voltage regulation at the DC bus during a change of load. Next, in the fault management section, a hierarchical failure mode effect analysis (FMEA) is proposed to enable a systematic design of the internal fault protection of the XFC SST as there are limited examples in the literature regarding the analysis of the safety and design of the protection of a power electronic converter system. Novel open circuit switch fault management methods for the converters in the system are presented. Finally, XFC SST based MV microgrid operations in grid connected mode and islanded mode are explored. A secondary control method for grid resynchronization is presented and a design process of control parameters is shown to ensure the stability of the secondary voltage and frequency regulation.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Evaluation of Tungsten—Steel Solid-State Bonding: Options and the Role of CALPHAD to Screen Diffusion Bonding Interlayers

Critical aspects of innovative design in engineering disciplines like infrastructure, transportation, and medical applications require the joining of dissimilar materials. This study investigates the literature on solid-state bonding techniques, with a particular focus on diffusion bonding, as an effective method for establishing engineering bonds. Welding and brazing, while widely used, may pose challenges when joining materials with large differences in melting temperature and can lead to mechanical property degradation. In contrast, diffusion bonding offers a lower temperature process that relies on solid-state interactions to develop bond strength. The joining of tungsten and steel, especially for fusion reactors, presents a unique challenge due to the significant disparity in melting temperatures and the propensity to form brittle intermetallics. Here, diffusion characteristics of tungsten–steel interfaces are examined and the influence of bonding parameters on mechanical properties are investigated. Additionally, CALPHAD modeling is employed to explore joining parameters, thermal stability, and diffusion kinetics. The insights from this research can be extended to join numerous dissimilar materials for specific applications such as aerospace, automobile industry, power plants, etc., enabling advanced and robust design with high efficiency.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Secure Federated Learning Across Heterogeneous Cloud and High-Performance Computing Resources: A Case Study on Federated Fine-Tuning of LLaMA 2

Federated learning enables multiple data owners to collaboratively train robust machine learning models without transferring large or sensitive local datasets by only sharing the parameters of the locally trained models. Here, in this article, we elaborate on the design of our Advanced Privacy-Preserving Federated Learning (APPFL) framework, which streamlines end-to-end secure and reliable federated learning experiments across cloud computing facilities and high-performance computing resources by leveraging Globus Compute, a distributed function as a service platform, and Amazon Web Services. We further demonstrate the use case of APPFL in fine-tuning an LLaMA 2 7B model using several cloud resources and supercomputers.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Accelerating computational fluid dynamics simulation of post-combustion carbon capture modeling with MeshGraphNets

Packed columns are commonly used in post-combustion processes to capture CO 2 emissions by providing enhanced contact area between a CO 2 -laden gas and CO 2 -absorbing solvent. To study and optimize solvent-based post-combustion carbon capture systems (CCSs), computational fluid dynamics (CFD) can be used to model the liquid–gas countercurrent flow hydrodynamics in these columns and derive key determinants of CO 2 -capture efficiency. However, the large design space of these systems hinders the application of CFD for design optimization due to its high computational cost. In contrast, data-driven modeling approaches can produce fast surrogates to study large-scale physics problems. We build our surrogates using MeshGraphNets (MGN), a graph neural network framework that efficiently learns and produces mesh-based simulations. We apply MGN to a random packed column modeled with over 160K graph nodes and a design space consisting of three key input parameters: solvent surface tension, inlet velocity, and contact angle. Our models can adapt to a wide range of these parameters and accurately predict the complex interactions within the system at rates over 1700 times faster than CFD, affirming its practicality in downstream design optimization tasks. This underscores the robustness and versatility of MGN in modeling complex fluid dynamics for large-scale CCS analyses.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Model-informed, Adaptive Physical Vapor Deposition to Fabricate Hierarchical Binary-alloy Thin-films

Designing next generation thin films, tailor-made for specific applications, relies on the availability of robust processing-structure-property relationships. Traditional structure zone diagrams are limited to low-dimensional mappings, with machine-learning methods only recently attempting to relate multiple processing parameters to the final microstructure. Despite this progress, structure-processing relationships are unknown for processing conditions that vary during thin-film deposition, limiting the range of microstructures and properties achievable. In this project, we employed a phase-field computational model combined with a genetic algorithm (GA) to identify and design time-dependent processing protocols that achieve tailor-made microstructures. We simulate the physical vapor deposition of a binary-alloy thin film by employing a phase-field model, where deposition rates and diffusivities are controlled via the genetic algorithm. Our GA-guided protocols achieve targeted microstructures with lateral and vertical concentration modulations, as well as more complex, hierarchical microstructures previously not described in simple structure zone diagrams. Our algorithm provides insight to experimentalists looking for additional avenues to design novel thin-film microstructures.

36 MATERIALS SCIENCE↗