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DOE OSTI2022

Dynamic Measurements of the Structural Evolution of Material Defects at the Mesoscale

This is a technical report to be published as part of the FY2021 annual overview package. We have designed experiments and developed analytical methods using images from x-ray and electron microscopy in order to quantify the behavior of crystal dislocation defects at their native nanometer-length and micro-length scales. The results of these analyses are used to directly inform theoretical physics models and guide interpretation of dark field x-ray microscopy (DFXM) images that offer spatial resolution surpassing the resolution of beamline optics. Additionally, we developed new analytical methods to automate the alignment of optics hardware used in both synchrotron and x-ray free electron laser beamline facilities. The tools and workflows developed for this project are now being deployed as proof-of-concept in reaction history analysis (RHA) for future programmatic integration.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Multi-Source Machine Learning and Thermoplastics Enhanced Aerostructure Manufacturing (mTEAM)

RTX Technology Research Center (RTRC), together with Collins Aerospace (Collins) and Oak Ridge National Laboratory (ORNL) has developed an Artificial Intelligence (AI) / Machine Learning (ML) guided solution to advance the manufacturing and assembly of high performance and lightweight thermoplastic composite (TPC) aerospace products. The solution aims to lower risk, cost and lead time for induction heating based welding and consolidation processes for TPC structure. The cost and lead time of part and material specific process development for induction welding (IW) and induction consolidation will be reduced by replacing traditional empirical methods with optimization methods that merge AI/ML and physics-based process simulations and process experiments with sensing and controls. TPC-IW process development is empirical in nature, and uncertainties in material & process behavior exist near & far from the induction coil. Physics-based simulations can be leveraged directly for process optimization but can be too computationally expensive to run in high fidelity and real time to do robust process optimization. The key impact of successful TPC induction consolidation and welding is cost & lead time reduction for part & material specific consolidation and welding recipes. This is an enabler for more rapid deployment of TPC structures via joining assembly, which can reduce energy & cost intensive usage of autoclaves & ovens. The solution aimed to advance the U.S. Department of Energy’s interests in using thermoplastics and automation in composite manufacturing for improvement of products for existing markets via increased production speeds, reduced costs, and lowered use of energy. Welded TPC structures can offer significant weight & energy savings for high-value commercial aerospace & industrial applications compared to metal & thermoset composite structures assembled by mechanical fastening and/or adhesive bonding. The project was organized into two Budget Periods. Budget Period 1 (BP1) was 15 months and its goal was to perform ML process optimization framework development & deployment on lab-coupon aerostructure components. A Go/No-Go Review was performed at the end of BP1 to verify fulfilment of key tasks & milestones to justify a Go Decision to move into the next Budget Period. Budget Period 2 (BP2) was 12 months and its goal was the deployment of the ML framework for ML process optimization of pilot industrial scale aerostructure components. The overall project aim was to develop & demonstrate ML-enhanced modeling framework that learns process-property mapping from multiple data sources at different fidelities. During BP1, the team accomplished key tasks & milestones to demonstrate the concept of multi-source ML for TPC aerostructure consolidation and assembly. First, the team completed documentation of induction based TPC heating requirements including baseline metrics to compare measured results against. Next the team completed demonstration of data generation from physics-based simulations for ML surrogate model generation and demonstrated the integration of physics-based simulation data into multi-source AI/ML algorithms. In parallel, the team established the lab-coupon scale induction welding system and completed a process to label and reduce generated data from physics-based simulation and experiments for ML surrogate models to enable multi-source ML model training & testing. To complete BP1, the team integrated physics-based simulation data and experimental data into multi-source ML algorithms. This was based on the team completing ML deployment of the induction welding on a lab system at RTRC and AI/ML deployment on existing induction welding line at Collins. ORNL visited both Collins and RTRC sites to witness the TPC induction welding process. Then, ORNL designed and constructed a new version of their vision-based sensing system better adapted to acquire process signals of the TPC induction welding process for process anomaly and defect detection. In BP2, the team accomplished key tasks & milestones to scale up multi-source ML for TPC aerostructure consolidation and assembly from the lab-coupon scale to the pilot-industrial scale. In BP2, the team demonstrated real time anomaly & defect detection via experiments performed by ORNL & RTRC. The team completed ML-optimization heating trials for TPC induction consolidation at Collins, and the team confirmed pilot industrial scale experimental data from Collins was compatible with the developed ML pipeline from RTRC. The team completed sub-element scale ML process optimization demonstration at RTRC, where the team leveraged RTRC’s robotic TPC welding setup to de-risk the ML process optimization by performing ML analysis of recorded temperatures to account for complex part features. Then, the team applied its ML-derived control strategies and ML process optimization framework at Collins to the pilot-industrial scale on a demo skin-stiffener part representative of a nacelle aerostructure fan cowl section. The key innovation is the AI/ML framework enabling effective process development of high performance, lightweight, energy efficient TPCs for composite aircraft structures.

36 MATERIALS SCIENCE↗

DOE OSTI2024

In situ Synchrotron X‐ray Metrology Boosted by Automated Data Analysis for Real‐time Monitoring of Cathode Calcination

Abstract Synchrotron X‐ray‐based in situ metrology is advantageous for monitoring the synthesis of battery materials, offering high throughput, high spatial and temporal resolution, and chemical sensitivity. However, the rapid generation of massive data poses a challenge to on‐site, on‐the‐fly analysis needed for real‐time process monitoring. Here, a weighted lagged cross‐correlation (WLCC) similarity approach is presented for automated data analysis, which merges with in situ synchrotron X‐ray diffraction metrology to monitor the calcination process of the archetypal nickel‐based cathode, LiNiO 2 . The WLCC approach, incorporating variables that account for peak shifts and width changes associated with structural transformations, enables rapid extraction of phase progression within 10 seconds from tens of diffraction patterns. Details are captured, from initial precursors to intermediates and the final layered LiNiO 2 , providing information for agile on‐site adjustments during experiments and complementing post hoc diffraction analysis by offering insights into early‐stage phase nucleation and growth. Expanding this data‐powered platform paves the way for real time calcination process monitoring and control, which is pivotal to quality control in battery cathode manufacturing.

36 MATERIALS SCIENCE↗

DOE OSTI2026

PVDeg: Enhancing Usability and AI-Driven Multi-Mechanism Degradation Modeling

PVDeg version 0.7.0, released in December 2025, introduced major enhancements to improve usability and performance. This update reorganized tutorials and tool notebooks to create a more intuitive experience, enabling users to easily follow and adapt workflows for their specific analyses. In addition to structural improvements, both the notebooks and core logic underwent significant optimization for efficiency, robustness, and style. These refinements were supported by new testing frameworks built on nbval and pytest, adherence to PEP8 standards, and extensive code refactoring, which collectively simplify onboarding for new developers. Looking ahead, version 0.8.0 will deliver advanced AI-driven capabilities. The primary focus is to further develop and automate the degradation workflow, designed to analyze PV module degradation across diverse locations and system configurations. By integrating large language models (LLMs) to scan literature and compile a comprehensive database of materials and degradation rates, this feature will enable modeling of multiple materials and mechanisms within a single, streamlined workflow. Users will be able to evaluate degradation impacts on different system architectures under varying environmental conditions, facilitating informed decisions on bill-of-materials optimization for specific deployment scenarios. These advancements position PVDeg as a powerful, user-friendly tool for accelerating PV reliability research and system design.

14 SOLAR ENERGY↗

DOE OSTI2020

A Dynamic Amplitude-Correcting Gradient Estimation Technique to Align X-ray Focusing Optics

High-brightness X-rays, as produced at synchrotrons and X-ray free electron laser (XFEL) facilities, are used to characterize materials in a variety of scientific experiments. In most cases, effective use of the high-energy light requires precisely-aligned focusing optics; one example being a compound refractive lens (CRL). To align a CRL, the position and rotation must be optimized along four axes. In practice, this is a labor-intensive, time-consuming manual process that can monopolize scarce experimental time at the necessary X-ray facilities. Models of the expected Xray transmission function suggest that this task can be automated; however, the temporally-varying intensity at X-ray free electron laser facilities preclude the direct use of standard implementations of optimization solvers such as steepest descent algorithms. In this paper, we propose a novel technique to estimate the gradient of noisy functions with temporally-varying amplitudes. We construct this dynamicamplitude correction by systematically sampling a fixed central location within the standard finite difference stencil, accounting for the observed changes in time, and normalizing the difference quotients against those fluctuations. In addition to a rigorous error analysis of the sampling technique, we demonstrate its efficacy in stochastic descent optimization methods. Further, we demonstrate how this approach may be implemented to optimize X-ray focusing optics at synchrotrons or XFEL facilities

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Inaugural Technologist in Communities Scanning Tour: Automated and Electrified On-Demand Mobility (Follow-On Summary Report: April 24-25, 2023) [Slides]

In 2023, the Technologist in Communities (TIC) program hosted its inaugural scanning tour across the American Southwest, with a goal of investigating the region's leading public mobility systems and their integration with on-demand public mobility services. The scanning tour concept was inspired by and named after a U.S. Department of Transportation Federal Highway Administration practice of hosting "scanning tours," both domestically and abroad, to explore innovative transportation practices throughout the 1990s and early 2000s. Guided by the idea that "seeing is believing," scanning tours created opportunities for government and industry representatives to collectively experience new technologies and best practices firsthand. In 2023, the National Renewable Energy Laboratory (NREL) followed suit by leading the inaugural TIC scanning tour. TIC, part of the Technology Integration program within the U.S. Department of Energy's (DOE's) Vehicle Technologies Office, supports positive energy and mobility outcomes in communities across rural to urban contexts. TIC enables technical experts to work directly with leaders and stakeholders in communities and assist them in implementing promising new technologies. This first TIC scanning tour invited NREL, DOE, and industry experts to survey innovative public mobility practices and their integration into public transit systems across the Southwest. The tour's goals included examining the state of innovation in public mobility in cities, communities, and airports; facilitating collaboration between entities; and sparking potential new partnerships. The following report summarizes key findings from the scanning tour.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Automated Approach to Accurate, Precise, and Fast Detector Simulation and Reconstruction

Detector simulation and reconstruction are a significant computational bottleneck in particle physics. Here, we develop particle-flow neural-assisted simulations (parnassus) to address this challenge. Our deep learning model takes as input a point cloud (particles impinging on a detector) and produces a point cloud (reconstructed particles). By combining detector simulations and reconstruction into one step, we aim to minimize resource utilization and enable fast surrogate models suitable for application both inside and outside large collaborations. We demonstrate this approach using a publicly available dataset of jets passed through the full simulation and reconstruction pipeline of the Compact Muon Solenoid (CMS) experiment. We show that parnassus accurately mimics the CMS particle flow algorithm on the (statistically) same events it was trained on and can generalize to jet momentum and type outside of the training distribution.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2026

Delivery Ring Spill Characterization and Impulse Study

High-intensity particle physics experiments require uniform beam extraction to prevent instantaneous rate spikes from overwhelming detector systems. By analyzing accelerator parameters and extracted beam dynamics, we directly inform spill regulation systems that make real-time adjustments to minimize non-uniformity. This Department of Energy Visiting Faculty Program project transitioned from characterizing Main Injector half-integer slow extraction for SpinQuest to Delivery Ring third-integer slow extraction for Mu2e. Working alongside the Fast Adaptive Neural Control (FANC) group, we developed an automated pipeline that aligns asynchronous instrument channels, embeds quality metrics, and isolates clean spill populations. Analyzing baseline spills alongside a dedicated quadrupole impulse study allowed us to quantify noise structures while mapping time-varying beam response and transit-delay dynamics. These empirical measurements directly ground digital twin models, supporting FANC’s deployment of real-time, FPGA-based neural network controllers in the Mu2e Spill Regulation System.

Dolen, James William [Purdue U., West Lafayette] (↗

DOE OSTI2024

Automated experimental design of safe rampdowns via probabilistic machine learning

Abstract Typically the rampdown phase of a shot consists of a decrease in current and injected power and optionally a change in shape, but there is considerable flexibility in the rate, sequencing, and duration of these changes. On the next generation of tokamaks it is essential that this is done safely as the device could be damaged by the stored thermal and electromagnetic energy present in the plasma. This works presents a procedure for automatically choosing experimental rampdown designs to rapidly converge to an effective rampdown trajectory. This procedure uses probabilistic machine learning methods paired with acquisition functions taken from Bayesian optimization. In a set of 2022 experiments at DIII-D, the rampdown designs produced by our method maintained plasma control down to substantially lower current and energy levels than are typically observed. The actions predicted by the model significantly improved as the model was able to explore over the course of the experimental campaign.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Repurposing a microfluidic formulation device for automated DNA construction

Microfluidic applications have expanded greatly over the past decade. For the most part, however, each microfluidics platform is developed with a specific task in mind, rather than as a general-purpose device with a wide-range of functionality. Here, we show how a microfluidic system, originally developed to investigate protein phase behavior, can be modified and repurposed for another application, namely DNA construction. We added new programable controllers to direct the flow of reagents across the chip. We designed the assembly of a combinatorial Golden Gate DNA library using TeselaGen DESIGN software and used the repurposed microfluidics platform to assemble the designed library from off-chip prepared DNA assembly pieces. Further experiments verified the sequences and function of the on-chip assembled DNA constructs.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

sas-temper

Modeling remains a considerable challenge for practitioners of SAXS and SANS because the materials being studied are not highly ordered, the length scales being studied are large, and the information content of the data is low. Data analysis is both challenging and time consuming. Novices often rely on the assistance of an expert, such as the instrument scientist who supported them at the facility where the experiment was performed, to analyze their data. The high flux provided by modern facilities makes it possible to study dozens of samples or sample conditions during a single trip. Ultimately, the high throughput of modern instruments limits access to instrument scientists. A bottleneck in the research effort results that reduces facility productivity. Sas-temper seeks to address this problem, as well as the intrinsic difficulties of being confident in non-linear least squared fitting of data, by providing tools that automate much of the manual process of initial data fitting and refinement, as well as by providing tools for characterizing the nature of the parameter space that fits the measured data. The tools provided by sas-temper help small-angle scattering practitioners transition data into results.

Heller, William [Oak Ridge National Lab. (ORNL), O↗

DOE OSTI2026

Best practices in software development for robust and reproducible geoscientific models based on insights from the Global Carbon Budget's dynamic vegetation models

Computational models play an increasingly vital role in scientific research by enabling the numerical simulation of complex processes. Such models are also fundamental in geosciences. For instance, they offer critical insights into the impacts of global change on the Earth system today and in the future. Beyond their value as research tools, models are also software products and should therefore adhere to certain established software engineering standards. However, scientists are rarely trained as software developers, which can lead to potential deficiencies in software quality like unreadable, inefficient, or erroneous code. The complexity of models, coupled with their integration into broader workflows, also often makes it challenging to reproduce results, evaluate processes, and build upon them. In this paper, we review the state and current practices of the development processes of the state-of-the-art land surface models used by the Global Carbon Budget. We combine the experience of modelers from the respective research groups with the expertise of software engineers from tech companies to outline key principles and tools for improving software quality in research. We explore four main areas: (1) model testing and validation, (2) scientific, technical, and user documentation, (3) version control, continuous integration, and code review, and (4) the portability and reproducibility of workflows. Our review reveals that while modeling communities are incorporating many best practices, significant room for improvement remains in areas such as automated testing, automated documentation, and reproducibility. Therefore, we here identify and promote essential software engineering practices, including numerous examples of practices from within the community that can serve as guidelines for other models and could help streamline processes across the entire community. We conclude with an open-source example implementation of these principles, demonstrating portable and reproducible data flows, a continuous integration setup, and web-based visualizations. This example may serve as a practical resource for model developers, users, and all scientists engaged in scientific programming.

Gregor, Konstantin [Technical Univ. of Munich (Ger↗

DOE OSTI2024

Fostering Geothermal Machine Learning Success: Elevating Big Data Accessibility and Automated Data Standardization in the Geothermal Data Repository: Preprint

The Department of Energy's (DOE) Geothermal Data Repository (GDR) has implemented improvements to both its data lakes and its data standards and automated data pipelines. The GDR data lakes have reduced storage and compute-related barriers to using large geothermal datasets, enabling these large datasets to be accessed by anyone with a modern computer and internet access. More recently, the GDR has been working to further reduce barriers through streamlining the data intake process, educating users on the process and requirements, and aiding users in accessing data from the data lakes. These improvements have augmented the quantity of datasets the GDR is able to accept into its data lakes and have enabled users who are new to cloud tools to access these datasets more easily, overall increasing the accessibility of big geothermal data for use in machine learning and other projects. In addition, the GDR now has built-in data standards and pipelines for drilling data, geospatial data, and distributed acoustic sensing (DAS) data. These standardization efforts aim to enhance the real-world applicability of geothermal machine learning outcomes by improving the quality of training data. Specifically, through standardizing high-value datasets, the GDR is reducing project-specific data curation requirements, thus allowing more time for actual research. By automating this process, the burden of standardization is lifted from the user, ultimately increasing the availability of standardized data.

accessibility↗

DOE OSTI2023

Simulating excited-state complex ensembles: Fluorescence and solvatochromism in amine-arene exciplexes

Exciplexes are excited-state complexes formed as a result of partial charge transfer from the donor to the acceptor species when one moiety of the donor–acceptor pair is electronically excited. The arene–amine exciplex formed between oligo-(p-phenylene) (OPP) and triethylamine (TEA) is of interest in the catalytic photoreduction of CO2 because it can compete with complete electron transfer to the OPP catalyst. Therefore, formation of the exciplex can hinder the generation of a radical anion OPP·− necessary for subsequent CO2 reduction. We report an implementation of a workflow automating quantum-chemistry calculations that generate and characterize an ensemble of structures to represent this exciplex state. We use FireWorks, Pymatgen, and Custodian Python packages for high-throughput ensemble generation. The workflow includes time-dependent density functional theory optimization, verification of excited-state minima, and exciplex characterization with natural transition orbitals, exciton analysis, excited-state Mulliken charges, and energy decomposition analysis. Fluorescence spectra computed for these ensembles using Boltzmann-weighted contributions of each structure agree better with experiment than our previous calculations based on a single representative exciplex structure [Kron et al., J. Phys. Chem. A 126, 2319–2329 (2022)]. The ensemble description of the exciplex state also reproduces an experimentally observed red shift of the emission spectrum of [OPP-4–TEA]* relative to [OPP-3–TEA]*. The workflow developed here streamlines otherwise labor-intensive calculations that would require significant user involvement and intervention.

Chemistry↗

DOE OSTI2024

ExaWorks software development kit: a robust and scalable collection of interoperable workflows technologies

Scientific discovery increasingly requires executing heterogeneous scientific workflows on high-performance computing (HPC) platforms. Heterogeneous workflows contain different types of tasks (e.g., simulation, analysis, and learning) that need to be mapped, scheduled, and launched on different computing. That requires a software stack that enables users to code their workflows and automate resource management and workflow execution. Currently, there are many workflow technologies with diverse levels of robustness and capabilities, and users face difficult choices of software that can effectively and efficiently support their use cases on HPC machines, especially when considering the latest exascale platforms. We contributed to addressing this issue by developing the ExaWorks Software Development Kit (SDK). The SDK is a curated collection of workflow technologies engineered following current best practices and specifically designed to work on HPC platforms. We present our experience with (1) curating those technologies, (2) integrating them to provide users with new capabilities, (3) developing a continuous integration platform to test the SDK on DOE HPC platforms, (4) designing a dashboard to publish the results of those tests, and (5) devising an innovative documentation platform to help users to use those technologies. Our experience details the requirements and the best practices needed to curate workflow technologies, and it also serves as a blueprint for the capabilities and services that DOE will have to offer to support a variety of scientific heterogeneous workflows on the newly available exascale HPC platforms.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

A New Era for Modern Bubble Chamber Technology: Cooling and Real-Time Control for the MAMBA Neutrino Bubble Chamber∗

Future neutrino experiments such as DUNE will be limited less by statistics than by how well neutrino--nucleus interactions are understood, and the cleanest way to improve that understanding is to measure interactions with light nuclei such as hydrogen or deuterium. The detector best suited to the job, the bubble chamber, has not been built for a neutrino beam in about fifty years. MAMBA (Modern Adaptive Modular Bubble chamber Archetype) is a small prototype at Fermilab intended to bring the technology back with modern cryogenics and automation, cycling continuously at 1~Hz. This paper summarizes my work on two of its subsystems during a summer internship. A new solid copper thermal link brought the coldhead to 21.3~K in a commissioning cooldown, near the 20~K operating target. An Industrial Shields Raspberry Pi programmable logic controller (PLC) running OpenPLC was characterized at a median round-trip response of 0.64~ms over 20,000 trials, with 0.66\% of trials exceeding 1~ms. Both results support continuous cycling.

Williams, Nicholas [Fermilab; DuPage Coll.]↗

DOE OSTI2023

Sensitivity analysis of an automated fault detection algorithm for residential air-conditioning systems

The state of the art of fault detection and diagnosis (FDD) for residential air-conditioning systems is expensive and not yet amenable to widespread implementation. FDD for homes can significantly reduce utility costs, and increase the lifespan of the equipment. The cost barriers currently, however, make FDD for homes economically unviable for large scale implementation. In prior work, we offered a solution to reduce FDD costs by proposing an automated fault detection algorithm to serve as a screening step before more expensive FDD tests can be conducted. The algorithm uses only the home thermostat and local weather information to identify thermodynamic parameters and detect high-impact air-conditioning faults, including those that occur during equipment installation. We had tested the algorithm on a single EnergyPlus™ model of a home in Orlando, Florida. The thermodynamic parameter identification process is highly nonconvex involving several local optimal solutions. In this paper we propose a novel method to select the best model for fault detection from among the list of local optimal solutions to make the algorithm more robust to homes of different construction, without which the fault detection process would be infeasible. Another unique contribution of the paper is implementing the solution on real-world data. We also bring the algorithm closer to market by testing it on real-world data. We implement the algorithm on data obtained from experiments conducted by the Florida Solar Energy Center (FSEC) on a laboratory home equipped with a heat pump where faults were intentionally added for a period of seven months. The algorithm successfully detected an undercharge fault with 70.6% accuracy, concurrent duct leakage and undercharge faults with 85.2% accuracy, and duct leakage faults with 69.1% accuracy. A sensitivity analysis is also performed on EnergyPlus models of nine types of homes that vary in construction to demonstrate the robustness of the algorithm. Finally, the algorithm achieves an average accuracy of 71% for no-fault condition, 77% for 40% undercharge fault, and 76% for duct-leak fault.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Qualification and Quantification of Porosity at the Top of the Fuel Pins in Metallic Fuels Using Image Processing

Approximately 130,000 metal fuel pins were irradiated in the Experimental Breeder Reactor II (EBR-II) during its 30 years of operation to develop and characterize existing and prospective fuels. For many of the metal fuel irradiation experiments, neutron radiography imaging was performed to characterize fuel behavior, such as fuel axial expansion. While several fuel expansion results obtained from neutron radiography imaging have been published, the analysis of neutron radiography for the purpose of describing statistical properties of porous matter formed on top of the fuel pins, also referred to as fluff in previous publications, is significantly less represented in the literature with just a single paper so far. This study aims to validate and augment results reported in previous publications using automated image processing. The paper describes the statistical properties of the porous matter in terms of nine parameters derived from radiography images and correlates those parameters with such fuel properties as composition, expansion, temperature, and burnup. The reported results are based on 1097 fuel pins of eight different fuel compositions. For three major fuel types, U-10Zr, U-8Pu-10Zr, and U-19Pu-10Zr, a clear negative correlation is found between the Pu content and five parameters describing the amount of porous matter generated. The parameters describing granularity properties, however, showed either negative correlation or nonlinear dependency from fuel composition. The parameters describing the amount showed a positive correlation with fuel axial expansion, while granularity parameters showed a negative correlation with axial expansion. The dependency on cladding temperature was found to be weak. A positive correlation is demonstrated for volume parameters and fuel burnup. In general, reported results confirm and validate findings published in previous studies using a much larger number of pins and automated processing techniques, which easily lend themselves to reproducibility, thus avoiding subjective bias.

36 MATERIALS SCIENCE↗