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DOE OSTI2025

Quantum Sensing Experiments at SQMS

The Superconducting Quantum Materials and Systems (SQMS) Center, led by Fermi National Accelerator Laboratory, is one of five U.S. Department of Energy-funded research centers dedicated to advancing quantum computing and quantum sensing. SQMS leverages its expertise in superconducting radio-frequency (SRF) cavities and transmon qubits to develop sensitive quantum sensors to probe fundamental physics. This presentation will highlight the progress and innovations in SQMS’s quantum sensing thrust, with a particular focus on searches for particles beyond the Standard Model, dark matter candidates, and gravitational waves. Recent developments include the search for dark photon dark matter using transmon qubits and widely tunable superconducting cavities (4 GHz–7 GHz), a quantum-enhanced axion dark matter search employing an itinerant single microwave photon counter, and efforts to detect low-mass axions and high-frequency gravitational waves using multimode superconducting cavities.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

University of Hawai‘i, Shallow Geothermal Resources: Energy Technology Innovation Partnership Project (Final Report)

Scientists at Lawrence Berkeley National Laboratory (Berkeley Lab) have teamed up with the University of Hawai‘i at Manoa (UH Manoa) through the U.S. Department of Energy’s Energy Technology Innovation Partnership Project to evaluate the technological and market feasibility of shallow geothermal heat exchanger (GHE) technology. UH requested this analysis to evaluate opportunities in building cooling, energy efficiency, and emissions reduction applications in Hawai‘i. UH has an abundance of geologic and geothermal data and is looking to the national labs’ expertise to execute this analysis. UH is also interested in investigating policy, regulatory, and business conditions advantageous for implementation of a pilot project and more broad deployment of this technology in Hawai‘i. In many locations around the world, the demands for heating and cooling are roughly balanced over the course of the year, so GHEs do not cause significant long-term changes in subsurface temperature. This is not the case in Hawai’i, where the demand for heating is very small, meaning that, over time, GHEs will add heat to the subsurface. If temperatures increase significantly, GHE systems will not work as designed. Regional groundwater flow has the potential to sweep heated water away from boreholes, thereby maintaining the functionality of the GHE system. Significant regional groundwater flow requires two things: a sufficiently large driving hydraulic head gradient (usually closely related to surface topography), and sufficient porosity and permeability to enable groundwater to flow in large enough quantities to enable near-borehole temperatures to be maintained at ambient values. Hawai‘i’s volcanic terrain offers ample surface topographic variation. The lava itself shows an extremely large range of porosity and permeability, so sites with large enough values of these properties must be selected. Numerical modeling of coupled groundwater and heat flow can be used to determine how large is large enough. Primarily, closed-loop systems have been investigated. Other options considered are open-loop systems and using cool seawater as the chilling source. Project work investigated the feasibility of GHE technology at two scales. At the island scale, GIS layers of various attributes relevant for GHE were combined to develop an overall favorability map for employing GHE in Hawai‘i. At the local scale, a hydrogeologic model for the subsurface component of a closed-loop system was developed for the Stan Sheriff Center at the UH Manoa campus. This site is considered promising because the rock below and immediately downgradient of the borefield is highly permeable, consisting of a subsurface karst system (limestone containing high-permeability open channels), which is underlain by a thick, high-permeability fractured basalt. Moreover, the site is near the base of the Ko‘olau Range, providing a large hydraulic head gradient. Thus, groundwater flow through the site is expected to be large, enabling efficient removal of heated groundwater. A full-GHE-system model of the site was also developed, with a simplified representation of the subsurface, in which groundwater flow is not considered and heat transfer is purely by conduction. Using the building cooling load data provided by UH, simulation results show that with groundwater flow present, a GHE can operate successfully for at least 10 years, but with no groundwater flow, the subsurface begins to heat up after only one year of operation, making the GHE unviable within 2-6 years. The team also developed a techno-economic model for this site to compare the cost of cooling using a GHE system with the costs of operating the current air-conditioning system. The GHE system is advantageous economically if favorable tax incentives and interest rates can be obtained.

15 GEOTHERMAL ENERGY↗

DOE OSTI2025

Metallurgical Analysis and Forward Modeling of Weld Distortion in SMR Containment Vessels

This work aimed to apply Sandia’s expertise in metallurgy and modeling to enable the use of hybrid laser arc welding for building nuclear reactor containment structures, via a collaboration with Holtec International. Experimental observations were coupled with finite element analysis to resolve microstructure development, mechanical properties, distortion, and residual stress in welds relevant to the production of the Holtec SMR-160. High residual stresses were observed in welds that were not subjected to preheat. Meanwhile, the microstructure of the welds generally exhibited a narrow heat affected zone relative to conventional arc welds. FEA appeared to be effective in simulating the thermal/mechanical conditions that occur during hybrid laser arc welding of simplified and instrumented test welds. Subsequently, FEA was used to perform sensitivity analyses for various weld geometries that would be prohibitively costly to assess with physical experiments. Insights from the study were used to inform Holtec’s welding process, and successful production welds were performed in 2025.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Master Services Agreement - Flexible Feeder/Distribution System Support: Cooperative Research and Development (Final Report)

PGE will engage NREL on a broad range of projects related to the integration of distributed energy resources (DERs) into the utility's operations. This portfolio of work could include projects focused on DER adoption models, advanced distribution management system (ADMS) and distributed energy management system (DERMS) design, DER dispatch strategy development, and DER valuation framework development. Additional topics could include long-term energy planning, renewable energy, energy efficiency and demand-side management. As well as technology evaluations and design guidance for building retrofits and new construction projects, energy and energy infrastructure planning, policies, and markets (and their analysis), energy storage, energy security and resilience (including energy system-related cybersecurity), transportation and mobility, technology integration analysis. Additionally, other assistance as requested by PGE consistent with NREL’s expertise.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Fossil Energy in the Hydrogen Economy – A Carbon-Water-Energy Nexus Adaptive Evaluation Platform

This project develops tools to evaluate fossil energy within the hydrogen economy. In particular, the project seeks to explore the Carbon-Water-Energy Nexus and develop adaptive evaluation tools. The primary goal of this project was to evaluate fossil-based hydrogen production methods with an emphasis on their sustainability, particularly with respect to carbon emissions and water use. The overall technical objectives that guided this evaluation consisted of 1) technology assessment, which sought to establish a comprehensive baseline of existing and emerging technologies for the generation, transportation, storage, and end use of hydrogen derived from fossil fuels, 2) carbon footprint analysis through quantification and analysis of carbon emissions associated with these hydrogen technologies, and identification of novel strategies and technologies that can effectively mitigate the carbon footprint, 3) water intensity assessment by evaluating the water needs (water-energy nexus) associated with different fossil fuel-based hydrogen technologies and proposing strategies to reduce water use, thus ensuring sustainable resource management, and 4) review of regulatory, policy and economic trends were examined to provide an overview of the factors influencing the adoption and integration of fossil fuel-derived hydrogen technologies into current energy markets. Beyond the technical outcomes, this project contributed to 5) education and workforce development through targeted training and educational opportunities for engineering students, preparing the next generation of professionals with technical, economic, and regulatory expertise in the hydrogen economy. Ultimately, this effort was intended to train the future workforce to provide useful insights to policymakers, industry stakeholders, and the broader energy community to facilitate informed decisions and responsible development within the hydrogen economy.

08 HYDROGEN↗

DOE OSTI2026

Desert-Urban System Integrated Atmospheric Monsoon (DUSTIEAIM) in the Southwestern United States Science Plan

The Desert-Urban System Integrated Atmospheric Monsoon (DUSTIEAIM) campaign is a groundbreaking, high-impact scientific mission that will transform how we understand and respond to energy and water challenges in one of America’s fastest-growing and most heat-stressed urban regions: Phoenix, Arizona. Starting in April 2026, this 18-month field campaign harnesses the full power of the U.S. Department of Energy (DOE) Atmospheric Radiation Measurement (ARM) user facility and an interdisciplinary science team including national laboratories, universities, and agencies with a broad range of subject-matter expertise. With cutting-edge instruments, active and passive ground-based sensors, radars, and integrated modeling, DUSTIEAIM will deliver the most comprehensive environmental data set ever collected for a desert-urban-agricultural interface.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Metal Complex Inks for Low-Cost Photovoltaic Material Metallization

The aim of the project titled “Metal Complex Inks for Low-Cost Photovoltaic Material Metallization” was to develop new metal complex conductive inks and pastes for PV, invented and commercialized by Electroninks, Inc. (EI, Austin, TX USA, https://electroninks.com), the only global supplier and scaled-manufacturing company of these metal complex inks. These materials were developed in this work for photovoltaic applications to significantly lower the cost of metallization, improve the manufacturability, and greatly reduce metal usage, while maintaining or improving device efficiencies when compared to traditional nanoparticle-based inks. The new pastes will do so by: 1) lowering the finger resistivity and precious metals usage by printing much denser (and therefore thinner/less material) metal films than possible with traditional particle-based screen-printed pastes; 2) decreasing the firing temperature to help preserve passivation; and 3) enabling a path to move the TW-scale PV industry from Ag to other materials including Ni, Cu, and Ni/Cu alloy pastes while continuing to leverage capital investment and expertise in screen printing metallization.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Oak Ridge National Laboratory Neutron Spin Echo Beamline on NB-2

Neutron Spin Echo (NSE) spectroscopy uniquely measures the Q-dependence of slow relaxation dynamics, and having such a machine at HFIR will advance polarized neutron spectroscopy and promote the study of biophysical and energy materials using neutrons. The 2018 Instrument Advisory Board (IAB) advises Neutron Sciences Directorate, ORNL to upgrade the cold neutron delivery system at HFIR, addressing geometrical challenges in neutron transfer from the bright cold source. This is being optimized now: the entrance to the guide system is moving closer to the source, and more guides are being added. However, there are still significant challenges to making the cold flux at the sample world-class. With the proposed guide system, NB-2 can deliver more than 10 6 polarized neutrons per cm 2 /sec below 8Å, and probably 10Å with further optimization. With no potential for running user experiments with neutrons longer than 15Å, the utility of such a machine for biological studies is limited. However, there is a large demand for this class of spectrometer in materials science, chemical engineering, and nanotechnology. Workshops held over the past decade and the three-source vision have highlighted the community's need for a low-angle, high-energy resolution spectrometer at HFIR. A detailed design study of this spectrometer is needed, focusing on optimizing the neutron delivery system for SANS-type studies. This neutron spectrometer would complement studies already performed on both SNSNSE and BASIS by overlapping and extend the dynamic range accessible, while acknowledging the proposed machine, EXPANSE, at the Second Target Station. Two technologies currently exist for such a spectrometer: traditional DC solenoids like those on BL-15 at SNS and IN15 at the ILL, and RF-flipper-based machines similar to RESEDA at FRMII. Either instrument would satisfy the scientific justification. However, there are strong business and scientific cases to utilize the thermal flux, the resonant expertise developed at ORNL, and the potential to utilize an entangled beam of neutrons to probe quantum matter by adopting the neutron resonant spin-echo configuration.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Radiation Dose Modeling for Niowave’s Accelerator Driven Uranium Target Assembly 3

Molybdenum-99 is a high-value radionuclide commonly used for medical purposes within the United States. The National Nuclear Security Administration (NNSA) seeks to reliably produce the radioisotope 99 Mo without the use of highly enriched uranium. NNSA’s Office of Material Management and Minimization (M3) provides funding and government laboratory expertise to private companies to expedite the production process domestically and currently funds designs that use low-enriched uranium or other 99 Mo production pathways. Several production designs are being explored across the industry, including uranium fission and photonuclear conversion of 100 Mo targets. Niowave Inc. seeks to produce 99 Mo via a high-energy electron accelerator that strikes a lead-bismuth eutectic target that ultimately produces a consistent neutron flux. The neutron flux then interacts in a subcritical reactor core configuration to produce fission in low-enriched or natural uranium targets. These fissionable targets are then processed to extract 99 Mo. The purpose of this work is to estimate the neutron and photon dose response across Niowave’s proposed facility for worker safety during operation. Owing to the size of the proposed Niowave facility and necessary shielding, unbiased Monte Carlo radiation transport is impractical, and variance reduction methods are required. This work focuses on the weight window variance reduction method to produce high confidence dose response results within a Monte Carlo radiation transport code. Specifically, an adjoint-informed weight window methodology was created to improve the dose response estimates for accelerator-driven subcritical reactor designs. This adjoint-informed methodology was implemented for Niowave’s proposed design and improved dose results at far-field locations across the facility. Acceptable dose rate contours for the proposed facility were generated across the facility and are presented in this work.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2023

RAPID Manufacturing Institute Final Report

The Rapid Advancement of Process Intensification Deployment (RAPID) Manufacturing Institute, founded in 2017, is a public/private partnership between the U.S. Department of Energy and the American Institute of Chemical Engineers (AIChE). RAPID promotes the development, deployment and commercialization of Process Intensification (PI) and Modular Chemical Process Intensification (MCPI) technologies, enabling U.S. manufacturing to reduce energy consumption, improve process efficiencies and lower investment and operating costs. This mission was carried out through parallel work breakdown structure elements including the establishment of committees to guide the operations and technical direction of RAPID, the establishment of management practices and institute processes, education and workforce development (EWD), and six technical focus areas for the development of technologies to advance PI and MCPI. Throughout the initial six-year cooperative agreement, RAPID worked to meet performance metrics which focused on the operation and sustainment of the institute, education and workforce development and the development of PI and MCPI for the advancement of U.S. manufacturing. All these metrics were successfully met through a total of 43 projects which leveraged $\$$70M Federal with $\$$90M cost share. As a result of these efforts, 84 private and public organizations were brought together by RAPID as members to co-invest in R&D, commercialization and deployment of innovative technologies. In the research portfolio, 82% of the 38 projects achieved > 20% energy efficiency improvement. A RAPID Test Network was developed with 51 testbed facilities to enable access to resources, facilities, tools, and expertise. Eight EWD programs were also developed with over 13,000 impressions. RAPID’s efforts to research, develop, demonstrate, and deploy high-impact PI and modular process technology solutions have enabled reduced energy use, increased sustainability, and improved profitability for U.S. manufacturing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

A Semi-supervised Hybrid Machine Learning Framework for the Qualification of Resistance Spot Welds

• Industries requiring high structural integrity, including automotive, aerospace, and construction, place considerable significance on weld quality classification. • The inspection normally involves human expertise through predefined quality metrics that are subjective, error-prone, and time-intensive • The challenge to classification model development is the scarcity of labeled data and imbalanced distributions in the data that are labeled. • This work develops a new hybrid methodology that achieves clustering using KMeans++ together with supervised classification to overcome these challenges. • The ensemble-based classifiers were identified as optimal, with accuracy enhancements of up to 8% using the pseudo-labeled dataset. • The work provides practical insight into feature engineering and machine learning integration in industrial quality assurance applications.

Rogers, Jeremy K. [Savannah River National Laborat↗

DOE OSTI2025

Building collaboration to advance our understanding of regional climate impacts of dust in California's San Joaquin Valley

This project successfully achieved its central objective of building collaborative research capabilities at UC Merced, a Hispanic-Serving Institution, to advance understanding of the regional climate impacts of dust in California's San Joaquin Valley. Through strategic partnerships with three DOE national laboratories (PNNL, LLNL, and LBNL), we developed critical expertise in the Energy Exascale Earth System Model (E3SM) and Atmospheric Radiation Measurement (ARM) facilities. Among the project's scientific contributions, one key publication includes demonstrating that fallowed agricultural lands are the primary source of anthropogenic dust in California's Central Valley, with dust activities increasing substantially between 2008 and 2022, in correlation with drought severity and expanded fallowed land coverage. This finding suggests that current climate models, including E3SM, likely underestimate the dust burden due to inadequate representation of agricultural land-use changes. Beyond the scientific contributions, the project successfully trained a PhD student, established ongoing collaborations resulting in multiple manuscripts in preparation, and positioned UC Merced to participate in the DUSTIEAIM campaign for 2026-2027, thereby building sustainable research capacity while addressing climate science questions directly relevant to the California Central Valley.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

A Novel Framework for Performance Evaluation and Design Optimization of PCM Embedded Heat Exchangers for the Built Environment

This research sheds light on the performance evaluation and design optimization of PCM-HXs for the built environment, addressing several barriers to practical issues to PCM-HX commercialization such as modeling aspects (i.e., modeling expertise and computational / time investment, etc.), manufacturing aspects (i.e., at-scale manufacturing, cost assessments, etc.) and experimental performance assessment (i.e., reliable experimental data, assessment of multiple PCM-working fluid combinations, etc.). We present a novel, comprehensive, and experimentally-validated design optimization framework for PCM-HXs capable of simulating any PCM-HX geometry with reasonable accuracy and significant computational time savings when compared to traditional CFD-based design practices. The framework was validated for a wide range of PCM-HX configurations, including a design optimization for a domestic hot water heater application where TES partially replaces electrical heating input. The resulting PCM-HXs were found to deliver 34-68% of the total daily hot water supply with only 5-10% package volume increase from the water heater, thus within U.S. DOE targets for TES systems. To identify the most promising HXs for PCM applications, first-order geometry and cost analyses were conducted based on off-the-shelf HX products. As part of this work, 9 PCM-HX prototypes were manufactured using additive and conventional manufacturing methods. Detailed economy-of-scale assessments were conducted for the most promising PCM-HXs and were found to have a good outlook for the next 5-10 years. The PCM-HX design optimization framework was validated through comprehensive in-house experimental testing using newly-developed PCM-to-fluid test facilities. In total,10 total in-house component-level experiments were conducted using these prototypes, including 9 with water and 1 with refrigerant (R410A) as the working fluid. It was found that the framework can successfully predict experimental thermal-hydraulic performance within ±10-20% the first time without manual design changes, eliminating the need for time-consuming and expensive prototyping efforts as part of the design process. As part of this work, a publicly-available PCM web tool was released which includes a PCM property database (531 PCMs) and PCM-HX modeling tool to assist the design community on common PCM-HX use-cases, e.g., single/multiple flow path(s) fluid-to-PCM and air-to-fluid-to-PCM configurations (https://ceeeweb.umd.edu/pcmapp/). This work will accelerate the design and time to market for next generation PCM-HXs.

25 ENERGY STORAGE↗

DOE OSTI2025

REopt/Microgrid Analysis (CRADA Final Report)

NREL is the only DOE national laboratory solely dedicated to advancing energy efficiency (EE) and renewable energy (RE) technologies and applications. Since its inception, NREL has supported both the public and the private sectors in implementing EE and RE systems and strategies to lower energy use and to meet remaining energy needs with resources having minimal environmental impact. NREL is now a sought-after resource for EE, RE, and energy systems integration expertise. CU Boulder is a public university located in Boulder, Colorado, with over 30,000 students. CU is committed to environmental sustainability and is interested in partnering with NREL to explore opportunities for RE on campus and evaluate an RE microgrid. The goal of this project is to assess the technical and economic potential for RE generation at CU and evaluate how RE may be incorporated as part of a microgrid to increase energy resiliency on campus.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Engineering Yeast for the Production of Acids and Esters (CRADA Final Report)

NREL and Lygos have a mutual interest in engineering yeast for the production of acids and esters as intermediates towards fuels or bioproducts. In particular, the yeast Pichia kudriavzevii is a fantastic candidate for the production of acid and ester based products including butyric acid and ethyl butyrate. However, the strain is relatively uncommon in the biotechnological space and as such there are not an abundant amount of genetic tools that are publically available. However, Lygos has been working with this species in particular for several years and has developed genetic tools and physiological characteristics and are well versed in engineering this strain for acid based products. While currently focusing on malonic acid-derived products, Lygos is not currently targeting butyric acid and ethyl butyrate but have a long term interest in these molecules and derivatives therein. This CRADA proposal seeks to leverage NREL’s immediate focus on butyric acid and ethyl butyrate, and general bioprocess expertise with Lygos’ specific knowledge on engineering P. kudriavzevii for the production of acid-based products.

09 BIOMASS FUELS↗

DOE OSTI2025

S&TR April/May 2025 Power Grid

At Lawrence Livermore National Laboratory, we focus on science and technology research to ensure our nation’s security. We also apply that expertise to solve other important national problems in energy, bioscience, and the environment. Science & Technology Review is published eight times a year to communicate, to a broad audience, the Laboratory’s scientific and technological accomplishments in fulfilling its primary missions. The publication’s goal is to help readers understand these accomplishments and appreciate their value to the individual citizen, the nation, and the world.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

S&TR June 2025 R&D 100 Awards

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

A Framework for Evaluating the Implementation Cost of Attacks on Large Language Models

Large Language Models (LLMs) have been increasingly proposed as a method to enhance productivity in tasks that involve language and code. However, these models are large, complex, and their capabilities are not easily understood and controlled, meaning that their adoption opens many possibilities for new cyberattacks and misuse. Numerous attacks on LLMs have been reported and summarized in literature reviews, but we found existing reviews lacking in understanding the implementation cost of the attacks - i.e., how much effort would an attacker need in terms of coding, expertise, and resources to adopt attacks presented in the literature. Therefore, we divide existing attacks on LLMs into a taxonomy, and define a cost evaluation framework to determine the cost of the attack. An attack’s cost can be 1) estimated from reading the publication about the attack or 2) determined by implementing the attack from that publication. We provide an example evaluation of a couple jailbreaking frameworks based on experiments, and then apply the more lightweight cost estimate to a representative selection of attacks across the taxonomy we define. We discuss the relative difficulty of the attacks and also highlight defenses that have attempted to mitigate these attacks and assess their effectiveness.

97 MATHEMATICS AND COMPUTING↗