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DOE OSTI2026

Integrated Strategies for Overcoming Resolution Limits in Electron Beam Lithography of Chemically Amplified Resists

Electron beam lithography (EBL) of chemically amplified resists (CARs) faces fundamental challenges, including stochastic electron scattering and acid diffusion, that limit resolution and reproducibility. Using SU-8 as a model CAR, this study systematically investigated complementary strategies to address these challenges, combining multipass exposure, proximity effect correction (PEC) with midrange correction factors, base quencher incorporation, and post-exposure bake (PEB) suppression. Monte Carlo simulations and calibrated PEC modeling revealed that extending the point spread function to include a midrange scattering component significantly improved critical dimension (CD) control across varying pattern densities, correcting deviations that conventional two-term PEC failed to capture. Multipass exposure, particularly 4-pass writing with a 25% offset, redistributed the dose to average stochastic beam and scattering fluctuations, reducing line-width roughness by more than 50% and yielding more uniform nanoscale features. Photoacid confinement was investigated by adding urea as a base quencher, which successfully reduced acid diffusion but introduced substantial sensitivity penalties without improving ultimate resolution or Z-factor performance, underscoring the trade-offs of chemical versus physical confinement. Suppressing PEB most directly minimized acid diffusion, resulting in improved Z-factors and reproducible 30 nm half-pitch dense line/space patterns. Overall, these results demonstrated that PEC with midrange correction, multipass strategies, quencher additives, and PEB-free processing addresses different aspects of the EBL process window and that their integration provides a comprehensive framework for managing stochastic scattering, diffusion, and chemical amplification effects. This framework advances dense nanoscale patterning in CARs and establishes guiding principles for optimizing resist design and process strategies in high-resolution EBL and potentially other advanced lithographies, such as extreme ultraviolet (EUV) lithography.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Preliminary Evaluation of Fuel Management Strategies for the Versatile Test Reactor (VTR)

Different fuel management approaches have been investigated for the Versatile Test Reactor (VTR). The main design variables were the number of batches, the number of (orifice) zones, and the loading pattern within the core. The optimization criteria are maximizing the fast flux at the centermost position, minimizing the peak assembly power, and reducing fuel consumption. Design constraints were mainly driven by material limits such as peak clad temperature, and maximum fuel burnup. The exploratory study determined that active fuel shuffling only brought very limited benefits. A three-orifice region was found to provide enough flexibility to ensure thermal criteria were met. Lastly, a flexible batch loading termed ‘5-6-8’ was identified as a promising management strategy from a resource utilization standpoint.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1996

A Novel Design Technique for Beam-Waveguide Antennas

The new 34-m beam-waveguide (BWG) antenna at Goldstone has a beam magnifier ellipse below ground level that transforms a 22-dB gain feedhorn into a high-gain 29-dB gain pattern for input to a standard four-mirror BWG system. It was initially designed for the X- an Ka-bands, and has a loss of less than 0.2 dB.

antenna↗

DOE OSTI2023

Patterned OLEDs: effect of substrate corrugation pitch and height

Abstract An ongoing OLED challenge is cost-effective enhancement of light extraction, i.e., increasing the external quantum efficiency ( EQE ∼20% in conventional devices). OLEDs on corrugated substrates often show enhanced EQE s providing insight into light emission processes. In particular, patterned plastic substrates directly imprinted easily at room temperature and amenable to low-cost R2R production are ideal for studying/optimizing various structures, further elucidating the extraction process. We show new semi-quantitative data of the effect of the pitch ( a ) and height/depth ( h ) of plastic substrate patterns on the OLEDs’ stack and EQE , focusing on new designs, interestingly, some showing surprisingly enhanced EQE s that were neither reported nor discussed before. These includ e : ( i ) shallow ( h < 200 nm) convex polycarbonate with a ∼ 750 versus ∼400 nm, where the h gradually decreases as the OLED stack is built and ( ii ) concave PET/CAB with large a (∼2.8 and ∼7.8 μ m), where the EQE enhancement of conformal OLEDs may be due largely to scattering. EQE s of green, blue, and white phosphorescent OLEDs were measured. OLEDs on substrates with narrow a ∼ 400 nm and low h < 200 nm s h owed no enhancement, resembling flat devices. In contrast, OLEDs on substrates with comparable or smaller h , but larger a ∼ 750 nm show signific a nt EQE enhancement despite h reduction across the stack. Green OLEDs with a ∼ 750 nm and h ∼ 160 to ∼180 nm, showed EQE s ∼30%, reaching ∼58% with substrate mode extraction. Surprisingly, fully conformal OLEDs on a PET/CAB substrate with a ∼ 7.8 μ m showed blue a nd white EQE s reaching ∼33%, without substrate mode extraction. The enhancing patterns increase the OLEDs’ EQE by reducing surface plasmon excitation and internal waveguiding. The experimental results for OLEDs on substrates with a < 2 μ m are supported by scattering matrix simulations that assume conformal stacks, incorporating diffraction for internal losses reduction. EQE enhancement not predicted by simulations may be due additionally to scattering mostly for substrates with a signific a ntly larger than the emitting wavelength.

42 ENGINEERING↗

DOE OSTI2016

Device Scale Modeling of Solvent Absorption using MFIX-TFM

Recent climate change is largely attributed to greenhouse gases (e.g., carbon dioxide, methane) and fossil fuels account for a large majority of global CO 2 emissions. That said, fossil fuels will continue to play a significant role in the generation of power for the foreseeable future. The extent to which CO 2 is emitted needs to be reduced, however, carbon capture and sequestration are also necessary actions to tackle climate change. Different approaches exist for CO 2 capture including both post-combustion and pre-combustion technologies, oxy-fuel combustion and/or chemical looping combustion. The focus of this effort is on post-combustion solvent-absorption technology. To apply CO 2 technologies at commercial scale, the availability and maturity and the potential for scalability of that technology need to be considered. Solvent absorption is a proven technology but not at the scale needed by typical power plant. The scale up and down and design of laboratory and commercial packed bed reactors depends heavily on the specific knowledge of two-phase pressure drop, liquid holdup, the wetting efficiency and mass transfer efficiency as a function of operating conditions. Simple scaling rules often fail to provide proper design. Conventional reactor design modeling approaches will generally characterize complex non-ideal flow and mixing patterns using simplified and/or mechanistic flow assumptions. While there are varying levels of complexity used within these approaches, none of these models resolve the local velocity fields. Consequently, they are unable to account for important design factors such as flow maldistribution and channeling from a fundamental perspective. Ideally design would be aided by development of predictive models based on truer representation of the physical and chemical processes that occur at different scales. Computational fluid dynamic (CFD) models are based on multidimensional flow equations with first principle foundations. CFD models can include a more accurate physical description of flow processes and be modified to include more complex behavior. Wetting performance and spatial liquid distribution inside the absorber are recognized as weak areas of knowledge requiring further investigation. CFD tools offer a possible method to investigating such topics and gaining a better understanding of their influence on reactor performance. This report focuses first on describing a hydrodynamic model for countercurrent gas-liquid flow through a packed column and then on the chemistry, heat and mass transfer specific to CO 2 absorption using monoethanolamine (MEA). The indicated model is implemented in MFIX, a CFD open source software package. The user defined functions needed to build this model are described in detail along with the keywords for the corresponding input file. A test case is outlined along with a few results. The example serves to briefly illustrate the developed CFD tool and its potential capability to investigate solvent absorption.

09 BIOMASS FUELS↗

DOE OSTI2020

Mixed-flow design for microfluidic printing of two-component polymer semiconductor systems

The rational creation of two-component conjugated polymer systems with high levels of phase purity in each component is challenging but crucial for realizing printed soft-matter electronics. Here, we report a mixed-flow microfluidic printing (MFMP) approach for two-component π -polymer systems that significantly elevates phase purity in bulk-heterojunction solar cells and thin-film transistors. MFMP integrates laminar and extensional flows using a specially microstructured shear blade, designed with fluid flow simulation tools to tune the flow patterns and induce shear, stretch, and pushout effects. This optimizes polymer conformation and semiconducting blend order as assessed by atomic force microscopy (AFM), transmission electron microscopy (TEM), grazing incidence wide-angle X-ray scattering (GIWAXS), resonant soft X-ray scattering (R-SoXS), photovoltaic response, and field effect mobility. For printed all-polymer (poly[(5,6-difluoro-2-octyl-2H-benzotriazole-4,7-diyl)-2,5-thiophenediyl[4,8-bis[5-(2-hexyldecyl)-2-thienyl]benzo[1,2-b:4,5-b′]dithiophene-2,6-diyl]-2,5-thiophenediyl]) [J51]:(poly{[N,N′-bis(2-octyldodecyl)naphthalene-1,4,5,8-bis(dicarboximide)-2,6-diyl]-alt-5,5′-(2,2′-bithiophene)}) [N2200]) solar cells, this approach enhances short-circuit currents and fill factors, with power conversion efficiency increasing from 5.20% for conventional blade coating to 7.80% for MFMP. Moreover, the performance of mixed polymer ambipolar [poly(3-hexylthiophene-2,5-diyl) (P3HT):N2200] and semiconducting:insulating polymer unipolar (N2200:polystyrene) transistors is similarly enhanced, underscoring versatility for two-component π -polymer systems. Mixed-flow designs offer modalities for achieving high-performance organic optoelectronics via innovative printing methodologies.

42 ENGINEERING↗

NASA NTRS2002

One-Dimensional Spontaneous Raman Measurements of Temperature Made in a Gas Turbine Combustor

The NASA Glenn Research Center is working with the aeronautics industry to develop highly fuel-efficient and environmentally friendly gas turbine combustor technology. This effort includes testing new hardware designs at conditions that simulate the high-temperature, high-pressure environment expected in the next-generation of high-performance engines. Glenn has the only facilities in which such tests can be performed. One aspect of these tests is the use of nonintrusive optical and laser diagnostics to measure combustion species concentration, fuel/air ratio, fuel drop size, and velocity, and to visualize the fuel injector spray pattern and some combustion species distributions. These data not only help designers to determine the efficacy of specific designs, but provide a database for computer modelers and enhance our understanding of the many processes that take place within a combustor. Until recently, we lacked one critical capability, the ability to measure temperature. This article summarizes our latest developments in that area. Recently, we demonstrated the first-ever use of spontaneous Raman scattering to measure combustion temperatures within the Advanced Subsonics Combustion Rig (ASCR) sector rig. We also established the highest rig pressure ever achieved for a continuous-flow combustor facility, 54.4 bar. The ASCR facility can provide operating pressures from 1 to 60 bar (60 atm). This photograph shows the Raman system setup next to the ASCR rig. The test was performed using a NASA-concept fuel injector and Jet-A fuel over a range of air inlet temperatures, pressures, and fuel/air ratios.

Hicks, Yolanda R.↗

DOE OSTI2022

Netostat: analyzing dynamic flow patterns in high-speed networks

Understanding flow traffic patterns in networks, such as the Internet or service provider networks, is crucial to improving their design and building them robustly. However, as networks grow and become more complex, it is increasingly cumbersome and challenging to study how the many flow patterns, sizes and the continually changing source-destination pairs in the network evolve with time. Here, we present Netostat, a visualization-based network analysis tool that uses visual representation and a mathematics framework to study and capture flow patterns, using graph theoretical methods such as clustering, similarity and difference measures. Netostat generates an interactive graph of all traffic patterns in the network, to isolate key elements that can provide insights for traffic engineering. We present results for U.S. and European research networks, ESnet and GEANT, demonstrating network state changes, to identify major flow trends, potential points of failure, and bottlenecks.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1975

The Texas Remote Sensing Training Project

The project was designed to train federal, state and regional agency managers, scientists and engineers. A one-week seminar was designed and implemented to build vocabulary, introduce technical subject areas and give students enough training to allow them to relate remote sensing technology to operational agency projects. The seminar was designed to perform the dual function of conveying enough remote sensing information to be of value as a stand-alone and preparing students for detailed pattern recognition training. The LARSYS III portion of the training project was executed exactly as designed in the LARSYS training materials package; the LARSYS package did not contain a LANDSAT training module. Two LANDSAT training modules were developed using Texas LANDSAT data. One module contained central Texas data and the second module contained coastal zone data.

Wells, J. B.↗

DOE OSTI2022

PWR loading pattern optimization with reinforcement learning

The core loading pattern optimization problem belongs to the class of combinatorial optimization problem and has been studied since the dawn of commercial nuclear energy industry. It is characterized by multiple objectives and constraints, with a very high number of candidate patterns, which makes it impossible to solve explicitly. Stochastic optimization methodologies including Genetic Algorithms and Simulated Annealing are used by different nuclear utilities and vendors to perform fuel cycle reload design. Nevertheless, hand-designed solutions continue to be the prevalent method in the industry. To improve the state-of-the-art core reload patterns, we aim to create a method as scalable as possible, that agrees with the designer's goal of performance and safety. To help in this task Deep Reinforcement Learning (DRL), in particular Proximal Policy Optimization is leveraged. DRL has recently experienced a strong impetus from its successes applied to games, sometimes even reaching 'super-human' performances. This paper lays out the foundation of this method and proposes to study the behavior of several hyper-parameters that influence the DRL algorithm. The algorithm is highly dependent on multiple factors such as an exploration/exploitation trade-off that manifests through different parameters such as the number of loading patterns seen and the number of samples collected before a policy update, but also the shape of the objective function derived for the core design. Experimental results also demonstrate the effectiveness of the method in finding high-quality solutions from scratch within a reasonable amount of time. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2019

Influence of scan pattern and geometry on the microstructure and soft-magnetic performance of additively manufactured Fe-Si

The influence of geometry and scan pattern on the microstructure evolution and magnetic performance of additively manufactured Fe-3Si components was investigated. To reduce eddy current losses, novel geometries were designed and built and the microstructure and properties of these samples were characterized. The laser scan pattern was shown to strongly influence both the as-built grain structure and strength of the crystallographic texture, resulting in measurable changes in the as-built magnetic performance. In thin wall samples, heat treatment resulted in an increase in the maximum relative magnetic permeability and decrease in power losses in most samples, consistent with grain growth. However, decreases in the spacing between thin walls to increase the stacking factor of the cross-section was shown to result in unwanted electrical shorting between walls and an increase in eddy current losses. Compared to simple parallel plate construction and a mesh structure, a novel cross-section design based on the Hilbert space filling curve was found to produce the lowest power losses. The mechanisms behind these results were explored using a combination of heat conduction and electromagnetic simulations, providing a route for future component and process optimization.

36 MATERIALS SCIENCE↗

DOE OSTI2026

LaueMatching: an approach for rapid and robust indexing of Laue diffraction patterns

Traditional Laue diffraction pattern indexing often struggles with noisy data, weak signals, peak overlap and missing reflections, particularly from complex or deformed microstructures. Here, we introduce LaueMatching, a high-throughput indexing algorithm designed to overcome these limitations. LaueMatching utilizes a fundamentally different approach based on direct pattern correlation: experimentally pre-processed images are compared against a comprehensive pre-computed library of simulated diffraction patterns corresponding to a dense grid of possible orientations. This approach bypasses the need for explicit peak identification and fitting, steps that are often a failure point for traditional methods. The algorithm rapidly and robustly indexes multiple crystallographic orientations and crystal systems simultaneously, even from challenging patterns. LaueMatching's effectiveness and accuracy have been rigorously tested and validated on diverse experimental (Ni, Al, EuAl 2 O 4 ) and simulated diffraction patterns, demonstrating high-fidelity orientation refinement. Code to implement this approach on both CPU and GPU resources can be downloaded from https://github.com/AdvancedPhotonSource/LaueMatching.

36 MATERIALS SCIENCE↗

NASA NTRS2011

Scanning and Defocusing Properties of Microstrip Reflectarray Antennas

A symmetric reflectarray, consisting of variable-size square patch elements with a commonly used mathematical model for the horn in the form of a cosine function, has been designed using the transmit mode technique for different f/D ratios with 10 dB edge taper. Subsequently, the antennas were analyzed for the radiation pattern and gain. The infinite array model was used to determine the reflection phase of each patch element in the design and analysis codes. By displacing the feed laterally, the scan characteristics were obtained, such as the beam deviation factor, gain loss, and pattern degradation. The properties of reflect arrays were compared to those of the conventional paraboloidal reflectors. The same procedure was used to study the scan properties of offset reflectarrays. There is no cross-polarized radiation in the principal planes for a symmetric system. Cross-polarized radiation exists in non-principal planes off broadside in symmetric systems, with greater levels for larger values of subtended angles. Such cross-polarized radiation level increases with subtended angle just as cross-polarization level increases with decreasing values of f/D ratios for symmetric paraboloids in non-principal planes. Pattern distortions and gain loss were found to be more severe in the case of a microstrip reflectarray compared to the conventional parabolic reflector. The scan performance of the reflect arrays was found to improve with f/D ratios as is true for paraboloids. In general, scanning by means of displaced feed is limited to a few beam - widths in reflectarrays. Feed displacement in the axial direction of a symmetric reflectarray was investigated and compared to that of paraboloids. The gain loss due to the defocused feed of a reflectarray was found to be nearly the same as that of a paraboloid of the same subtended angle for larger values of f/D, and for displacements away from the antenna. The gain loss of an axially defocused reflectarray was found to be greater than that of a paraboloid for displacements closer to the antenna, especially for smaller values of f/D. In general, the performance of a defocused reflectarray was found to be poorer than that of a comparable paraboloid reflector.

Rengarajan, Sembiam↗

NASA NTRS1984

Analysis and testing for rotordynamic coefficients of turbulent annular seals with different, directionally homogeneous surface-roughness treatment for rotor and stator elements

A theory is presented, based on a simple modification of Hirs' turbulent lubrication equations, to account for different but directionally-homogeneous surface roughness treatments for the rotor and stator of annular seals. The theoretical results agree with von Pragenau's predictions that a damper seal which uses a smooth rotor and a rough stator yields more net damping than a conventional seal which has the same roughness for both the rotor and stator. Experimental results for four stators confirm that properly-designed roughened stators yield higher net damping values and substantially less leakage than seals with smooth surfaces. The best seal from both damping and leakage viewpoints uses a round-hole-pattern stator. Initial results for this stator suggest that, within limits, seals can be designed to yield specified ratios of stiffness to damping.

Childs, D. W.↗

NASA NTRS1980

Low power, compact charge coupled device signal processing system

A variety of charged coupled devices (CCDs) for performing programmable correlation for preprocessing environmental sensor data preparatory to its transmission to the ground were developed. A total of two separate ICs were developed and a third was evaluated. The first IC was a CCD chirp z transform IC capable of performing a 32 point DFT at frequencies to 1 MHz. All on chip circuitry operated as designed with the exception of the limited dynamic range caused by a fixed pattern noise due to interactions between the digital and analog circuits. The second IC developed was a 64 stage CCD analog/analog correlator for performing time domain correlation. Multiplier errors were found to be less than 1 percent at designed signal levels and less than 0.3 percent at the measured smaller levels. A prototype IC for performing time domain correlation was also evaluated.

Bosshart, P. W.↗

DOE OSTI2023

Emulating the Deutsch-Josza algorithm with an inverse-designed terahertz gradient-index lens

An all-dielectric photonic metastructure is investigated for application as a quantum algorithm emulator (QAE) in the terahertz frequency regime; specifically, we show implementation of the Deustsh-Josza algorithm. The design for the QAE consists of a gradient-index (GRIN) lens as the Fourier transform subblock and patterned silicon as the oracle subblock. First, we detail optimization of the GRIN lens through numerical analysis. Then, we employed inverse design through a machine learning approach to further optimize the structural geometry. Through this optimization, we enhance the interaction of the incident light with the metamaterial via spectral improvements of the outgoing wave.

Blackwell, Ashley N.↗

NASA NTRS1998

Non-Gimbaled Antenna Pointing: Summary of Results and Analysis

There is considerable interest at this time in developing small satellites for quick-turnaround missions to investigate near-earth phenomena from space. One problem to be solved in mission planning is the means of communication between the control infrastructure in the ground segment and the satellite in the space segment. A nominal small-satellite mission design often includes an omni-directional or similar wide-pattern antenna on the satellite and a dedicated ground station for telemetry, tracking, and command support. These terminals typically provide up to 15 minutes of coverage during an orbit that is within the visibility of the ground station; however, not all orbits will pass over the ground station so that coverage gaps will exist in the data flow. To overcome this general limitation on data transmission for low-earth orbiting satellites, the Space Network (SN), operated by the National Aeronautics and Space Administration, (NASA) has been designed to transmit data to and from user satellites through the Tracking and Data Relay Satellites (TDRS) in geostationary orbit and interfacing to the White Sands Complex (WSC) in New Mexico for the data's ground entry point. The advantage of the SN over a fixed ground station is that all low-earth-satellite orbits will be within the visibility area of at least one TDRS within the SN for a large part of the orbit and the potential exists to establish a communications link if the user satellite can point an antenna in the direction of any one of the relay satellites. Within NASA, there is considerable interest in seeing that small satellite developers are aware of the advantages to the SN and that designs to include the SN are part of the satellite design. Small satellite users have not often considered using the SN because of: (1) The 26-dB link penalty differential between direct broadcast to a ground station and transmission through a TDRS to the ground; (2) The class of satellite is too small to support high-gain antennas and associated attitude control and drive electronics; (3) The class of satellites is severely weight and power limited; (4) There are perceived problems in scheduling communications for this class of user on the SN. This report addresses the potential for SN access using non-gimbaled, i.e. fixed-pointed, antennas in the design of the small satellite using modest transmission power to achieve the necessary space-to-ground transmissions. The advantage of using the SN is in the reduction of mission costs arising from using the SN infrastructure instead of a dedicated, proprietary ground station using a similar type of communications package. From the simulations and analysis presented, we will show that a modest satellite configuration can be used with the space network to achieve the data transmission goals of a number of users and thereby rival the performance achieved with proprietary ground stations. In this study, we will concentrate on the return data link (from the user satellite through a TDRS to the ground data entry point). The forward command link (from the ground data entry point through a TDRS to the user satellite) will usually be a lower data rate service and the data volume will also be considerably lower than the return link's requirement. Therefore, we assume that if the return link requirements are satisfied, then the forward link requirements can also be satisfied.

Horan, Stephen↗

NASA NTRS2001

Interface Pattern Selection in Directional Solidification

The central focus of this research is to establish key scientific concepts that govern the selection of cellular and dendritic patterns during the directional solidification of alloys. Ground-based studies have established that the conditions under which cellular and dendritic microstructures form are precisely where convection effects are dominant in bulk samples. Thus, experimental data can not be obtained terrestrially under pure diffusive regime. Furthermore, reliable theoretical models are not yet possible which can quantitatively incorporate fluid flow in the pattern selection criterion. Consequently, microgravity experiments on cellular and dendritic growth are designed to obtain benchmark data under diffusive growth conditions that can be quantitatively analyzed and compared with the rigorous theoretical model to establish the fundamental principles that govern the selection of specific microstructure and its length scales. In the cellular structure, different cells in an array are strongly coupled so that the cellular pattern evolution is controlled by complex interactions between thermal diffusion, solute diffusion and interface effects. These interactions give infinity of solutions, and the system selects only a narrow band of solutions. The aim of this investigation is to obtain benchmark data and develop a rigorous theoretical model that will allow us to quantitatively establish the physics of this selection process.

Trivedi, Rohit↗