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DOE OSTI2025

Electric Grid Security (EGS) FY24 Annual Report

Sandia’s Electric Grid Security program advances a national vision of a secure, resilient, and affordable electric system for all users. Our achievements reflect a strategic approach combining technology development; modeling, simulation, and data analytics; and partnered demonstrations and outreach to further the adoption of advanced grid and storage technologies. Our FY24 efforts leverage the strengths of our partnerships—spanning Sandia’s core science and technology competencies as well as external technology leaders—to develop the solutions today which enable the grid of tomorrow. Key accomplishments in this report that support our strategy span our technical program areas and include: • The advancement of energy storage technologies, including creation of a national Long Duration Energy Storage Consortium; • Applications of artificial intelligence and machine learning to enhanced grid operations and planning; • Development of solid-state power conversion technologies and a new medium-voltage research lab; • New technologies to assess wildfire vulnerabilities and mitigate potential impacts; • Advanced applications of new cybersecurity technologies with industry partners; • Contributions to understanding the impacts of electromagnetic pulses and geomagnetic disturbances on grid components; and • Digital twin development for hybrid microgrids with multiple generators, storage, and loads.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Detector Response and Battery Reliability

The Sandia National Laboratories (SNL) Material Control and Accountability (MC&A) measurements team performs confirmation measurements of Special Nuclear Material (SNM) at different locations around Sandia. The measurement team has access to two High purity Germanium (HPGe) detectors, the AEGIS (Model: AEGIS-BEGE5030), and the ORTEC (Model: trans-SPEC-DX-100). These two can operate purely on battery power, but the response of the detectors while on battery power is not well documented. To enhance our knowledge with these detectors the team wants to investigate the detectors response to changes in battery range, wall charging, and mid operation battery swaps (Hot Swaps).

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

A Cultural Resource Survey of 661.5 Acres on the Tonopah Test Range (TTR), Nellis Air Force Base, Nye County, Nevada

This report presents the results of a Section 110 cultural resource survey of Pedro Lake and the surrounding area. Sandia National Laboratories’ (Sandia) cultural resources program, in collaboration with personnel from the cultural resource department from the Northern Ranges of the Nevada Test and Training Range (NTTR), Nellis Air Force Base (NAFB) surveyed 267.71 hectares (ha) (661.50 acres [ac]) for the project, located on the Tonopah Test Range (TTR) at Nellis Air Force Base, Nye County, Nevada. The survey resulted in the update of two previously recorded archaeological sites, the documentation of 15 newly discovered archaeological sites, and 18 isolated occurrences. The results of the survey are presented herein.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Development and Full Load Demonstration of a 900°C Solid Particle Receiver for Concentrating Solar Power Applications - noLimits

Sandia National Laboratories (SNL) and the German Aerospace Centre (DLR) are world leaders in the joint and separate development of very high temperature next generation solar concentrator systems using solid particles. This project “noLimits” is meant to provide the critical performance information needed to commercialize DLR’s CentRec® solar receiver and ancillary particle systems (conveying systems, storage vessels, flow control equipment etc.) developed at Sandia National Laboratories (SNL). Performance information (at power levels closer to a small scale Concentrating Solar Power (CSP) plant) will be obtained at full load conditions (2.5 MWt ) and at 900 °C-1000 °C particle outlet temperatures at the National Solar Thermal Test Facility (NSTTF) located at SNL. Heliogen was proposed to be joining the project as a commercial partner to provide the commercialization route for this receiver design, if successful, as Heliogen acquired the intellectual property (IP) from DLR.

14 SOLAR ENERGY↗

DOE OSTI2025

Casing Annulus Monitoring of CO 2 Injection Using Wireless Autonomous Distributed Sensor Networks

Effective and secure carbon subsurface storage, involving the deep underground injection of CO 2 into geological formations where it is permanently trapped, is paramount to mitigating CO 2 emissions (Figure I). Ensuring the integrity of these storage sites and detecting potential leakage through the casing annulus necessitates robust monitoring. This work provides the first integrated demonstration of a wireless casing-annulus monitoring architecture that can operate in highly attenuating cement-brine environments relevant to CO 2 storage. This project focused on developing and validating a novel sensor system for integration with autonomous monitoring near the cement reservoir interface. The goal was a fully integrated Technology Readiness Level (TRL) 4/5 field validation of a distributed wireless intelligent sensor system providing real-time, direct subsurface formation measurements to enhance fluid movement monitoring in the cemented casing annulus. Achieving this objective required the development and integration of 1) wireless autonomous microsensor technology by California Institute of Technology (Caltech); 2) sensor packaging and emplacement technology by Research Triangle Institute (RTI); and 3) smart well completions using wireless active casing collars and NOV pipe by the Sandia National Lab (SNL). The collaboration with the Caltech team in this project aimed to develop millimeter-scale radio frequency identification (RFID) sensors capable of detecting CO 2 , pH, and/or methane levels. These sensors are engineered to be impervious to fluids, allowing them to be mixed with cement and installed within the casing annulus. They operate using RFID protocols at frequencies of 902–928 MHz for both power and communication. A Sandia National Laboratories’ team engaged their expertise in the development of a Smart Collar system designed for the wireless data collection from these RFID sensors embedded in the cement annulus and transmission of this information to the ground surface via IntelliPipe/IntelliServ NOV drill pipe. This is accomplished through inductive coupling at the collar, which facilitates data transfer through each segment of the pipe. Because the system cannot transmit a direct current signal to power the Smart Collar, both power and communication were implemented using alternating current and electromagnetic signals at varying frequencies. Furthermore, the developed microsensor technology had to be demonstrated and validated in comparison with reference transducer measurements in a field test site at The University of Texas at Austin (UT-Austin). Although the full sensor suite did not reach field-deployment readiness, the system-level integration achieved in this project establishes a validated pathway for future incorporation of advanced microsensors.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Electrokinetically Enhanced Rare Earth Element Separation through Polymer Coated Capillary Arrays

I, Kyle McCarthy, will give an oral presentation on research findings from Energy and Homeland Security LDRD "A New, Green Approach to Rare Earth Element (REE) Purification Based on Electrokinetics." in talk titled "Electrokinetically Enhanced Rare Earth Element Separation through Polymer Coated Capillary Arrays." at the upcoming Sandia postdoc technical showcase. I will also attend other live presentations and conduct professional networking. This fits within Sandia's energy security mission.

McCarthy, Kyle Patrick [Sandia National Laboratori↗

DOE OSTI2025

Using High-Performance Cameras for Advanced Plasma Diagnostics

We will present insights, challenges, and recent progress on using a multi-megapixel deep-depletion CCD camera for quantitative X-ray spectra in a single-hit exposure mode in order to optimize X-ray diffraction experiments. We will also present some applications of Sandia’s in-house developed hybrid CMOS (hCMOS) sensors, which can record up to four full frames of optical or X-ray images in sequences with only a few nanoseconds interframe timing in a single line-of-sight.

Geissel, Matthias [Sandia National Laboratories (S↗

DOE OSTI2026

2025 Mykonos Facility Report

This document summarizes the activities at the Mykonos Pulsed Power Facility during the calendar year 2025. Section 1 reports on the yearly shot statistics along with some facility highlights. Section 2 discusses the many improvements we were able to complete this year, thanks to the generous Mykonos Academic Access Programs (MAAP) funding from SSAP and Sandia strategic investments. Section 3 focuses on each individual campaign and their respective results.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

Sierra/SD – User’s Guide for NasGen – 5.28

NasGen provides a path for migration of structural models from Nastran bulk data format (BDF) into both an Exodus mesh file and an ASCII input file for Sierra Structural Dynamics (Salinas) and Solid Mechanics (Adagio). Many tools at Sandia National Labs (SNL) use the Exodus format. This document describes capabilities and limitations of the NasGen translation software.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Inspecta Technical Report

Sandia National Laboratories (SNL) has developed Inspecta (International Nuclear Safeguards Personal Examination and Containment Tracking Assistant), an AI-powered smart digital assistant (SDA) equipped with robotic capabilities. This innovative tool aims to enhance the effectiveness, efficiency, and safety of international nuclear safeguards inspections. Inspecta is designed to assist inspectors on-site by supporting or automating tasks that are often mundane, hazardous, or prone to errors. In 2021, the development team established the specifications for Inspecta by thoroughly analyzing International Atomic Energy Agency (IAEA) documents and consulting with former IAEA inspectors and subject matter experts. This process involved aligning in-field inspection tasks with existing commercial and open-source technologies, thereby creating a roadmap for the initial prototype of Inspecta and identifying areas requiring further research and development. From 2022 to 2025, the focus shifted to integrating a critical inspection activity—the examination of seals—into an early version of Inspecta. This phase has involved the development of both software and hardware capabilities essential for this task. This report outlines the advancements in Inspecta’s functionalities, particularly those that support the seal examination process.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2025

Neutron diagnostics and neutron generation with Z-Petawatt

We are developing a versatile neutron test platform at the “Chama” target chamber at Sandia to utilize Z-Petawatt in support of Z’s neutron diagnostic work. Details and first results are given in the poster.

Geissel, Matthias [Sandia National Laboratories (S↗

DOE OSTI2026

Sierra/SD– User’s Guide for NasGen - 5.30

NasGen provides a path for migration of structural models from NASTRAN bulk data format (BDF) into both an Exodus mesh file and an ASCII input file for Sierra Structural Dynamics (Salinas) and Solid Mechanics (Presto). Many tools at Sandia National Labs use the Exodus format. NasGen was written specifically for Salinas and Presto but should be usable with a number of these packages.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

A Portable Wave Tank and Wave Energy Converter for Engineering Dissemination and Outreach

Wave energy converters are a nascent energy generation technology that harnesses the power in ocean waves. To assist in communicating both fundamental and complex concepts of wave energy, a small-scale portable wave tank and wave energy converter have been developed. The system has been designed using commercial off-the-shelf components, and all design hardware and software are openly available for replication. This project builds on prior research conducted at Sandia National Laboratories, particularly in the areas of WEC device design and control systems. By showcasing the principles of causal feedback control and innovative device design, SIWEED not only serves as a practical demonstration tool but also enhances the educational experience for users. This paper presents the detailed system design of this tool. Furthermore, via testing and analysis, we demonstrate the basic functionality of the system.

educational↗

DOE OSTI2025

Pressure-temperature equation of state of Al 2 ⁢O 3 up to 14 Mbar and 40 kK

Sapphire (Al 2 ⁢O 3 ), known for its remarkable incompressibility at ambient conditions, plays a pivotal role in both static and dynamic compression research. Accurately characterizing its equation of state (EoS) is essential for these applications. Here, we present a complete Hugoniot of Al 2 ⁢ O 3 as locus of experimentally assessed, high-precision, pressure, density and temperature states up to 14 Mbar and 43 kK. The Hugoniot is established with single shock experiments using magnetically launched hyper velocity flyers on the Z Accelerator at Sandia National Laboratories. We explore principal Hugoniot states at very high shock 𝑇 and 𝑝 in the solid phase, tracking the solid-liquid boundary and culminating at 2.4-fold compression, where data provides a direct constraint on the liquid phase. Corresponding shock release data probe thermodynamic states complementary to the Hugoniot and place additional constraints on tabular EoS models. Our findings indicate a significant deviation from existing tabular EoS models for Al 2 ⁢ O 3 dictating a comprehensive overhaul. We develop two advanced EoSs for Al 2 ⁢ O 3 the SESAME 97412 model, featuring an extensive phase diagram that includes three solid phases and the liquid phase, and the updated LEOS 2200m2 model. EoS development is assisted with Quantum Molecular Dynamics simulations. Our experimental data allows for stringent testing of our EoSs. Both models accurately capture the Hugoniot of Al 2 ⁢O 3 up to the highest pressures and temperatures. Rigorous experimental determination of extreme pressures and temperatures, paired with sophisticated models, advances the frontier of EoS development beyond 1 terapascal.

Kalita, Patricia [Sandia National Laboratories (SN↗

DOE OSTI2025

Viziv Wireless Power Transfer Evaluation

Under direction from the DOE Office of Electricity, Sandia National Laboratories performed testing of the Viziv system to evaluate the quality of the Zenneck surface wave and potential application to long range power transfer. This report documents the test methodology as well as the test results. This includes an analysis of prior test data collected by Viziv.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Sierra/SD – User’s Guide for NasGen (V.5.24)

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Xyce™ Parallel Electronic Simulator Version 7.10 Release Notes

The Xyce™ Parallel Electronic Simulator has been written to support the simulation needs of Sandia National Laboratories’ electrical designers. Xyce™ is a SPICE-compatible simulator with the ability to solve extremely large circuit problems on large-scale parallel computing platforms, but also includes support for most popular parallel and serial computers.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Unraveling fundamental mechanisms of silicon nitride crystallization in microelectronics manufacturing

This research project investigates the fundamental mechanisms of silicon nitride (SiN) crystallization, aiming to enhance the understanding of this critical material in microelectronics manufacturing. Through a collaborative effort between Sandia National Laboratories, the University of Tennessee, and the University of Florida, we developed a comprehensive framework that integrates experimental techniques, atomistic modeling, meso-scale simulations, and an integrated multi-scale model to capture this physical phenomenon on multiple time and length scales . The project developed a new machine learning based atomistic potential and utilized advanced phase field modeling to capture the complexities of polycrystalline growth and the influence of mechanical stresses on crystallization dynamics. By employing a grain tracker algorithm, the meso-scale model effectively identified and tracked individual crystal grains, enabling the simulation of anisotropic growth behaviors reflective of SiN’s physical properties. The integration of atomistic simulations with meso-scale modeling created a powerful multi-scale framework that validated atomistic inputs and enhanced predictive accuracy for crystallization dynamics at larger scales, validated experimentally. This adaptable modeling capability not only accelerates development times by informing manufacturing processes but also serves as a valuable starting point for understanding crystallization physics in similar materials. The insights gained from this research unlock new opportunities for the development of advanced materials tailored for future microelectronics and photonics applications. Overall, this project represents a significant advancement in understanding of fundamental physics of SiN and establishes a foundation for future research in material science, bridging the gap between atomic-level phenomena and macroscopic material behaviors for practical applications.

36 MATERIALS SCIENCE↗