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DOE OSTI2021

The case for digital twins in metal additive manufacturing

The digital twin (DT) is a relatively new concept that is finding increased acceptance in industry. A DT is generally considered as comprising a physical entity, its virtual replica, and two-way digital data communications in-between. Its primary purpose is to leverage the process intelligence captured within digital models—or usually their faster-solving surrogates—towards generating increased value from the physical entities. The surrogate models are created using machine learning based on data obtained from the field, experiments and digital models, which may be physics-based or statistics-based. Anomaly detection and correction, and diagnostic closed-loop process control are examples of how a process DT can be deployed. In the manufacturing industry, its use can achieve improvements in product quality and process productivity. Metal additive manufacturing (AM) stands to gain tremendously from the use of DTs. This is because the AM process is inherently chaotic, resulting in poor repeatability. However, a DT acting in a supervisory role can inject certainty into the process by actively keeping it within bounds through real-time control commands. Closed-loop feedforward control is achieved by observing the process through sensors that monitor critical parameters and, if there are any deviations from their respective optimal ranges, suitable corrective actions are triggered. The type of corrective action (e.g. a change in laser power or a modification to the scanning speed) and its magnitude are determined by interrogating the surrogate models. Because of their artificial intelligence (AI)-endowed predictive capabilities, which allow them to foresee a future state of the physical twin (e.g. the AM process), DTs proactively take context-sensitive preventative steps, whereas traditional closed-loop feedback control is usually reactive. Apart from assisting a build process in real-time, a DT can help with planning the build of a part by pinpointing the optimum processing window relevant to the desired outcome. Again, the surrogate models are consulted to obtain the required information. In this article, we explain how the application of DTs to the metal AM process can significantly widen its application space by making the process more repeatable (through quality assurance) and cheaper (by getting builds right the first time).

36 MATERIALS SCIENCE↗

DOE OSTI2024

Towards an understanding of particle-scale flaws and microstructure evolution in cold spray via accumulation of single particle impacts

Cold spray coatings are the sum of countless individual bonding events between single particles impacting on top of one another at high velocities. Thus, the collective behavior of microparticles must be considered to elucidate the origins of coating flaws at the scale of the particles and larger, or the dynamic evolution of the overall coating microstructure. Laser-induced particle impact testing (LIPIT) has been extensively used to study single-particle impacts, and in this work is adapted to study the accumulation of numerous particles with knowledge of each individual particle's impact parameters (particle size, velocity). The method reproducibly deposits stacks of gold particles (>20 particles) with different characteristic spectra of impact velocity. The observation of impact-induced erosion lets us define a critical velocity for material-build-up that is higher than that for single-particle bonding. The quantitative single-particle data are analyzed in a correlative manner to the structure and flaws in the resulting stacks, providing some first statistical connections between, e.g., strain and recrystallization, or aberrant particle characteristics and defects. The results highlight opportunities for the study of many-particle phenomena in microparticle impact—from interaction of particles in cold spray to multi-step erosion processes—with a quantitative view of the behavior of single particles.

Erosion↗

DOE OSTI2021

Creating self-assembled arrays of mono-oxo (MoO 3 ) 1 species on TiO 2 (101) via deposition and decomposition of (MoO 3 ) n oligomers

Significance The design and synthesis of hierarchically ordered oxides remains a critical challenge in material science and catalysis. Here, we demonstrate that well-ordered homotopic arrays of mono-oxo (MoO 3 ) 1 can be easily prepared on anatase TiO 2 (101) via the deposition of (MoO 3 ) n oligomers. As revealed by our combined experiential and theoretical studies, the oligomers spontaneously decompose and self-assemble into chemically identical and thermally stable monomers. The oligomer decomposition is permitted at room temperature due to the dynamic coupling of decomposition steps to the lattice phonons of TiO 2 . We identify transient mobility of the oligomers as key to the self-assembly of the complete overlayer. The ease of preparation and thermal stability of this atomically precise system makes it highly suitable for a broad range of applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Entropic control of the free-energy landscape of an archetypal biomolecular machine

Biomolecular machines are complex macromolecular assemblies that utilize thermal and chemical energy to perform essential, multistep, cellular processes. Despite possessing different architectures and functions, an essential feature of the mechanisms of action of all such machines is that they require dynamic rearrangements of structural components. Surprisingly, biomolecular machines generally possess only a limited set of such motions, suggesting that these dynamics must be repurposed to drive different mechanistic steps. Although ligands that interact with these machines are known to drive such repurposing, the physical and structural mechanisms through which ligands achieve this remain unknown. Using temperature-dependent, single-molecule measurements analyzed with a time-resolution-enhancing algorithm, here, we dissect the free-energy landscape of an archetypal biomolecular machine, the bacterial ribosome, to reveal how its dynamics are repurposed to drive distinct steps during ribosome-catalyzed protein synthesis. Specifically, we show that the free-energy landscape of the ribosome encompasses a network of allosterically coupled structural elements that coordinates the motions of these elements. Moreover, we reveal that ribosomal ligands which participate in disparate steps of the protein synthesis pathway repurpose this network by differentially modulating the structural flexibility of the ribosomal complex (i.e., the entropic component of the free-energy landscape). Here, we propose that such ligand-dependent entropic control of free-energy landscapes has evolved as a general strategy through which ligands may regulate the functions of all biomolecular machines. Such entropic control is therefore an important driver in the evolution of naturally occurring biomolecular machines and a critical consideration for the design of synthetic molecular machines.

Science & Technology - Other Topics↗

DOE OSTI2022

A Trajectory-Driven Algorithm for Differentiating SRB Measures on Unstable Manifolds

Sinai-Ruelle-Bowen (SRB) measures are limiting stationary distributions describing the statistical behavior of chaotic dynamical systems. Directional derivatives of SRB measure densities conditioned on unstable manifolds are critical in the sensitivity analysis of hyperbolic chaos. These derivatives, known as the SRB density gradients, are by-products of the regularization of Lebesgue integrals appearing in the original linear response expression. In this paper, we propose a novel trajectory- driven algorithm for computing the SRB density gradient defined for systems with high-dimensional unstable manifolds. We apply the concept of measure preservation together with the chain rule on smooth manifolds. Due to the recursive one-step nature of our derivations, the proposed procedure is memory-efficient and can be naturally integrated with existing Monte Carlo schemes widely used in computational chaotic dynamics. Here, we numerically show the exponential convergence of our scheme, analyze the computational cost, and present its use in the context of Monte Carlo integration.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Port Electrification Handbook: A Reference to Aid U.S. Port Energy Transitions

Port electrification can take many forms, such as electrifying cargo handling equipment or deploying a microgrid to power critical port infrastructure. To help evaluate the growing challenge of increased electrification and its impacts on the system, the U.S. Department of Energy, Office of Electricity’s Microgrids R&D [research and development] program created this Port Electrification Handbook through a project led by Pacific Northwest National Laboratory. The goals of this handbook are the following: help port operators and planners evaluate different electrification technologies, explain how these technologies could aid and impact ports and surrounding communities, provide step-by-step considerations for port electrification.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Advocating for view and daylight in buildings: Next steps

With the exponential growth in population and commensurate increased density in urban cities, access to daylight and views to nature is being severely curtailed in buildings. In parallel, increasingly urgent demands to sharply reduce building energy use and associated greenhouse gas emissions are being made to mitigate climate change. There are many challenges and performance tradeoffs associated with the building facade (i.e., daylight and view versus solar and glare control); increased prioritization of health and well-being as a fundamental human requirement could adversely affect building energy-efficiency. Given the current state of knowledge on the effects of daylight and view on health and well-being in buildings, we identify critical needs in research, tools and technologies that if satisfied may enable more effective use of daylight and view in buildings within the constraints of climate change. Lack of knowledge regarding the complex causal mechanisms of window views on human factors is a severely limiting factor in forward progress. Current models and methods to derive bidirectional scattering distribution functions (BSDFs) will need to be modified. Developers of energy-efficient window technologies will need more guidance to shape product development. Advanced window technologies and integrated design can enable attainment of both health and well-being and net zero energy goals, but considerable work will be needed to make such options turnkey and broadly available.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Godiva IV Simulated Radiation Field Characterization and Variance Reduction

Godiva IV is a system comprised of highly enriched uranium alloyed with molybdenum in the form of fuel plate rings. The reactor, along with its predecessors, was designed with the unique ability to satisfy interests in the super-prompt-critical reactor operation space. Originally, the reactor was part of the Los Alamos Critical Experiments Facility (LACEF) at Technical Area-18 (TA-18). The radiation field around Godiva at this facility was well characterized and understood. As a fast neutron system, the neutron spectrum in and around Godiva was close to a Watt Fission spectrum. The Kiva where Godiva IV was located at LACEF was made of thin, sheet metal walls which did not contribute significantly to the neutron spectrum. Following the transition of LACEF to the National Critical Experiments and Research Center (NCERC) in Nevada, Godiva-IV was moved from TA-18 to the Device Assembly Facility (DAF) at the Nevada National Security Site (NNSS). Part of this move brought renewed interest in radiation field characterization. The new facility introduced significant changes to the environment surrounding Godiva, and preliminary foil irradiation results suggested that the room contribution to the neutron spectrum was significant. Unlike at TA-18, a large thermal neutron signature was added to the fast spectrum from Godiva due to significant room return. A primary goal due to the additional complexity that the room return adds to the Godiva IV radiation emission spectrum was the development of an efficient Monte Carlo N-Particle (MCNP) calculation capable of characterizing the neutron spectrum anywhere in the room around Godiva. A campaign of activation foil irradiations and analysis were completed to support the validation of the MCNP model. The modeling of these foils in MCNP can be easily done with a standard volumetric neutron flux tally. However, given the multitude of locations and reaction rates to be modeled, further steps must be taken to increase the efficiency of these calculations in MCNP. During this study, a benchmark model currently under development for Godiva IV was used. A qualitative assessment of the thermal neutron contributors was performed using spatial neutron distribution plots. Additional detail was added to the model based on the qualitative results showing the thermal spectrum’s large sensitivity to hydrogenous material. Neutron energy spectra was evaluated at discrete locations in the room around Godiva to quantify the relative contribution of various components. It was discovered that the concrete walls are the largest contributor to the thermal signature, with minor contributions from plastic components surrounding Godiva. Following these results, two different variance reduction techniques were implemented to improve the problem efficiency in these calculations. In the first approach, an F5 point detector tally was implemented in the standard Godiva IV criticality problem. The second approach involved a weight-window generator implementation with an F5 point detector tally in a fixed source problem. The weight window implementation reduced the runtime from 42739.55 minutes to 1803.34 minutes (computer time), compared to the F5 KCODE implementation.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Lithium crystallization at solid interfaces

Understanding the electrochemical deposition of metal anodes is critical for high-energy rechargeable batteries, among which solid-state lithium metal batteries have attracted extensive interest. A long-standing open question is how electrochemically deposited lithium-ions at the interfaces with the solid-electrolytes crystalize into lithium metal. Here, using large-scale molecular dynamics simulations, we study and reveal the atomistic pathways and energy barriers of lithium crystallization at the solid interfaces. In contrast to the conventional understanding, lithium crystallization takes multi-step pathways mediated by interfacial lithium atoms with disordered and random-closed-packed configurations as intermediate steps, which give rise to the energy barrier of crystallization. This understanding of multi-step crystallization pathways extends the applicability of Ostwald’s step rule to interfacial atom states, and enables a rational strategy for lower-barrier crystallization by promoting favorable interfacial atom states as intermediate steps through interfacial engineering. Our findings open rationally guided avenues of interfacial engineering for facilitating the crystallization in metal electrodes for solid-state batteries and can be generally applicable for fast crystal growth.

25 ENERGY STORAGE↗

DOE OSTI2024

High-Penetration Microgrids Providing Grid Stability Using Frequency Watt Control

The U.S. grid is rapidly transitioning towards utilizing inverter-based renewable energy resources such as solar, wind, and batteries, reducing the carbon emission footprint. Inverter-based microgrid control architectures remain a critical focus to address power system stability issues in future high penetration markets lacking spinning generation assets. Idaho National Laboratory (INL) is researching an active layered inverter based frequency-Watt control scheme that provides distribution level stability in high-penetration markets where grid inertia is lacking. Hardware in the loop case study was implemented using INL’s Microgrid Testbed to combat scalable frequency deviations ranging from 60 Hz down to 50 Hz initialized by a hydropower model implementing step loads using a 540-kW grid emulator. Our research findings demonstrate the importance of distribution level, inverter-based active frequency-Watt controls utilizing a battery energy storage system (BESS) to provide adequate frequency support at the point of common coupling without major power infrastructure upgrades.

14 SOLAR ENERGY↗

DOE OSTI2022

Informing Nature-based Climate Solutions for the United States with the best-available science

Nature-based Climate Solutions (NbCS) are managed alterations to ecosystems designed to increase carbon sequestration or reduce greenhouse gas emissions. While they have growing public and private support, the realizable benefits and unintended consequences of NbCS are not well understood. At regional scales where policy decisions are often made, NbCS benefits are estimated from soil and tree survey data that can miss important carbon sources and sinks within an ecosystem, and do not reveal the biophysical impacts of NbCS for local water and energy cycles. The only direct observations of ecosystem-scale carbon fluxes, for example, by eddy covariance flux towers, have not yet been systematically assessed for what they can tell us about NbCS potentials, and state-of-the-art remote sensing products and land-surface models are not yet being widely used to inform NbCS policymaking or implementation. As a result, there is a critical mismatch between the point- and tree-scale data most often used to assess NbCS benefits and impacts, the ecosystem and landscape scales where NbCS projects are implemented, and the regional to continental scales most relevant to policymaking. Here, we propose a research agenda to confront these gaps using data and tools that have long been used to understand the mechanisms driving ecosystem carbon and energy cycling, but have not yet been widely applied to NbCS. Furthermore, we outline steps for creating robust NbCS assessments at both local to regional scales that are informed by ecosystem-scale observations, and which consider concurrent biophysical impacts, future climate feedbacks, and the need for equitable and inclusive NbCS implementation strategies. We contend that these research goals can largely be accomplished by shifting the scales at which pre-existing tools are applied and blended together, although we also highlight some opportunities for more radical shifts in approach.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Laser-driven high-resolution MeV x-ray tomography

The need for high-resolution MeV x-ray tomography to observe the three-dimensional structure of dense, large-sized objects is rapidly increasing for the non-destructive evaluation of critical additively manufactured parts, national security, and other applications. We report a demonstration of high-resolution MeV computed tomography of a dense, large object with a laser-driven x-ray source. A record detector-limited MeV radiograph resolution of < 200 µm as determined with the Bennett approximation of the point spread function was achieved by irradiating millimeter-thick tungsten targets with 300 TW femtosecond laser pulses at a 0.5 Hz repetition rate. A tungsten alloy step wedge spectrometer indicates that the peak of the x-ray emission is between 1 and 2 MeV, with an endpoint energy of 19 MeV. To illustrate the radiographic imaging capability of the system, a tomographic reconstruction of a nickel superalloy turbine blade ( maximum $ρr$ = 139 g/cm 2 ) with sub-millimeter resolution was performed using 2160 individual radiographs. The small x-ray source size opens the prospect of extremely high-resolution tomographs of large, dense objects. This laser-driven approach has major advantages for non-destructive evaluation.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

Building a Prospective LCA Framework to Analyze Emerging Technologies in a Dynamic System Context

NREL's Lifecycle Analysis Integration into Opensource Numerical models (LiAISON) framework computes temporally explicit life cycle impacts and resource uses for specific technologies (foreground) in a dynamic system context (background). LiAISON computes results for a series of environmental mid-points enabling an analysis of prospective tradeoffs of emerging technologies toward 2100. This prospective feature is of critical importance when analyzing present-day emerging technologies whose large-scale impacts during deployment phases will occur in different, future system contexts. LiAISON systematically accounts for dynamic system changes by applying an integrated background of the future energy-economy-land-climate system, generated by exogenous integrated assessment models (IAMs). Using IAM scenarios, LiAISON generates a time-series of life cycle inventory (LCI) databases, which are then used to calculate the impacts per functional unit per time step. This expands current practice of using static, future system assumptions, e.g., a specific grid-mix each year. Further, IAM scenarios are provided in a standardized format of shared-socioeconomic pathways (SSP) and representative concentration pathways (RCP) combinations. These are coherent, regularly, published, and peer-reviewed scenario combinations that establish a reproducible and standardized societal and climate mitigation futures context. They are comparable across IAMs and expand the system boundary of the traditional LCA by including dimensions such as societal and behavioral changes. We apply the framework to assess two emerging Power-to-Hydrogen processes, high temperature electrolysis using solid oxide fuel cell (HT-SOE) and polymer electrolyte membrane electrolysis (PEME). We compare the technologies to a baseline Hydrogen production process via steam methane reforming. Despite the decarbonized electricity systems' beneficial effects on the PtH2 processes' carbon intensities, we find environmental tradeoffs, which require technology improvements via learning-by-doing to be alleviated. Future work via ongoing collaborations will focus on linking the framework to other energy-economy-land-climate models and open-source life cycle inventory databases.

ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

High Penetration Microgrids Providing Grid Stability Using Frequency-Watt Control Presentation

The U.S. grid is rapidly transitioning towards utilizing inverter-based renewable energy resources such as solar, wind, and batteries, reducing the carbon emission footprint.Inverter-based microgrid control architectures remain a critical focus to address power system stability issues in future high penetration markets lacking spinning generation assets. Idaho National Laboratory (INL) is researching an active layered inverter based frequency-Watt control scheme that provides distribution level stability in high-penetration markets where grid inertia is lacking. Hardware in the loop case study was implemented using INL’s Microgrid Testbed to combat scalable frequency deviations ranging from 60 Hz down to 50 Hz initialized by a hydropower model implementing step loads using a 540-kW grid emulator. Our research findings demonstrate the importance of distribution level, inverter-based active frequency-Watt controls utilizing a battery energy storage system (BESS) to provide adequate frequency support at the point of common coupling without major power infrastructure upgrades.

13 HYDRO ENERGY↗

DOE OSTI2025

Dehydrogenation vs Apparent Hydrogenation: Unraveling the Mechanisms of He and O 2 Plasma Etching on Colloidal Nanocrystal Films

Removing organic ligands from colloidal nanoparticles is critical for fabricating solid-state devices, yet accurately quantifying this removal remains a significant analytical challenge. Here, we establish a robust and accessible method for this quantification by calibrating Raman spectroscopy against precise ion beam analysis (IBA) for nanoparticle assemblies (CNAs) processed by helium (He) and oxygen (O 2 ) plasmas. We demonstrate that the calibration curves are remarkably independent of plasma power and pressure, depending critically only on the choice of feed gas. He plasma induces rapid dehydrogenation and cross-linking, evidenced by a much faster decrease in the C–H Raman signal relative to the actual carbon loss. Conversely, O 2 plasma leads to a surprising “apparent hydrogenation”, where the carbon backbone is removed significantly faster than the C–H signal diminishes. This counterintuitive effect is explained by a serial mechanism of oxidative fragmentation; β-scission cleaves the alkyl chains, and subsequent stabilization steps enrich the remaining film with hydrogen-rich methyl-terminated fragments, while carbon is efficiently removed as volatile CO. This work provides calibrated functions that enable the rapid determination of absolute carbon content in processed CNAs using simple Raman spectroscopy with uncertainties of ∼8% for O 2 and ∼12% for He plasma, offering a vital tool for both process diagnostics and fundamental studies of plasma–matter interactions in colloidal nanocrystal films.

Animal feed↗

DOE OSTI2026

Mass Spectrometric Determination of Site-Specific O -Acetylation in Rhamnogalacturonan I Oligomers

O-acetylation, a common modification in rhamnogalacturonan I (RG-I), is critical for various biological processes, including plant growth, stress responses, and pathogen defense. Precise determination of the degree and specific positions of acetylation is therefore essential. To date, nuclear magnetic resonance (NMR) and tandem mass spectrometry have been employed to identify O-acetyl positions in pectin oligosaccharides. Although NMR is effective, it requires pure, high-concentration samples. Tandem mass spectrometry (MS), which uses smaller sample amounts, faces challenges due to O-acetyl migration between monosaccharide positions. The multiple steps in pectin sample analysis can further promote O-acetyl migration, especially near free hydroxyl groups. Moreover, during tandem MS, O-acetyl groups may detach, complicating the accurate tracking. This study presents an approach to lock O-acetyl groups by introducing trideuteroacetyl and propionyl substituents onto free hydroxyls of RG-I or partially acetylated RG-I. By combining matrix-assisted laser desorption/ionization time-of-flight (MALDI-TOF) MS and electrospray ionization (ESI) MS with MS/MS or tandem mass spectrometry (MSn), we devised a way to determine the monosaccharide sequence in the oligomer and the precise positions of O-acetyl groups in partially acetylated RG-I. This method enables the study of the regiospecificity of recombinant pectin O-acetyltransferases and can be applied to other oligosaccharides to determine acyl positions.

O-acetylation↗

DOE OSTI2024

Discovery of GuaB inhibitors with efficacy against Acinetobacter baumannii infection

ABSTRACT Guanine nucleotides are required for growth and viability of cells due to their structural role in DNA and RNA, and their regulatory roles in translation, signal transduction, and cell division. The natural antibiotic mycophenolic acid (MPA) targets the rate-limiting step inde novoguanine nucleotide biosynthesis executed by inosine-5´-monophosphate dehydrogenase (IMPDH). MPA is used clinically as an immunosuppressant, but whetherin vivoinhibition of bacterial IMPDH (GuaB) is a valid antibacterial strategy is controversial. Here, we describe the discovery of extremely potent small molecule GuaB inhibitors (GuaBi) specific to pathogenic bacteria with a low frequency of on-target spontaneous resistance and bactericidal efficacyin vivoagainstAcinetobacter baumanniimouse models of infection. The spectrum of GuaBi activity includes multidrug-resistant pathogens that are a critical priority of new antibiotic development. Co-crystal structures ofA. baumannii, Staphylococcus aureus, andEscherichia coliGuaB proteins bound to inhibitors show comparable binding modes of GuaBi across species and identifies key binding site residues that are predictive of whole-cell activity across both Gram-positive and Gram-negative clades of Bacteria. The clearin vivoefficacy of these small molecule GuaB inhibitors in a model ofA. baumanniiinfection validates GuaB as an essential antibiotic target. IMPORTANCE The emergence of multidrug-resistant bacteria worldwide has renewed interest in discovering antibiotics with novel mechanism of action. For the first time ever, we demonstrate that pharmacological inhibition ofde novoguanine biosynthesis is bactericidal in a mouse model ofAcinetobacter baumanniiinfection. Structural analyses of novel inhibitors explain differences in biochemical and whole-cell activity across bacterial clades and underscore why this discovery may have broad translational impact on treatment of the most recalcitrant bacterial infections.

Microbiology↗

DOE OSTI2024

Port Electrification Handbook: A reference to aid U.S. port energy transitions

Port electrification can take many forms, such as electrifying cargo handling equipment or deploying a microgrid to power critical port infrastructure. To help evaluate the growing challenge of increased electrification and its impacts on the system, Pacific Northwest National Laboratory developed this Port Electrification Handbook with support from the U.S. Department of Energy, Office of Electricity’s Microgrids R&D [research and development] program. The goals of this handbook are the following: (1) Help port operators and planners evaluate different electrification technologies; (2) Explain how these technologies could aid and impact ports and surrounding communities; and (3) Provide step-by-step considerations for port electrification.

24 POWER TRANSMISSION AND DISTRIBUTION↗