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DOE OSTI2023

Cutting force estimation from machine learning and physics-inspired data-driven models utilizing accelerometer measurements

Monitoring cutting forces for process control may be challenging because force measurements typically require invasive instrumentation. To remedy this situation, two new methods were recently developed to estimate cutting forces in real time based on the use of on-machine accelerometer measurements. One method uses machine learning, while another uses a physics-inspired data-driven approach, to generate a model that estimates cutting forces from on-machine accelerations. The estimated forces from both approaches were compared against cutting force data collected during various milling operations on several machine tools. The results reveal the advantages and disadvantages of each model to estimate real-time cutting forces.

Vogl, Greg↗

DOE OSTI2023

The Postdoc Accord in Theoretical High Energy Physics

We present the results of a survey meant to assess the opinion of the high-energy physics theory (HET) community on the January 7th postdoc acceptance deadline - specifically, whether there is a preference to shift the deadline to later in January or February. This survey, which served for information-gathering purpose only, is part of a community conversation on the optimal timing of an acceptance deadline and whether the community would be better served by a later date. In addition, we present an analysis of data from the postdoc Rumor Mill, which gives a picture of the current hiring landscape in the field. We emphasize the importance of preserving a universal deadline, and the current results of our survey show broad support for a shift to a later date. A link to the survey, frequently asked questions, a running list of supporters, and next steps can be found on our companion web page.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Quantum dot microscope apparatus comprising a nanoscale semiconductor on the tip of a fiber, a tunneling electrical lead and a capacitive electrical lead on the fiber

A quantum dot microscope apparatus is provided. A further aspect employs a tilted or tapered end or tip on a microscopic probe. Another aspect of the present apparatus employs a probe including a quantum dot with only one tunneling lead connected to a power source. A manufacturing aspect includes creating a tapered or asymmetrically shaped specimen-facing end of a probe where a quantum dot is located on the end. A further manufacturing aspect includes using focused ion-beam milling to create a tip or end of a quantum dot microscope probe.

Tessmer, Stuart Holden↗

DOE OSTI2023

Iron-based nanoparticles and grains

Example nanoparticles may include an iron-based core, and a shell. The shell may include a non-magnetic, anti-ferromagnetic, or ferrimagnetic material. Example alloy compositions may include an iron-based grain, and a grain boundary. The grain boundary may include a non-magnetic, anti-ferromagnetic, or ferrimagnetic material. Example techniques for forming iron-based core-shell nanoparticles may include depositing a shell on an iron-based core. The depositing may include immersing the iron-based core in a salt composition for a predetermined period of time. The depositing may include milling the iron-based core with a salt composition for a predetermined period of time. Example techniques for treating a composition comprising core-shell nanoparticles may include nitriding the composition.

Wang, Jian-Ping↗

DOE OSTI2022

An influence of manufacturing tolerances on Pin-Cell k-infinity of MOX fuel using data from the FUBILA experiment program

An influence of manufacturing tolerances (MTs) was evaluated on the pin-cell k-infinity of MOX fuel through the random sampling of CASMO5 calculations. The data from the FUBILA experiment program was used as the manufacturing parameters. For the uncertainties of element/isotope mass fractions, their covariance matrices were calculated by the generalized least square method. The total k-infinity uncertainty was 120-250 pcm (percent mille). From the breakdown of k-infinity uncertainty per materials, the MTs of fuel pellet had a dominant influence. The individual influences were also evaluated for element/isotope mass fractions, an inner/outer diameter, and a density. Those of element/isotope mass fractions were less than a few dozen pcm. Since the perturbations of fuel pellet diameter and density caused large variations to the total amount of heavy metals and effect of spatial self-shielding, they had a negative correlation with the k-infinity perturbation. On the AG3 (Al-Mg alloy) over-cladding, the inner/outer diameter perturbations had both negative and positive correlations. The negative one was due to decrease in amount of light water and the positive one was due to increase in amount of AG3. Since the effect of neutron slowing-down by light water had a dominant influence, the influence of the former negative correlation was larger than that of the latter positive correlation. It is, therefore, concluded that the consideration of the MTs that had a large influence on the effect of neutron slowing-down is important for precise quantification of the pin-cell k-infinity uncertainty of MOX fuel. (author)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Beam dynamics corrections in the measurement of the anomalous precession frequency at the Muon $g-2$ experiment at Fermilab

The Muon $g-2$ experiment at Fermilab (E989) aims to measure the anomalous magnetic moment of the muon with an accuracy of 140 ppb (parts per billions). This accuracy, obtained by adding in quadrature a statistical and a systematic contribution of comparable value (100 ppb), will allow to reduce the experimental uncertainty (from the previous E821 experiment at BNL \cite{bnl}) of a factor of 4, and represents one of the most precise tests of the Standard Model (SM) theory of elementary particles. The first result on the Run-1 dataset \cite{prl} was released on April 7, 2021, showing a very good agreement with the previous result from BNL experiment, with a slightly better uncertainty. The corresponding experimental average increases the significance of the discrepancy between the measured and Standard Model prediction of 4.2$\sigma$ \cite{white_paper}.\\ \noindent The measured quantity is the muon magnetic anomaly a$_\mu$=$\frac{g_\mu-2}{2}$ where g$_\mu$ is the gyromagnetic factor of the muon. Dirac's equation predicts g$_\mu$ = 2, while radiative corrections, dominated by the QED contribution due to an exchange of a virtual photon, causes a per-mille correction on this quantity. By including all the SM contributions, a$_\mu$ is known at 370 ppb. The E989 experiment measures $a_\mu$ injecting positive muons with momentum of 3.1 GeV/$c$ polarized longitudinally in bunches (called $fills$) with an average rate of 12 Hz, in a storage ring of 14 meters diameter. Due to the parity violation in the weak muon decay, high energy positrons produced are emitted preferably in the muon's spin direction. By counting the number of positrons with energy greater then 1.7 GeV in function of the time, the frequency precession of the muon spin is measured, that together with the measurement of the magnetic field, allows to extract $a_\mu$. The positrons are detected with 24 electromagnetic calorimeters, that measure the energy and the arrival time of the positrons, each made of 54 crystals of lead fluoride (PbF$_2$) read by silicon photomultipliers (SiPM). Together with calorimeters, two tracking detectors are used to make non-destructive measurements of the muon beam characteristic by reconstructing the muon decay position extrapolating backward the decay positrons. The knowledge of the beam motion inside the ring plays a fundamental role in the analysis of $a_{\mu}$, where the measured anomalous precession frequency $\omega_a$ must be corrected for four main beam dynamics effects. A first correction is associated with the presence of an electric field responsible of the vertical focusing on the storage ring, where vertical direction is orthogonal to the orbit and horizontal direction is along the storage ring radius. Due to the oscillations in the vertical direction, the so called vertical betatron oscillations, a second correction is necessary to account for an average angle associated with the muon motion off the ideal orbit. A third correction is caused by lost muons in the ring which have a different spin phase at the injection respect to the decay ones. Finally, due to the correlation between the vertical and horizontal beam motion of the muons and the acceptance of the calorimeter, a correction (called ``phase-acceptance") arises. In Run1, due to the presence of two damaged resistors in one electrostatic quadrupole, this correction had a prominent role. The replacement of the damaged resistors before Run2 decreased this effect by one order of magnitude, and a further reduction in Run-3 was provided by an improved orbit.\\ \noindent The work of this Thesis focuses on the beam dynamics corrections on $\omega_a$. Due to the prominent role in Run-1 a special attention has been put to the phase-acceptance correction\footnote{The effect of this correction on the E821 BNL measurement of the $g-2$ has been evaluated to be within the quoted systematic error.}. Chapter \ref{ch:anomalous_magnetic_moment} introduces the anomalous magnetic moment of the muon. Chapter \ref{ch:early_experiment} describes the history of the Muon $g-2$ experiments. Chapter \ref{ch:theory} discusses the Standard Model prediction and possible new physics scenario. Chapter \ref{ch:muon_g2_experiment} describes the E989 experiment, whose experimental technique and the apparatus are discussed focusing on the improvements needed to reach the final goal on $a_\mu$ measurement. The original work of the Thesis is discussed in the last 5 chapters. Chapter \ref{ch:experiment_technique} presents the analysis technique to extract $\omega_a$, Chapter \ref{ch:beam_dynamics} describes the beam dynamics in the E989 experiment, Chapter \ref{ch:beam_dynamics_correction} discusses the beam dynamics correction to $\omega_a$, and Chapter \ref{sec:pa_corr} focuses on the phase acceptance correction. Finally Chapter \ref{ch:run23_analysis_improvements} contains the Run-2/3 improvements which are expected to allow for an increased precision ons the beam dynamics co...

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Decarbonizing Hydrogen Production: Assessing A Net-Negative Pathway

Hydrogen is gaining prominence as a key factor in the world's transition to a cleaner energy future. The International Energy Agency (IEA)'s Global Hydrogen Review 2023 reports that the number of low-emission hydrogen production projects is increasing rapidly. The potential for growth in new applications such as heavy industry, transportation, and power generation is significant. The IEA urges more decisive action to spur demand for low-emission hydrogen to achieve climate goals. While hydrogen is produced through various industrial methods, each with its own advantages and disadvantages, low-carbon hydrogen is critical for mitigating climate change and is incentivized by the Clean Hydrogen Production Tax Credit (45V). To this end, we have evaluated a commercial technology that can produce low- or negative-carbon hydrogen via ethanol catalytic oxidative reforming. This study assessed life cycle greenhouse gas emissions (carbon intensity or CI) associated with the hydrogen production technology. A total of 24 scenarios were evaluated, encompassing (a) Gen1 versus Gen2 ethanol inputs, (b) carbon capture and sequestration (CCS) of upstream fermentation CO2, and (c) oxygen sourcing via air separation unit (ASU) versus purchased or on-site production of oxygen as a byproduct of hydrogen electrolysis with a proton exchange membrane (PEM). Key findings include that the base case CI for hydrogen production using Gen2 ethanol from corn stover is lower than Gen1 dry mill corn ethanol. The study also points out that the CI for hydrogen production using PEM-O2 is lower than that using ASU-O2, whether the PEM-O2 is produced on-site or off-site (importing). When sourcing oxygen from on-site PEM-O2, the Gen1 and Gen2 ethanol-derived hydrogen exhibit favorable net-negative CI values for all evaluated scenarios, especially if the upstream ethanol CCS is included. As a reference, the 45V regulatory threshold for generating clean hydrogen tax credits is a CI below 0.45 kg CO2e/kg hydrogen.

BIOMASS FUELS,HYDROGEN↗

DOE OSTI2023

ADVANCED TECHNIQUES FOR ENERGY INPUT REDUCTION IN GYPSUM WALLBOARD DRYING

Gypsum has been used for thousands of years in building and construction applications, starting with the pyramids in ancient Egypt, to “Plaster of Paris” in the midcenturies, and to the now-ubiquitous drywall in modern-day houses. Production of gypsum drywall boards takes several steps with high energy and water consumption. The current state of the art in industry is a process that begins by mining gypsum and reducing its particle size by milling. These gypsum particles undergo calcination to convert the gypsum (calcium sulfate dihydrate) into stucco (calcium sulfate hemihydrate). The stucco is mixed with additives and enough water to form a slurry that can be poured onto a conveyor belt and molded into the desired geometry. The stucco reacts with the water, converting back into gypsum. The remaining water is then dried from the board to form the final product. While only ~20 wt. % of water is needed for the conversion of stucco to gypsum, significant excess water is needed to ensure sufficient fluidity of the slurry for processibility. This is due to the low quality of the stucco particles produced in high throughput calcination units, which disintegrate upon mixing with water, thereby reducing the fluidity and processability of the slurry. This project aims to produce high-quality stucco particles by dielectric calcination. In doing so, particle integrity can be maintained through the slurry formulation step, and particle size distribution of the stucco can be adjusted to increase fluidity with less excess water. With less water remaining unreacted in the board, significant energy can be saved in drying the product. The project aims to 1) develop a dielectric calcination method to TRL 3, 2) determine optimal and practical particle size distributions to minimize excess water in the slurry, and 3) reduce the energy consumption of the drying process.

Conforti, Kameron↗

DOE OSTI2025

Custom Equipment Development for Processing of Surplus Plutonium

The Strategic Laboratory Assessment (SLA), a collaborative team of SRNL and ORNL personnel, has been established to advance the objectives of the Surplus Plutonium Disposition (SPD) Project, by identifying and developing technologies to accelerate disposition, reduce life cycle costs, minimize worker radiation exposure, improve worker safety, and minimize Surplus Plutonium Disposition Program risks. [1] The SLA team has identified can cutting and plutonium (Pu) oxide size reduction as two glovebox processes where technology enhancements would be valuable. The DOESTD-3013 package currently in use for Pu downblending requires cutting two nested cans before the inner convenience can that holds the Pu oxide may be accessed for further processing. A rotary tubing-style cutter is used for opening the 3013 packages within the glovebox. Collet changeouts are required between cutting of the outer and inner cans. The SLA team is currently developing and testing an adjustable-clamp can cutter design that eliminates collet changeouts and allows cutting of the outer and inner can at the same time, resulting in significant reduction of radiological dose and process time, as well as improved ergonomics. To meet the Pu oxide particle size requirement, size reduction of Pu oxide agglomerations must be performed within the process gloveboxes. The SLA team has identified jaw crushing technology as an alternative to the currently employed rotary mill. Jaw crusher advantages include reduced dust within the glovebox, increased batch sizes, and easier integration with other glovebox processes due to the flow-through nature of jaw crushing. Commercially manufactured jaw crushers are either too large and/or too heavy for implementation in the SPD gloveboxes, so the SLA team is developing and testing a custom jaw crusher to meet the needs of the SPD Project.

Krementz, Daniel [Savannah River National Laborato↗

DOE OSTI2024

Microstructure development of novel composite heating elements for steel decarbonization

The iron and steel industry is critical for the modern world but is also responsible for 7% of the total energy sector CO2 emissions. It is a difficult industry to decarbonize due to the high temperature heat required for the production of steel, such as reheating steel slabs to ~1250 °C for hot rolling. Electrification of this process using resistive heating is currently not possible due to the poor creep resistance of MoSi2 heating elements, which need to be operated well below their maximum temperatures when mounted horizontally. To solve this problem, novel MoSi2 composite heating elements with SiBCN ceramic reinforcements are being developed using high energy ball milling and electric field assisted sintering (EFAS). The microstructure and density of the composites after sintering depends on the sintering parameters chosen. Herein we present the effects of EFAS sintering parameters on the microstructure and density of the MoSi2-SiBCN composites.

36 - MATERIALS SCIENCE↗

DOE OSTI2023

Direct Alpha Spectrometry of Nuclear Fallout

Advanced instruments and methods are under development to allow direct alpha spectrometry of nuclear fallout debris near the point of collection, to support nuclear forensics (NF). New approaches are needed to support NF in order to accelerate the process for data generation and reduce the overall timeline for decision making. Fallout debris at short time periods following detonation can be difficult to work with for alpha spectrometry, due to the presence of intense beta radiation originating from significant quantities of high-activity fission products. Intense beta radiation can challenge traditional silicon-based high-resolution alpha spectrometers. Addressing this, single-crystal (sc) chemical vapor deposition (CVD) produced diamond semiconductors have been studied for use for alpha spectrometry for assaying nuclear fallout debris. Tests have been performed using scCVD sensors to assay a variety of actinide-bearing samples. Sample preparation, when done, has been limited to pulverization using a mechanical ball mill. To reduce measurement times, multi-chip arrays of scCVD diamond semiconductor have been developed in form factors suitable for field deployment in support of NF objectives. These arrays have been tested using high-beta-activity sol gel surrogate nuclear explosive debris (SNED) containing varying concentrations of uranium and plutonium. Results from the use of scCVD detectors with sol gel SNED will be presented.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗

DOE OSTI2025

Insulation Activation and Contamination in Low-Power Experiments

Among the diverse advanced nuclear reactor concepts being developed are designs that expect to operate at much higher temperatures than conventional light-water reactors, and therefore require alternative materials for components capable of withstanding these extreme temperatures. Insulation is one such component where alternative high-temperature industrial composites are being considered. Low-power experiments can provide an opportunity for advancing our understanding of material behavior under irradiation; however, these experiments are not without occupational hazards. The focus of this paper is the potential for activation of insulating composites when exposed to neutron fluence during reactor experiments, and to discuss the subsequent contamination of the testing area. This paper will also discuss practical measures for preventing the creation and inhalation of activated particulate matter (i.e., dust), such as engineering and administrative controls and personal protective equipment. This paper evaluates the suitability of several insulation materials for use in reactor experiments based on their activation from neutron irradiation. The materials considered are Pyrogel XTE by Aspen Aerogel, Cerablanket and Kaowool by Morgan Advanced Materials, Thermo-12 Gold by Johns Manville, and Maxsil CF6-2000 by McAllister Mills. Although these materials are not yet widely used in the nuclear industry, they are common in other industries due to their thermal insulating properties. These materials produce dust while handling that can pose health and safety hazards, which could be further exacerbated by activation. The analysis presented in this paper utilizes a deterministic method developed to predict the activation source term of the provided insulation materials. The method calculates the atomic density of each element within the composites and simulates their exposure to a specified neutron flux density representative of low power experimental conditions. During the irradiation phase and throughout the extensive cooling period, neutron absorptions and nuclear decays are tracked for relevant isotopes. The residual activity within each composite is then assessed to identify the material with the lowest potential radiological hazard to workers. Dust will be created during installation and removal of insulating materials and may also be generated during the experiment. Contamination of surrounding surfaces due to dispersion is highly likely unless preventative measures are taken. The results of this analysis are used to estimate an internal dose from inhalation of activated dust, which is significantly lower than the allowable whole-body dose. However, the risk of internal exposure may increase if the dust becomes a transport vector for nuclear material. The goals of this paper are to enhance the understanding of the potential activation and contamination hazards from the use of these insulating materials in low-power nuclear experiments and to foster safer work environments through informed decision-making and strategic planning. This work ultimately contributes to a broader understanding of how new non-nuclear materials for advanced reactors impact the radiological safety of co-located workers, helping to ensure the responsible management of radioactive materials during installation and decommissioning activities.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗

DOE OSTI2026

Ether of Orbifolds

The orbifold lattice has been proposed as a route to practical quantum simulation of Yang--Mills theory, with claims of exponential speedup over all known approaches. Through analytical derivations, Monte Carlo simulation, and explicit circuit construction, we identify compounding costs entirely absent in Kogut--Susskind formulations: a mass-dependent Trotter overhead that scales as $m^4$, non-singlet contamination that grows as $m^2$ and worsens with penalty terms, and a mandatory mass extrapolation. Monte Carlo simulations of SU(3) establish a universal scaling: the continuum limit forces $m^2 \propto 1/a$, binding the Trotter step to the lattice spacing through a cost unique to orbifolds. For a fiducial $10^3$ calculation, the orbifold is $10^4$--$10^{10}$ times more expensive than every published alternative. These results indicate that the claimed computational advantages do not at present survive quantitative scrutiny.

Lamm, Henry [Fermilab] (ORCID:0000000330330791)↗

DOE OSTI2026

Optimizing Energy Use in Pulp & Paper with DOE’s Energy Intensive Industries Resources

The U.S. pulp and paper industry is the third-largest energy consumer in manufacturing, accounting for roughly 10% of sector energy use. Improving energy efficiency reduces operating costs and strengthens competitiveness. To support this effort, the U.S. Department of Energy (DOE), through Oak Ridge National Laboratory (ORNL), launched the Energy Intensive Industries (EII) Initiative. A two-year pilot across 45 industrial sites identified more than 4 trillion Btu/year in potential energy savings. This presentation outlines plans for a follow-up technical assistance program tailored to pulp and paper mills. Available resources include a cost-savings scoping tool, implementation planning guidance, and technical support for applying advanced methods such as Pinch Analysis for integrated process-utilities optimization. The session introduces key Pinch Analysis principles and highlights case studies demonstrating measurable improvements. ORNL also seeks industry feedback on barriers to efficiency improvements, including technology gaps and resource needs. DOE’s broader objective is to accelerate productivity and economic competitiveness across U.S. energy-intensive industries.

Kamath, Dipti [ORNL] (ORCID:0000000278739994)↗

DOE OSTI2026

Prioritizing Transformative Energy Efficiency Technologies in the Pulp and Paper Sector Through Levelized Cost of Conserved Energy

This presentation explores how the U.S. pulp and paper sector can prioritize energy efficiency (EE) technologies using the Levelized Cost of Conserved Energy (LCCE) metric. As mills face market shifts and rising costs, technologies such as advanced drying, membrane concentration, waste heat recovery, and recovery boiler replacements offer potential savings but face economic barriers. LCCE enables consistent comparison of technologies by calculating cost per unit of energy saved, including capital, operating, and potentially non-energy benefits like productivity, maintenance, and safety improvements. Preliminary findings show economies of scale significantly influence recovery boiler replacement feasibility, with larger systems achieving lower LCCE values. Ongoing work incorporates non-energy benefits to provide a more comprehensive cost-effectiveness assessment and guide research, development, and deployment priorities for underutilized and emerging technologies.

Kamath, Dipti [ORNL] (ORCID:0000000278739994)↗

DOE OSTI2025

Status of the Down-Blending of Irradiated IGR Graphite Fuel in Kazakhstan

Dry processing remains the primary solution for managing the down-blending of irradiated IGR HEU fuel. Several tasks have been initiated and completed to achieve this, including lab modernization, lab-scale and full-scale testing, designing and fabricating an in-paddle mixing drum, and commissioning both a down-blending system and a crushing and milling system. Additionally, a testing and training center was modernized, the equipment was successfully commissioned, and the IGR HEU fuel blocks were repackaged into daily containers. The training of operators and the construction of a new down-blending facility are tasks that will need to be completed in the near future. The progress in these areas continues to validate that the proposed method for down-blending irradiated HEU graphite fuel, followed by cementation of the down-blended material for permanent disposition, appears to be achievable.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗

DOE OSTI2026

Learning the generating functional for variance reduction in lattice QCD

The generating functional in quantum field theory provides the natural framework for constructing correlation functions as derivatives with respect to source operators. We present a methodology that leverages machine-learned normalizing flows to reduce the variance of arbitrary $N$-point correlation functions of bosonic operators in lattice gauge field theory calculations by encoding a representation of the generating functional. We show that it is possible to systematically approach noiseless estimators of correlation functions in this framework. We demonstrate this methodology with applications to calculations of glueball correlation functions and Wilson loops in Quantum Chromodynamics and Yang-Mills theory. The results show up to three orders of magnitude variance reduction.

Abbott, Ryan [Columbia U.] (ORCID:0000000258778005↗

DOE OSTI2026

Creep Performance of Novel Composite Heating Elements for Reheat Furnace Electrification

The iron and steel industry is critical for the modern world but is also very energy intensive and is a low margin industry. Hot rolling requires reheating steel slabs to ~1250 °C for hot rolling and involves yield loss due to scale formation. Electrification of this process using resistive heating could improve yield but is currently not possible due to the poor creep resistance of MoSi2 heating elements, which need to be operated well below their maximum temperatures when mounted horizontally. To solve this problem, novel MoSi2 composite heating elements with SiBCN ceramic reinforcements are being developed using high energy ball milling and spark plasma sintering. The creep performance of different heating elements and their corresponding microstructures and electrical properties will be presented.

36 - MATERIALS SCIENCE↗