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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Extrusion‐Spheronization of Mock Energetic Materials

The primary method for producing plastic bonded explosive (PBX) granules, or “prills”, has remained relatively unchanged for 70 years despite the complex nature of the process. In this work, we demonstrate the feasibility of using an extrusion‐spheronization technique to produce prills for PBX applications. We begin by detailing an inert formulation with similar properties of PBXs and then demonstrate the extrusion‐spheronization processing of these materials. A study is then performed where the spheronization process time of the extruded materials is varied and the resultant prills are morphologically characterized. Further, these prills are then pressed into high‐density articles and subject to compression testing to elucidate trends in process, properties, and performance. It was found that, for our formulation (95 wt.% melamine/5 wt.% polymer binder) and process, a spheronization time of 60 s yielded relatively uniform particles that exhibited improved poured, tapped, and pressed densities. Mechanical strength did not have a strong trend with process time as all spheronized materials had similar peak compression stress at failure. After further optimization, extrusion‐spheronization may be a promising path for future PBX formulation.

extrusion spheronization↗
DOE OSTI2020

Robust Event Simulation Variants Endowed to Ns-3 for General Exploration

Sandia's ns-3 contributions are modifications to the open source ns-3 network simulator that enable simulation speedup. One improvement, for example, removes the need for simulating the transmission and receipt of packets between nodes that are too distant to actually be able to communicate. In large-scale simulations this optimization has shown significant gains in performance. Additional contributions will pave the way for parallel discrete simulation (PDES) in ns-3. SAND2020-12456 O Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Dickson, Joseph↗
DOE OSTI2025

Local practically safe extremum seeking with assignable rate of attractivity to the safe set

We present Assignably Safe Extremum Seeking (ASfES), an algorithm designed to minimize a measured, static objective function while maintaining a measured, static metric of safety (a control barrier function or CBF) to be positive in a practical sense. We ensure that for trajectories with safe initial conditions, the violation of safety can be made arbitrarily small through appropriately chosen design constants. We also guarantee an assignable “attractivity” rate: from unsafe initial conditions, the trajectories approach the safe set, in the sense of the measured CBF, at a rate no slower than a user-assigned rate. Similarly, from safe initial conditions, the trajectories approach the unsafe set, in the sense of the CBF, no faster than the assigned attractivity rate. The feature of assignable attractivity is not present in the semiglobal version of safe extremum seeking, where the semiglobality of convergence is achieved by slowing the adaptation. We also demonstrate local convergence of the parameter to a neighborhood of the minimum of a quadratic objective function constrained to the safe set with a linear CBF. The ASfES algorithm and analysis are multivariable, but we also extend the algorithm to a Newton-Based ASfES scheme which we show is only useful in the scalar case. The proven properties of the designs are illustrated through simulation examples.

42 ENGINEERING↗
DOE OSTI2021

J/Psi Photoproduction Near Threshold With CLAS12

The structure of the proton is comprised of quarks and a sea of gluons. A mechanism that can extract the characteristics of the hidden-color correlations of the nuclear wavefunction is the production of charm near threshold. Due to the fact that momentum transfer is large near threshold in the production of J/ψ , all three valence quarks must act coherently to ex- change energy for the reaction to occur. Models have been developed to predict the nature of J/ψ photoproduction at these specific energies. These include production mechanisms with the two-gluon and three-gluon exchanges. The transferred momentum dependence of the differential cross sections are sensitive to the gluonic form factors, which describe the distribution of color charge in the proton. The CLAS12 detector is capable of measuring J/ψ photoproduction at the energy range close to the threshold. Work showcased in this dissertation encompasses the preparation of the CLAS12 experiments, including the optimization of tracking reconstruction through the study of the Torus magnetic field. In terms of software, contributions were made to the CLAS12 Event Builder, a key stage of reconstruction where event-by-event information is summarized for efficient data analysis. After the run periods were successfully completed, analysis of the RG-A data commenced and an analysis framework was developed to measure the differential and total cross sections of J/ψ photoproduction in Hall B.

Newton, Joseph↗
DOE OSTI2022

A flexible linear diffusion acceleration to k-eigenvalue neutron transport with SN discontinuous finite element method

In this paper, we derive a flexible linear diffusion acceleration (LDA) for k-eigenvalue neutron transport discretized with discontinuous finite element method (DFEM) and discrete ordinates(SN). This LDA is based on our two pieces of previous works: the flexible non linear diffusion acceleration (NDA) for DFEM-SN and LDA for k-eigenvalue neutron transport using pre-conditioned Jacobian-free Newton-Krylov with self-adjoint angular flux (SAAF), continuous finite element method(CFEM), and SN. We point out the differences between LDA and NDA for DFEM-SN and the difference between DFEM-SN and SAAF-CFEM-SN for LDA. Numerical tests are presented to compare the convergence behaviour of NDA and LDA. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Scalable Techniques for Stochastic Power Flow Problems (Final Report)

The proposed research focuses on developing scalable algorithms for two-stage security-constrained OPF problems with AC power flow constraints, a class of problems complicated by (i) scale arising from a scenario representation; and (ii) the presence of nonlinearity, nonconvexity, and possibly second-stage discreteness or complementarity. Unfortunately, most existing solvers cannot contend with both challenges simultaneously; accordingly, the proposed research focuses on developing solution techniques that can both scale with the number of scenarios and contend with nonconvexity and second-stage complementarity. We consider three avenues for addressing such problems: (i) Variable sample-size SQP (VS-SQP) methods that combine sparse Quasi-Newton updates with a scalable variance-reduced stochastic gradient scheme for stochastic QP subproblems, allowing for contending with second-stage complementarity via regularization; (ii) Variable sample-size stochastic Interior-point (VS-sIP) schemes that propose a sampling-based regularized (to allow for contending with complementarity) interior-point schemes in which a Schur-complement technique is employed for decomposing the Newton direction computation step; (iii) Variable sample-size tractable ADMM (VS-tADMM) schemes combine variable sample-sizes with carefully designed techniques for resolving each of the nonconvex updates (by leveraging the QCQP structures). We intend to compare the three schemes using performance profiles in terms of solution quality, scalability, etc. and then select one scheme which will then be developed and further refined in Python for purposes of the GO competition.

42 ENGINEERING↗
DOE OSTI2026

ReMU: regional minimal updating for model-based derivative-free optimization

Derivative-free optimization (DFO) problems are optimization problems where derivative information is unavailable or extremely difficult to obtain. Model-based DFO solvers have been applied extensively in scientific computing. Powell's NEWUOA (2004) [Powell, The NEWUOA software for unconstrained optimization without derivatives, in Large-Scale Nonlinear Optimization, Nonconvex Optimization and its Applications Vol. 83, G. Di Pillo and M. Roma, eds., Springer, 2006, pp. 255–297] and Wild's POUNDerS (2014) [Wild, Solving derivative-free nonlinear least squares problems with POUNDERS, in Advances and Trends in Optimization with Engineering Applications, T. Terlaky, M.F. Anjos, and S. Ahmed, eds., SIAM, 2017, pp. 529–540] explore the numerical power of the minimal norm Hessian (MNH) model for DFO and contributed to the open discussion on building better models with fewer data to achieve faster numerical convergence. Another decade later, we propose the regional minimal updating (ReMU) models, and extend the previous models into a broader class, including the H 2 norm models [Xie and Yuan, Least H 2 norm updating of quadratic interpolation models for derivative-free trust-region algorithms, IMA J. Numer. Anal. 46 (2025), pp. 21–50]. This paper shows motivation behind ReMU models, computational details, theoretical and numerical results on particular extreme points and the barycentre of ReMU's weight coefficient region, and the associated KKT matrix error and distance. Novel metrics, such as the truncated Newton step error, are proposed to numerically understand the new models' properties. A new algorithmic strategy, based on iteratively adjusting the ReMU model type, is also proposed, and shows numerical advantages by combining and switching between the barycentric model and the classic least Frobenius norm model in an online fashion.

derivative-free trust-region methods↗
DOE OSTI2026

RegularizedOptimization.jl: A Julia framework for regularized and nonsmooth optimization

RegularizedOptimization.jl is a Julia package that implements families of quadratic regularization and trust-region methods for solving the nonsmooth optimization problem $^{\textrm{minimize}}_{𝑥∈ℝ^𝑛}$ 𝑓(𝑥) + ℎ(𝑥) subject to 𝑐(𝑥) = 0, (1) where 𝑓 ∶ ℝ 𝑛 → ℝ and 𝑐 ∶ ℝ 𝑛 → ℝ 𝑚 are continuously differentiable, and ℎ ∶ ℝ 𝑛 → ℝ∪{+∞} is lower semi-continuous. The nonsmooth objective ℎ can be a regularizer, such as a sparsity inducing penalty, model simple constraints, such as 𝑥 belonging to a simple convex set, or can be a combination of both. All 𝑓, ℎ, and 𝑐 can be nonconvex. RegularizedOptimization.jl provides a modular and extensible framework for solving (1), and developing novel solvers. Currently, the following solvers are implemented: • Trust-region solvers TR and TRDH (Aravkin et al., 2022; Leconte & Orban, 2025) • Quadratic regularization solvers R2, R2DH and R2N (Aravkin et al., 2022; Diouane, Habiboullah, et al., 2024) • Levenberg-Marquardt solvers LM and LMTR (Aravkin et al., 2024) used when 𝑓 is a least-squares residual. • Augmented Lagrangian solver AL (De Marchi et al., 2023). All solvers rely on first derivatives of 𝑓 and 𝑐, and optionally on their second derivatives in the form of Hessian-vector products. If second derivatives are not available, quasi-Newton approximations can be used. In addition, the proximal mapping of the nonsmooth part ℎ, or adequate models thereof, must be evaluated. At each iteration, a step is computed by solving a subproblem of the form (1) inexactly, in which 𝑓, ℎ, and 𝑐 are replaced with appropriate models around the current iterate. The solvers R2, R2DH, and TRDH are particularly well suited to solve the subproblems, though they are general enough to solve (1). All solvers are allocation-free, so re-solves incur no additional allocations. To illustrate our claim of extensibility, a first version of the AL solver was implemented by an external contributor. Furthermore, a nonsmooth penalty approach, described in Diouane, Gollier, et al. (2024), is currently being developed, that relies on the library to efficiently solve the subproblems.

Gollier, Maxence [Polytechnique Montréal, QC (Cana↗
DOE OSTI2025

Creating Favorable Pt/Co Interfaces via a Two‐Step Approach for Constructing Highly Durable PtCo Intermetallic Fuel Cell Catalysts

Structurally ordered PtCo intermetallics are one of the most promising oxygen-reduction catalysts in proton exchange membrane fuel cells (PEMFCs) due to their intrinsically improved catalytic activity and stability relative to PtCo solid-solution alloys. However, increasing the heating temperature to achieve a desirable high degree of ordering results in severe particle agglomeration and low mass activity and stability. Herein, a two-step synthesis approach is developed to create an L1 2 -Pt 3 Co intermetallic structure with an increased ordering degree and well-dispersed ultrafine particles. The first step of the synthesis yields ultrafine Pt nanoparticles that are well-dispersed on the ZIF-8-derived carbon support. The second adsorption step enables us to fine-tune the Pt and Co interfaces, assisted by optimal amino acids, to establish a favorable Co-rich environment around fine Pt nanoparticles, facilitating Co diffusion into the Pt crystalline under mild thermal conditions (<800 °C). In conclusion, this two-step ordered L1 2 -Pt 3 Co catalyst is systematically evaluated using membrane electrode assemblies under heavy-duty vehicle (HDV) conditions and demonstrated exceptional performance and durability, retaining 1.35 A cm -2 only a 7% loss in current density at 0.7 V after an extensive accelerated stress test of 150,000 voltage cycles.

30 DIRECT ENERGY CONVERSION↗