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DOE OSTI2026

High-Temperature SiC Cladding End Plug Irradiation Design and HFIR Readiness

This report documents the design of a High Flux Isotope Reactor (HFIR) irradiation experiment intended to evaluate irradiation effects on the hermeticity of silicon carbide (SiC) end plug specimens under a radial fast neutron flux gradient at representative light-water reactor (LWR) temperatures of approximately 300 °C. The overarching goal of this work is to statistically evaluate SiC end plug hermeticity and mechanical properties following irradiation using the high-throughput irradiation capability discussed here. Each specimen consists of a short section of SiC fiber–reinforced SiC (SiC/SiC) tube with a single monolithic SiC end plug joined to one end. The experiment allows up to 66 specimens to be irradiated in six different stacks within a dry, sealed irradiation capsule derived from the previously developed high-temperature SiC/SiC cladding bowing experiment. The neutronics basis, thermal analysis, and HFIR readiness of the experiment are discussed in this report for two possible design cases. The first design case is based on existing approval documentation and components that are on hand and approved for use, so the experiment insertion would require only specimen receipt, specimen pre-irradiation characterization, experiment assembly, and final fabrication package approval. The second design case provides improved thermal robustness and the preferred end plug geometry but requires fabrication of a modified holder and revisions to the HFIR approval documentation, in addition to the other activities required for the first design case, before insertion.

Hott, Daniel [Oak Ridge National Laboratory (ORNL)↗

DOE OSTI2026

The Case for a Muon Collider

In the search for future high-energy collider technologies, the muon collider has emerged as an extremely promising long-term option. The muon’s large mass relative to the electron allows it to reach high mass energies with a small footprint. This talk will first provide an overview of the scientific potential of a future muon collider, followed by a discussion of the key technical challenges that must be overcome, given the muon’s short lifetime and the many acceleration stages in a collider. This talk concludes with encouragement for audiences to join the ongoing international research and development efforts for a muon collider.

Keeler, Dominic [Purdue U., West Lafayette] (ORCID↗

DOE OSTI2026

Reservoir Sediment Management and Monitoring Database

Overview This dataset compiles dam sediment management and monitoring information from surveys, case studies, and journal articles. Additionally, features described by the National Inventory of Dams (i.e., presence of sluice gates) are included to indicate known infrastructure features that may address sediment releases. The location and description of records from downstream monitoring gages are catalogued in order to help with tracking conditions over time (e.g., before and after management actions, as operations change, etc.). The data help address national scale understanding of challenges and solutions related to the accumulation of sediment behind a dam as well as downstream passage. Sediment trapping causes problems as it reduces storage capacity, disrupts dam and reservoir function, impedes access for recreation, alters water quality/habitat conditions, and contributes to riverbank and coastal erosion within the reservoir. Data compilation from a variety of sources is a first step towards assessing system-wide efficacy of management solutions. This dataset was developed under the Water Power Technologies Office funded effort which began as a Seedling on Reservoir Sedimentation Data, and was supported by the Reservoir Sedimentation Modeling Framework and Data Analysis project. These projects have addressed challenges in describing sediment transport, trapping, and management at dams throughout the US. Methodology An outer join on dams/reservoirs with surveys and survey reports (documented in the RESSED database, USBR or USACE databases, project websites, etc.) with the National Inventory of Dams, based on the NIDID to determine dams with documented management and/or sluice gates. Additional dams with documented management activity were identified through review of technical articles from the past 25 years in Journal of Hydrology, Journal of Water Resources Planning and Management, Geomorphology, Journal of Hydraulic Engineering, Water, Journal of Cleaner Production, International Journal of Sediment Research, Nature Scientific Reports, Earth Surface Processes and Landforms, and Environmental Science and Pollution Research. Individual records were created for each survey or management activity documented. To evaluate downstream sediment monitoring records, the nhdPlusTools and dataRetrieval packages in R were used to find gages within 10km of each dam in the management database. Length of record and location of matched gages were retrieved for those parameters relevant to sediment concentration or total sediment discharge.

Hansen, Carly [ORNL] (ORCID:0000000193280838)↗

DOE OSTI2024

Interim report for the International Muon Collider Collaboration (IMCC)

The International Muon Collider Collaboration (IMCC) [1] was established in 2020 following the recommendations of the European Strategy for Particle Physics (ESPP) and the implementation of the European Strategy for Particle Physics-Accelerator R&D Roadmap by the Laboratory Directors Group [2], hereinafter referred to as the the European LDG roadmap. The Muon Collider Study (MuC) covers the accelerator complex, detectors and physics for a future muon collider. In 2023, European Commission support was obtained for a design study of a muon collider (MuCol) [3]. This project started on 1st March 2023, with work-packages aligned with the overall muon collider studies. In preparation of and during the 2021-22 U.S. Snowmass process, the muon collider project parameters, technical studies and physics performance studies were performed and presented in great detail. Recently, the P5 panel [4] in the U.S. recommended a muon collider R&D, proposed to join the IMCC and envisages that the U.S. should prepare to host a muon collider, calling this their "muon shot". In the past, the U.S. Muon Accelerator Programme (MAP) [5] has been instrumental in studies of concepts and technologies for a muon collider.

43 PARTICLE ACCELERATORS↗

DOE OSTI2022

KBase Educators Handbook

The KBase Educators Handbook is a community resource for educators teaching biology, computational biology, and bioinformatics using KBase. The Handbook includes supporting documentation on how to join and access community-developed resources for teaching with KBase, best practices, and guidelines on how to contribute to the KBase Educators Community.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

BUTTER-E - Energy Consumption Data for the BUTTER Empirical Deep Learning Dataset

The BUTTER-E - Energy Consumption Data for the BUTTER Empirical Deep Learning Dataset adds node-level energy consumption data from watt-meters to the primary sweep of the BUTTER - Empirical Deep Learning Dataset. This dataset contains energy consumption and performance data from 63,527 individual experimental runs spanning 30,582 distinct configurations: 13 datasets, 20 sizes (number of trainable parameters), 8 network "shapes", and 14 depths on both CPU and GPU hardware collected using node-level watt-meters. This dataset reveals the complex relationship between dataset size, network structure, and energy use, and highlights the impact of cache effects. BUTTER-E is intended to be joined with the BUTTER dataset (see "BUTTER - Empirical Deep Learning Dataset on OEDI" resource below) which characterizes the performance of 483k distinct fully connected neural networks but does not include energy measurements.

Array↗

DOE OSTI2021

Strength in Rotary Friction Welding of Five Dissimilar Nickel-Based Superalloys

Advanced manufacturing processes improve the cost and quality of goods. Rotary friction welding is a fast, energy-efficient, and reliable joining process for metals, but new applications are hindered by large development costs for each new alloy. Each alloy set has different welding characteristics; therefore, lessons learned from a single alloy are not always broadly applicable. To establish knowledge that is applicable across multiple alloys, a family of different superalloys were welded to discover process trends that were applicable beyond a single alloy set. In this study, weld symmetry did not correlate to weld strength across alloy systems. Some alloys’ strongest welds occurred at maximum symmetry, whereas high asymmetry was associated with different alloys’ maximum strength. High feed rates, high welding forces, low energy, and low temperatures all resulted in high-strength welds across all alloy and geometry combinations. Tensile strengths greater than 95% of base-metal strength were recorded for most alloy systems.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Section-level genome sequencing and comparative genomics of Aspergillus sections Cavernicolus and Usti.

The genus Aspergillus is diverse, including species of industrial importance, human pathogens, plant pests, and model organisms. Aspergillus includes species from sections Usti and Cavernicolus, which until recently were joined in section Usti, but have now been proposed to be non-monophyletic and were split by section Nidulantes, Aenei and Raperi. To learn more about these sections, we have sequenced the genomes of 13 Aspergillus species from section Cavernicolus (A. cavernicola, A. californicus, and A. egyptiacus), section Usti (A. carlsbadensis, A. germanicus, A. granulosus, A. heterothallicus, A. insuetus, A. keveii, A. lucknowensis, A. pseudodeflectus and A. pseudoustus), and section Nidulantes (A. quadrilineatus, previously A. tetrazonus). We compared these genomes with 16 additional species from Aspergillus to explore their genetic diversity, based on their genome content, repeat-induced point mutations (RIPs), transposable elements, carbohydrate-active enzyme (CAZyme) profile, growth on plant polysaccharides, and secondary metabolite gene clusters (SMGCs). All analyses support the split of section Usti and provide additional insights: Analyses of genes found only in single species show that these constitute genes which appear to be involved in adaptation to new carbon sources, regulation to fit new niches, and bioactive compounds for competitive advantages, suggesting that these support species differentiation in Aspergillus species. Sections Usti and Cavernicolus have mainly unique SMGCs. Section Usti contains very large and information-rich genomes, an expansion partially driven by CAZymes, as section Usti contains the most CAZyme-rich species seen in genus Aspergillus. Section Usti is clearly an underutilized source of plant biomass degraders and shows great potential as industrial enzyme producers. Citation: Nybo JL, Vesth TC, Theobald S, Frisvad JC, Larsen TO, Kjaerboelling I, Rothschild-Mancinelli K, Lyhne EK, Barry K, Clum A, Yoshinaga Y, Ledsgaard L, Daum C, Lipzen A, Kuo A, Riley R, Mondo S, LaButti K, Haridas S, Pangalinan J, Salamov AA, Simmons BA, Magnuson JK, Chen J, Drula E, Henrissat B, Wiebenga A, Lubbers RJM, Müller A, dos Santos Gomes AC, Mäkelä MR, Stajich JE, Grigoriev IV, Mortensen UH, de Vries RP, Baker SE, Andersen MR (2025). Section-level genome sequencing and comparative genomics of Aspergillus sections Cavernicolus and Usti. Studies in Mycology 111: 101-114. doi: 10.3114/sim.2025.111.03.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2024

Modeling-Based Design and Optimization of a Gradient Composite Transition Joint

An innovative additively manufactured gradient composite transition joint (AM-GCTJ) has been designed to join dissimilar metals, to address the pressing issue of premature failure observed in conventional dissimilar metal welds (DMWs) when subjected to increased cyclic operating conditions of fossil fuel power plants. The transition design, guided by computational modeling, developed a gradient composite material distribution, facilitating a smooth transition in material volume fraction and physical properties between different alloys. This innovative design seeks to alleviate structural challenges arising from distinct material properties, including high thermal stress and potential cracking issues resulting from the thermal expansion mismatch typically observed in conventional DMWs. In this study, we investigated the creep properties of transition joints comprising Grade 91 steel and 304 stainless steel through a combination of simulations and creep testing experiments. The implementation of a gradient composite design in the plate transition joint resulted in a significant enhancement of creep resistance when compared to the baseline conventional DMW. For instance, the creep rupture life of the transition joint was improved by > 400% in a wide range of temperature and stress testing conditions. Meanwhile, the failure location shifted to the base material of Grade 91 steel. Such enhancement can be primarily attributed to the strong mechanical constraint facilitated by the gradient composite design, which effectively reduced the stresses on the less creep-resistant alloy in the transition zone. Beyond examining plate joints, it is crucial to assess the deformation response of tubular transition joints under pressure loading and transient temperature conditions to substantiate and demonstrate the effectiveness of the design. The simulation results affirm that the tubular transition joint demonstrates superior resistance compared to its counterpart DMW when subjected to multiaxial stresses in tubular structures. In addition, optimization of the transition joint’s geometry dimensions has been conducted to diminish the accumulated deformation and enhance the service life. Lastly, the scalability and potential of the innovative transition joints for large-diameter pipe applications are addressed.

Zhang, Wei↗

DOE OSTI2026

Demonstration of high-rate manufacturing of π-joint using additive manufacturing

Bonded composite π-joints are critical to support wing geometries in aerospace/aircraft structures. Its lightweight and robust load-bearing capabilities/design guarantee high structural integrity and reliability. Current manufacturing techniques of π-joints are complex and laborious, and do not always offer high-quality joining. This study presents a high-rate manufacturing approach to fabricate π-joints using an integrated Additive Manufacturing and Compression Molding (AMCM) process. The joints were manufactured using unidirectional aerospace-grade LMPAEK/CF at 60% fiber loading for the stiffeners/skin and LM-PAEK/GF as the adhesive and characterized to evaluate their microstructure and strength. While the results indicate void formation at the joint caused by inadequate pressure, the peak tensile load of 600N recorded is akin to injection-autoclave molded π-joints, which validates the potential of this high-rate integrated approach to eliminate time-consuming and labour-intensive processes of making π-joints to reduce cost and produce high-quality joints.

Marathe, Umesh [ORNL]↗

DOE OSTI2022

Finding values in lignin: A promising yet under-utilized component of the lignocellulosic biomass

This article outlines the technical and economic potentials of lignin in unlocking sustainable biorefineries. The benefits of using this highly functionalized biopolymer for the growth of sustainable economy have been highlighted. But practically, the possibility of commercially substituting petroleum oil with lignin is still not very high as the estimated biofuel production cost is 2–3 times higher than the former one. However, with the advancement in technology and more efficient measures by biorefineries such as storing and processing the biomass near the field so as to reduce the transportation cost, it is possible to gain higher profits. Companies like Domtar, Stora Enso, Borregaard’s LignoTech, VITO, and Chemelot InSciTe have been promoting commercial value of lignin. The growth of lignin market after the start-up production at various sites has been discussed in this review. Combining the complete “start-to-finish” analysis with economic evaluation gives a pragmatic overview of the possibilities whether lignin will join petroleum oil as an efficient and cost-effective renewable source.

Jassal, Vidhisha↗

DOE OSTI2021

Mitochondrial Genomes of the United States Distribution of Gray Fox (Urocyon cinereoargenteus) Reveal a Major Phylogeographic Break at the Great Plains Suture Zone

We examined phylogeographic structure in gray fox (Urocyon cinereoargenteus) across the United States to identify the location of secondary contact zone(s) between eastern and western lineages and investigate the possibility of additional cryptic intraspecific divergences. We generated and analyzed complete mitochondrial genome sequence data from 75 samples and partial control region mitochondrial DNA sequences from 378 samples to investigate levels of genetic diversity and structure through population- and individual-based analyses including estimates of divergence (FST and SAMOVA), median joining networks, and phylogenies. We used complete mitochondrial genomes to infer phylogenetic relationships and date divergence times of major lineages of Urocyon in the United States. Despite broad-scale sampling, we did not recover additional major lineages of Urocyon within the United States, but identified a deep east-west split (~0.8 million years) with secondary contact at the Great Plains Suture Zone and confirmed the Channel Island fox (Urocyon littoralis) is nested within U. cinereoargenteus. Genetic diversity declined at northern latitudes in the eastern United States, a pattern concordant with post-glacial recolonization and range expansion. Beyond the east-west divergence, morphologically-based subspecies did not form monophyletic groups, though unique haplotypes were often geographically limited. Gray foxes in the United States displayed a deep, cryptic divergence suggesting taxonomic revision is needed. Secondary contact at a common phylogeographic break, the Great Plains Suture Zone, where environmental variables show a sharp cline, suggests ongoing evolutionary processes may reinforce this divergence. Follow-up study with nuclear markers should investigate whether hybridization is occurring along the suture zone and characterize contemporary population structure to help identify conservation units. Comparative work on other wide-ranging carnivores in the region should test whether similar evolutionary patterns and processes are occurring.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Cultivating a culture of inclusivity in heliophysics

A large number of heliophysicists from across career levels, institution types, and job titles came together to support a poster at Heliophysics 2050 and the position papers for the 2024 Heliophysics decadal survey titled “Cultivating a Culture of Inclusivity in Heliophysics,” “The Importance of Policies: It’s not just a pipeline problem,” and “Mentorship within Heliophysics.” While writing these position papers, the number of people who privately shared disturbing stories and experiences of bullying and harassment was shocking. The number of people who privately expressed how burned out they were was staggering. The number of people who privately spoke about how they considered leaving the field for their and their family’s health was astounding. And for as much good there is in our community, it is still a toxic environment for many. If we fail to do something now, our field will continue to suffer. While acknowledging the ongoing growth that we as individuals must work toward, we call on our colleagues to join us in working on organizational, group, and personal levels toward a truly inclusive culture, for the wellbeing of our colleagues and the success of our field. This work includes policies, processes, and commitments to promote: accountability for bad actors; financial security through removing the constant anxiety about funding; prioritization of mental health and community through removing constant deadlines and constant last-minute requests; a collaborative culture rather than a hyper-competitive one; and a community where people can thrive as whole persons and do not have to give up a healthy or well-rounded life to succeed.

mental health↗

DOE OSTI2025

Roles for epigenetics in wood formation and stress response intrees–from basic biology to forest management

Annual model and crop species have been the subject of most epigenetic studies for plants. In contrast to annuals, forest trees persist on natural landscapes and experience environmental variation within and across seasons, years, and decades or even centuries. Most forest trees species are undomesticated and typically grown on variable landscapes with no irrigation or application of agricultural chemicals. Forest trees must thus rely on their inherent ability to alter growth and physiology to mitigate the effects of changing abiotic and biotic stressors. Like other plants, trees have mechanisms encoded in their genomic DNA sequence that can respond directly to stress events such as drought or heat. Hypothetically, it would be highly advantageous to join these mechanisms with a dynamic “memory” of past exposure to stress. It is now well established that annual model and crop plants can establish epigenetic-based memory of stress events that support more rapid and robust response to stress in the future. Here, evidence is discussed for epigenetic regulation and “memory” in two fundamental biological processes in trees, wood formation and abiotic stress response. Wood formation is an ideal trait for epigenetic research in trees, as wood formation is highly responsive to environmental conditions and includes multiple rapid developmental changes as cells adopt distinct fates within complex tissues. This is followed by a discussion of research needs that would provide the foundation for new epigenetic applications for forestry.

Groover, Andrew↗

DOE OSTI2021

Mitigation of Galvanic Corrosion in Bolted Joint of AZ31B and Carbon Fiber-Reinforced Composite Using Polymer Insulation

The use of polymer insulation to mitigate galvanic corrosion was examined for bolted joints of AZ31B Mg alloy and carbon fiber-reinforced composite. To assess the corrosion behaviors of bolted joints with and without polymer insulation, solution immersion and salt spray exposure (ASTM B117) tests were conducted, and the corrosion depths and volumes were determined for the joint specimens after the tests. The polymer-insulated bolted joints exhibited much lower corrosion depths and volumes, highlighting the effective mitigation of galvanic corrosion. The reductions of joint strength in the post-corrosion joint specimens were relatively small (up to ~10%) in the polymer-insulated group but greater (up to 90%) in the group with no insulation. Cross-sectional characterization of post-corrosion joints with polymer insulation revealed local pits developed on AZ31B under galvanic influence, indicating that limited galvanic attack (that did not decrease the joining integrity significantly) could still occur during a long salt spray exposure (~1264 h) owing to the permeation of an aqueous corrosive medium.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Atomic Diffusivities of Yttrium, Titanium and Oxygen Calculated by Ab Initio Molecular Dynamics in Molten 316L Oxide-Dispersion-Strengthened Steel Fabricated via Additive Manufacturing

Oxide-dispersion-strengthened (ODS) steels have long been viewed as a prime solution for harsh environments. However, conventional manufacturing of ODS steels limits the final product geometry, is difficult to scale up to large components, and is expensive due to multiple highly involved, solid-state processing steps required. Additive manufacturing (AM) can directly incorporate dispersion elements (e.g., Y, Ti and O) during component fabrication, thus bypassing the need for an ODS steel supply chain, the scale-up challenges of powder processing routes, the buoyancy challenges associated with casting ODS steels, and the joining issues for net-shape component fabrication. In the AM process, the diffusion of the dispersion elements in the molten steel plays a key role in the precipitation of the oxide particles, thereby influencing the microstructure, thermal stability and high-temperature mechanical properties of the resulting ODS steels. In this work, the atomic diffusivities of Y, Ti, and O in molten 316L stainless steel (SS) as functions of temperature are determined by ab initio molecular dynamics simulations. The latest Vienna Ab initio Simulation Package (VASP) package that incorporates an on-the-fly machine learning force field for accelerated computation is used. At a constant temperature, the time-dependent coordinates of the target atoms in the molten 316L SS were analyzed in the form of mean square displacement in order to obtain diffusivity. The values of the diffusivity at multiple temperatures are then fitted to the Arrhenius form to determine the activation energy and the pre-exponential factor. Given the challenges in experimental measurement of atomic diffusivity at such high temperatures and correspondingly the lack of experimental data, this study provides important physical parameters for future modeling of the oxide precipitation kinetics during AM process.

Chemistry↗

DOE OSTI2020

In Situ and Post-Mortem Characterizations of Ultrasonic Spot Welded AZ31B and Coated Dual Phase 590 Steel Joints

Ultrasonic spot welding using different welding conditions was applied to join dissimilar metals of galvanized DP590 steel and AZ31B magnesium sheets. In situ high-speed imaging, digital image correlation, and infrared thermography were utilized to quantitatively study the interfacial relative motion, surface indentation, and heat generation across the joint faying interface and the sheet/sonotrode interfaces under the welding condition of moderate welding power and short welding time. For welds made with high power and long welding time, lap shear tensile tests as well as fatigue tests were carried out. Different fracture modes were observed after the lap shear tensile tests and fatigue tests performed under different peak loads. Post-weld cross-sectional analysis with scanning electron microscopy coupled with energy dispersive X-Ray spectroscopy revealed the variation of morphology and chemical composition at the joint interface for welds made with different welding conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Determination of Location-Specific Solidification Cracking Susceptibility for a Mixed Dissimilar Alloy Processed by Wire-Arc Additive Manufacturing

Solidification cracking is a major obstacle when joining dissimilar alloys using additive manufacturing. In this work, location-specific solidification cracking susceptibility has been investigated using an integrated computational materials engineering (ICME) approach for a graded alloy formed by mixing P91 steel and Inconel 740H superalloy. An alloy mixture of 26 wt.% P91 and 74 wt.% Inconel 740H, with high configurational and total entropy, was fabricated using wire arc additive manufacturing. Microstructure characterization revealed intergranular solidification cracks in the FCC matrix, which increased in length along with the enrichment of Nb (~27 to 56 wt.%) and Cu (~87 wt.%) in the middle and top regions. DICTRA simulations to model location-specific solidification cracking susceptibility showed that the top region with the highest cooling rate (270 K/s) has the highest solidification cracking susceptibility in comparison with the middle and bottom regions. This is in good agreement with the experimentally observed varying crack length. From Scheil simulations, it was deduced that enrichment of Nb and Cu affected the solidification range as high as ~77%, in comparison with the matrix composition. The overall solidification cracking susceptibility and freezing range was highest for the 26 wt.% P91 alloy amongst the mixed compositions between P91 steel and 740H superalloy, proving that solidification characteristics play a major role in alloy design for additive manufacturing.

20 FOSSIL-FUELED POWER PLANTS↗