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At least 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Embedding Fiber Optic Sensors in Stainless Steel using Spark Plasma Sintering for Structural Health Monitoring in Harsh Environments

Embedded fiber optic sensors such as fiber Bragg gratings (FBGs) offer a unique route for distributed real-time in-situ imaging of various engineering parameters for numerous purposes. This study advanced the current sensor embedding approaches by exploring a spark plasma sintering (SPS)-assisted technology to embed FBGs in high-temperature structural materials and demonstrated the capability of temperature measurement. In this approach, single-mode FBGs were integrated into stainless steel (SS) 316L components using SPS, followed by the evaluation of the bonding quality between the FBGs and matrix, the optical attenuation of the fibers induced by embedding, and the sensing characters of the FBGs under temperature stimuli. The results demonstrated that superior bonding was achieved between the FBGs and highly-densified SS316L. Examination of the behavior of Bragg gratings validated signal fidelity after embedding. Real-time thermal imaging under temperature cycling using the FBGs demonstrated the effectiveness of the technique for smart materials manufacturing.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

SAVY-4000 Finite-Element Drop Test Analysis

PFE Auxiliary Systems conducted drop testing on SAVY-4000 containers to evaluate structural response under 12-foot drop conditions. In support of that effort, a finite-element modeling capability was developed to simulate drop response across multiple container sizes and impact orientations. The purpose of this work was to provide a consistent analysis framework that could support interpretation of testing, compare response trends across multiple configurations, and generate quantities of interest for later comparison with experimental data. More broadly, the analysis and testing were intended to assess whether the containers continued to perform their primary function after a 12-foot drop, namely maintaining structural integrity and containment of the contents. The modeling approach combined an implicit preload analysis with an explicit drop simulation so that each drop event began from a mechanically realistic assembled condition, including compression of the silicone O-ring. Separate models were developed for 2-quart, 5-quart, 12-quart, and 10-gallon containers. The results were evaluated in terms of strain-gauge response, collar-lid gap behavior, and accumulated plastic strain. In addition, parametric studies were performed on the 2-quart container to assess sensitivity to O-ring stiffness, friction, canister thickness, geometry tolerance, and mesh density. The simulations showed that predicted drop responses depended strongly on both container size and drop orientation. Gap metrics identified cases in which the predicted collar-lid opening exceeded the nominal O-ring cross-section threshold, while plastic strain metrics identified localized regions of elevated permanent deformation. Parametric studies showed that the predicted response was especially sensitive to the assumed O-ring stiffness and contact friction, while the geometry tolerance study produced smaller changes in the cases examined. The main value of this work was that it established a repeatable modeling and simulation workflow to support drop-test implementation, evaluate effects of future configuration changes, and understand modeling assumptions that most influenced predicted response. At the current stage, the results were viewed as preliminary model predictions rather than validated predictions. The next step would be to compare drop-test data to the model so that predictive values of the workflow could be refined and used with greater confidence to assess whether the containers maintained structural integrity and containment of the contents after a 12-foot drop.

42 ENGINEERING↗
DOE OSTI2025

Investigation of residual stress distribution in wire-arc directed energy deposited refractory molybdenum alloy utilizing numerical thermo-mechanical analysis and neutron diffraction method

Directed energy deposition (DED), a metal additive manufacturing (AM) technique, offers higher deposition rates and energy efficiency, making it suitable for fabricating components from refractory molybdenum alloys, such as molybdenum-titanium-zirconium (TZM). However, large thermal gradients and non-equilibrium thermal cycles in DED could generate high residual stress in the component, potentially deteriorating quality and performance. Thus, this study aims to investigate residual stress generation and its distribution in wire-arc DED of TZM thin-wall, utilizing thermo-mechanical analysis and high-fidelity neutron diffraction (ND) method. Two interpass temperatures (50°C and 200°C) have been considered to investigate their impact on residual stress formation. During experiments, in-situ thermal data has been recorded using thermocouples, which have been utilized for calibrating the thermal model. Thermocouple data shows a good agreement with the simulation results, having a difference of less than 10 %. Post-deposition part deformation has been observed, which is measured using a coordinate measuring machine, showing maximum values of 0.93 mm and 0.78 mm for interpass temperatures of 50°C and 200°C, respectively. Numerical predictions of distortion deviated by less than 15% from the experimental results. ND measurement and simulation results indicate that residual stress magnitude and evolution vary across the TZM deposits, revealing microstructural anisotropy in both conditions. Notably, lower interpass temperatures resulted in higher residual stresses, confirmed by experimental and simulation data. Further, this study demonstrated that an integrated experimental and thermo-mechanical analysis can potentially reveal the temperature history, part deformation, and residual stress formation in wire-arc DED TZM alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Artificial Intelligence and Machine Learning for Bioenergy Research: Opportunities and Challenges

The integration of artificial intelligence and machine learning (AI/ML) with automated experimentation, genomics, biosystems design, and bioprocessing technologies is poised to revolutionize scientific investigation and, particularly, bioenergy research. To identify the opportunities and challenges in this emerging research area, the U.S. Department of Energy’s (DOE) Biological and Environmental Research program (BER) and Bioenergy Technologies Office (BETO) held a joint virtual workshop on AI/ML for Bioenergy Research (AMBER) on August 23–25, 2022. These interests have since been amplified in a September 2022 Executive Order, “Advancing Biotechnology and Biomanufacturing Innovation for a Sustainable, Safe, and Secure U.S. Bioeconomy,” to promote a whole-of government approach to biotechnology development (White House 2022). Approximately 50 scientists with various backgrounds and expertise from academia, industry, and DOE national laboratories met to discuss the opportunities and challenges of AI/ML for bioenergy research. Workshop participants were tasked with assessing the potential for AI/ML and laboratory automation to advance biological understanding and engineering in general. They particularly examined how integrating AI/ML tools with laboratory automation could accelerate biosystems design and optimize biomanufacturing. Discussions included the data and computational infrastructure needed to augment biosystems design applications and the expertise and workforce development efforts urgently required to shift integrated systems toward bioenergy research more broadly. Participants discussed many existing and future applications of AI/ML for biosystems design ranging from enzymes to plants and microbes, microbiomes, and bioprocess development. They also identified three key categories of scientific and technical opportunities and challenges: high-quality data, AI/ML algorithms, and laboratory automation. Several main takeaways emerged from the workshop: 1. Numerous AI/ML and automated experimentation applications exist for a variety of DOE mission needs in energy and the environment; 2. Exemplary research grand challenges for which AI/ML could provide solutions include: building microbes and microbial communities to specifications, developing closed-loop autonomous design and control for biosystems design, and advancing scale-up and automation; 3. Lack of sufficient high-quality, annotated data hinders the development of AI/ML applications; 4. New and improved AI/ML tools are needed, particularly those meeting the specific needs of the BER and BETO research communities; 5. Trade-offs in performance, cost, and reliability exist between deploying commercially available versus building custom-developed instrumentation and software for automated or autonomous experimentation; translation of manual to automated or autonomous methods is often a nontrivial endeavor; 6. Training a new generation of young scientists who can develop and apply AI/ML tools is needed to solve long-standing scientific challenges in bioenergy research. The integration of AI/ML tools and automated experimentation represents a new data-driven research paradigm complementary to the traditional hypothesis-driven research paradigm. This paradigm accelerates design and optimization of biological systems and processes for a variety of DOE mission needs in energy and the environment. The AMBER workshop broadly explored the potential of this new paradigm for bioenergy research, of particular interest to BER and BETO, and identified key challenges and opportunities that DOE can address in the coming years by leveraging its unique capabilities and resources.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Full Vorticity Budget of the Arabian Sea from a 0.1° Ocean Model: Sverdrup Dynamics, Rossby Waves, and Nonlinear Eddy Effects

Abstract The Arabian Sea, influenced by the Indian monsoon, has many unique features, including its basin-scale seasonally reversing surface circulation and the Great Whirl, a seasonal anticyclonic system appearing during the southwest monsoon close to the western boundary. To establish a comprehensive dynamical picture of the Arabian Sea, we utilize numerical model output and design a full vorticity budget that includes a fully decomposed nonlinear term. The ocean general circulation model has 0.1° resolution and is mesoscale eddy-resolving in the region. In the western boundary current system, we highlight the role of nonlinear eddies in the life cycle of the Great Whirl. The nonlinear eddy term is of leading-order importance in this feature’s vorticity balance. Specifically, it contributes to the Great Whirl’s persistence in boreal fall after the weakening of the southwesterly winds. In the open ocean, Sverdrup dynamics and annual Rossby waves are found to dominate the vorticity balance; the latter is considered as a key factor in the formation of the Great Whirl and the seasonal reversal of the western boundary current. In addition, we discuss different forms of vertically integrated vorticity equations in the model and argue that the bottom pressure torque term can be interpreted analogously as friction in the western boundary and vortex stretching in the open ocean.

58 GEOSCIENCES↗
DOE OSTI2026

AI-Based Analytics and Energy Modeling Framework for Characterizing Urban Energy Systems

Developing location-specific district energy models is essential for understanding energy patterns and supporting efficient management and planning decisions. However, accurately characterizing these models remains challenging due to gaps in building characteristics and labor-intensive traditional modeling workflows. To address these challenges, we develop an AI-based framework that integrates top-down and bottom-up building energy data to automate urban energy model characterization. The framework trains multimodal deep learning models using heterogeneous ResStockTM datasets to infer missing building characteristics from varying levels of known information and generate simulation-ready inputs for district-scale energy modeling. It also employs a conditioning-based injection approach to generate ”what-if” scenarios, enabling users to explore retrofit, efficiency, and technology-upgrade pathways. Integrated within URBANoptTM, a bottom-up district energy modeling platform for simulating co-located buildings, the framework infers detailed building-level inputs required for bottom-up simulations. Both localized and generalized AI models are developed to learn relationships across categorical, numerical, and time-series data, enabling reconstruction of missing attributes and generation of targeted upgrade scenarios. We demonstrate this methodology on a residential neighborhood in Baltimore, MD, assessing internal consistency against ResStock reference data and URBANopt simulation, and comparing selected attributes against real-world building characteristics. Results show strong overall predictive accuracy in data completion and scenario generation, with localized and generalized models offering complementary trade-offs between precision and scalability. Overall, our automated framework streamlines energy modeling and provides a reliable framework for urban building energy characterization.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Improvements to a class of hybrid methods for radiation transport: Nyström reconstruction and defect correction methods

In this study, two modifications are introduced for improving the accuracy, versatility, and robustness of a class of hybrid methods for radiation transport. In general, such methods are constructed by splitting the radiative flux into collided and uncollided components to which low- and high-resolution angular approximations are applied, respectively. In this work we focus on discrete ordinates discretizations of high and low order. The first modification we introduce changes the way in which the collided component is mapped into the uncollided component at the end of each time step in a simulation. The new mapping is a Nyström-type reconstruction that is applicable to arbitrary discrete ordinates quadratures, is guaranteed to preserve positivity of the solution provided that all ordinate weights are positive, is significantly more accurate than previous methods, and can be readily extended to other discretizations such as moment methods, finite element methods, and diffusion approximations. The second modification leverages integral deferred correction (IDC) to iteratively correct for the splitting error introduced by the inconsistency in angular discretization between the collided and uncollided components, in addition to improving the accuracy of the low-order temporal error that is treated by traditional IDC methods. Numerical tests in one- and two-dimensional geometries are used to demonstrate the increased accuracy and efficiency of the proposed modifications. It is found that the two techniques combined yield methods with solution accuracy and memory requirements comparable to that of monolithic discrete ordinates methods while reducing runtime by as much as a factor of between two and ten, depending on the problem.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2020

State-of-the-art short-term electricity market operation with solar generation: A review

With the accelerating penetration of solar energy in energy systems, market operations concerning the solar-associated intermittency are widely discussed. How to correctly model the solar generation in the market and solve the uncertainty-based operation problems call for solutions. Unlike other renewable resources, solar power can be more easily applied to the demand side through behind-the-meter installations in a distributed manner with significant future extensibility. The corresponding operational rules in the markets are largely being revised. Over the past two decades, with the development of deregulated power markets, numerous studies related to uncertainty-based market operations tend to transform the market from a deterministic and centralized framework to a stochastic and decentralized one. As the relevant literature is most recent, this paper reviews their contributions to electricity market operations with solar integration and underlines the research directions of this topic and ongoing industry practices. A thorough review of the electricity markets worldwide with solar energy is provided. A variety of proposed mathematical solutions to the problem are also addressed.

14 SOLAR ENERGY↗
DOE OSTI2020

Quantifying thermal barrier coating delamination through luminescence modeling

Thermal barrier coatings (TBCs) are widely used in the hot sections of gas turbine systems as they are remarkably efficient in insulating the underlying superalloys, leading to higher operating temperatures and therefore enhancing the performance of the engines. However, this benefit is only possible if the integrity of the TBC under aggressive thermo-mechanical environments is ensured. Delamination is a common but hard to detect failure mode. We present, in this work, supported by experimentation, the implementation of a modeling approach applying the Kubelka-Munk theory to provide numerical quantification of luminescence contrast and intensity due to top coat delamination in TBCs. The method relies on the drastic change in reflectivity when a delamination forms, exploiting it for high-contrast luminescence mapping. Two distinct TBC configurations containing an erbium-doped yttria-stabilized zirconia (YSZ:Er 3+ ) layer for delamination sensing were used to validate this model. A delamination zone induced by Rockwell indentation was successfully tracked by measuring an increase of the intensity of the erbium emission line at 562 nm. Luminescence-based methods for delamination detection can provide a revolutionary non-invasive technique, with potential for both off-line and on-line engine monitoring.

36 MATERIALS SCIENCE↗
DOE OSTI2020

NNSA-IAEC Science Area V Environmental ISR: Waste Management and Subsurface Science (Final Report FY18-FY20)

In August 2017, the U.S. National Nuclear Security Administration (NNSA) and the Israel Atomic Energy Commission (IAEC) launched a joint waste management program to evaluate the feasibility of siting a radioactive waste repository at intermediate depths in Israel. The bilateral collaboration involves three National Laboratories (LLNL, LANL, and Sandia), and the Nuclear Research Center, Negev, Geological Survey of Israel, and Ben Gurion University in Israel. This research is designed to assist with the evaluation of locations for an intermediate nuclear waste repository in Israel. This final report is a high-level summary of the results from the past three years by the team that worked on the WM-2: Radionuclide colloid-facilitated transport in fractured carbonate rock project for Science Area V, Environmental ISR: Subsurface Science and Waste Management. We have completed all of our tasks and met all of our milestones. MW-2 had three integrated tasks. Task 1 was laboratory experiments investigating colloid transport of radionuclides in natural fractured carbonate rocks from the Avdat formation, Israel. Task 2 was field experiments injecting radionuclide analogues pre-sorbed to clay colloids into fractured carbonate rock, and task 3 was numerical modeling of laboratory and field experimental results to assess the importance of colloids in the migration of relevant radionuclides. This task was incorporated into tasks 1 and 2. A 4 th task was initiated in FY20, to investigate the role of organics in facilitating radionuclide transport under the same conditions explored in task 1 due to the high organic content of the rocks being investigated for the immediate borehole locations. Preliminary results will be summarized here and the work will continue in FY21-23. The overall objective of this research is to evaluate the role of colloids (naturally occurring < 1 micron particles) in facilitating the transport of long-lived radionuclides from a nuclear waste repository situated in fractured carbonate rocks. Currently little data exists on radionuclide transport in carbonate rocks, but this is the main rock type available for siting a repository in Israel. Laboratory experiments were carried out in both Israel and the U.S., field experiments have taken place in Israel, and reactive transport modeling involved LLNL, LANL and Israel partner institutions. LLNL hosted a graduate student, Emily Tran, from Ben Gurion University in FY18 and FY19 and much of the work presented here was part of her PhD research.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Classification of Ultrasonic Weld Quality using Acoustic Signatures Acquired During Manufacture

Ultrasonic welding is a process is based on generating a solid-state bond between two metals by applying moderate pressure and high intensity sound waves (20-70 kHz frequencies) at their interface. During the solid-state process numerous material, surface, instrument, and environmental factors contribute to bond formation, strength, and durability. The inherent difficulty of measuring and controlling each of these factors has, to date, made predicting bond quality elusive. In this work, a Sonics model MWB20 ultrasonic spot welder with integral base, was used to produce a variety of welds of different metal foils under varying weld conditions. Acoustic measurements were recorded throughout the measurement process. Subsequent analysis of the signals using metrics that approximate the energy dispersed during the weld proved to successfully predict weld quality. Two metrics based on normalized energy differential and Renyi entropy were developed into Python and C++ scripts for direct analysis of weld acoustic data.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Charge And Dynamic Current On Tubular Antennas For Various Drive Conditions

The mixed boundary value problem of a tubular conductor is solved using an approximate representation of its Fourier coefficients. A two term solution is derived, which represents the solution over an extremely broad range of aspect ratios. This representation is used to find the electrostatic solution and capacitance of a charged tube as well as the solution of a tube in a uniform field and its dipole moment. This second case is directly useful as a model for a monopole electric field probe. This approximation is a special case of a representation using a combination of Chebyshev and Legendre polynomials. Combining the charged tube and tube in a uniform field allows the solution of voltage driven tubular antennas. Comparisons are made with numerical solutions using piecewise sinusoidal representations of the current. The results are also generalized to the dynamic case and up to and beyond the first resonance. Simple corrections for finite gap and delta gap drives to magnetic frill drives are examined using infinite tube integral transform representations. Corrections between magnetic frill drives and coaxial drives are also given. Approximate drive corrections using conformal mapping and an effective radius are also discussed. Finally, this efficient current representation is applied to the magnetic problem involving simple tubular solenoids.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

McMillan map and nonlinear Twiss parameters

In this article we consider two dynamical systems: the McMillan sextupole and octupole integrable mappings originally introduced by Edwin McMillan; the second one is also known as canonical McMillan map. Both of them are simplest symmetric McMillan maps with only one intrinsic parameter, the trace of the Jacobian at the fixed point. While these dynamical systems have numerous of applications and are used in many areas of math and physics, some of their dynamical properties have not been described yet. We fulfill the gap and provide complete description of all stable trajectories including parametrization of invariant curves, Pioncaré rotation numbers and canonical action-angle variables. In the second part we relate these maps with general chaotic map in McMillan-Turaev form. We show that McMillan sextupole and octupole mappings are first order approximations of dynamics around the fixed point, in a similar way as linear map and quadratic invariant (Courant-Snyder invariant in accelerator physics) is the zeroth order approximation (known as linearization). Finally we suggest the new formalism of nonlinear Twiss parameters which incorporate dependence of rotation number as a function of amplitude, in contrast to e.g. betatron phase advance used in accelerator physics which is independent of amplitude. Specifically in application to accelerator physics this new formalism is capable of predicting dynamical aperture around 1-st, 2-nd, 3-rd and 4-th order resonances for flat beams, which is critical for beam injection/extraction.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Predicting Geologic Behavior in Carbon Storage Projects Using Graph Neural Network

This study was invited to presented at NVIDIA's GTC conference to highlight the potential of Graph Neural Network as a novel and promising methodology for predicting pressure and saturation evolution in carbon storage projects. Carbon capture and storage (CCS) technology plays a pivotal role in mitigating greenhouse gas emissions, facilitating the transition to a low-carbon future. Effective management of subsurface reservoirs is essential to ensure the safe and efficient storage of captured carbon dioxide (CO₂). Accurate predictions of pressure and saturation over time are critical for evaluating the long-term performance and integrity of CCS projects. In recent years, Graph Neural Network (GNN) has emerged as a powerful framework for analyzing complex data in graph-structured domains. This abstract explores the application of GNN to forecast pressure and saturation evolution in carbon storage projects. Traditional numerical simulations of subsurface reservoirs have proven successful in providing pressure and saturation forecasts. However, these simulations involve massive amounts of computational effort and require extensive domain expertise for proper model calibration and validation. Graph Neural Operator offers an alternative approach that harnesses the inherent graph structure of reservoirs, where nodes represent reservoir grid cells and edges represent the geological connectivity between them.

Shih, Chung Yan↗
DOE OSTI2026

A novel approach to RF power coupling in Radio-Frequency Quadrupole (RFQ) structures: built-in coaxial double-loop coupling port

Efficient and reliable RF power couplers in accelerating cavities require precise impedance matching and mechanical stability to ensure optimal beam energy transfer. In radio-frequency quadrupole (RFQ) accelerators, power is commonly delivered using waveguide iris or coaxial loop couplers. Iris couplers can handle high RF power but lack tunability, while coaxial loop couplers offer tuning flexibility but are limited in power handling and thermal performance. We propose a new RFQ power coupling concept utilizing a single input coaxial center-fed double-loop antenna built into a vane in an RFQ structure . The design integrates back-to-back loops into the RFQ vanes, fed by a TEM coaxial transmission line with standard 50-Ω characteristic impedance. The configuration can allow straightforward and easy ceramic window replacement without retuning, and coupling strength is adjusted with protruding tuning rods. Numerical simulations, performed with both a simplified RFQ model and the Spallation Neutron Source RFQ, demonstrate improved RF performance and reduced dipole mode excitation. The results establish the coaxial double-loop coupler as a practical alternative for high-power RFQ coupling applications.

Lee, Sung-Woo [ORNL] (ORCID:000000030915835X)↗
DOE OSTI2021

Integrating micromagnets and hybrid nanowires for topological quantum computing

Majorana zero modes are expected to arise in semiconductor-superconductor hybrid systems, with potential topological quantum computing applications. One limitation of this approach is the need for a relatively high external magnetic field that should also change direction at the nanoscale. This proposal considers devices that incorporate micromagnets to address this challenge. We perform numerical simulations of stray magnetic fields from different micromagnet configurations, which are then used to solve for Majorana wavefunctions. Several devices are proposed, starting with the basic four-magnet design to align magnetic field with the nanowire and scaling up to nanowire T-junctions. The feasibility of the approach is assessed by performing magnetic imaging of prototype patterns.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Quantum complexity of time evolution with chaotic Hamiltonians

We study the quantum complexity of time evolution in large-N chaotic systems, with the SYK model as our main example. This complexity is expected to increase linearly for exponential time prior to saturating at its maximum value, and is related to the length of minimal geodesics on the manifold of unitary operators that act on Hilbert space. Using the Euler-Arnold formalism, we demonstrate that there is always a geodesic between the identity and the time evolution operator e -iHt whose length grows linearly with time. This geodesic is minimal until there is an obstruction to its minimality, after which it can fail to be a minimum either locally or globally. We identify a criterion — the Eigenstate Complexity Hypothesis (ECH) — which bounds the overlap between offdiagonal energy eigenstate projectors and the k-local operators of the theory, and use it to argue that the linear geodesic will at least be a local minimum for exponential time. We show numerically that the large-N SYK model (which is chaotic) satisfies ECH and thus has no local obstructions to linear growth of complexity for exponential time, as expected from holographic duality. In contrast, we also study the case with N = 2 fermions (which is integrable) and find short-time linear complexity growth followed by oscillations. Our analysis relates complexity to familiar properties of physical theories like their spectra and the structure of energy eigenstates and has implications for the hypothesized computational complexity class separations PSPACE * BQP/poly and PSPACE * BQSUBEXP/subexp, and the “fast-forwarding” of quantum Hamiltonians.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Specialization Restricts the Evolutionary Paths Available to Yeast Sugar Transporters

Functional innovation at the protein level is a key source of evolutionary novelties. The constraints on functional innovations are likely to be highly specific in different proteins, which are shaped by their unique histories and the extent of global epistasis that arises from their structures and biochemistries. These contextual nuances in the sequence–function relationship have implications both for a basic understanding of the evolutionary process and for engineering proteins with desirable properties. Here, we have investigated the molecular basis of novel function in a model member of an ancient, conserved, and biotechnologically relevant protein family. These Major Facilitator Superfamily sugar porters are a functionally diverse group of proteins that are thought to be highly plastic and evolvable. By dissecting a recent evolutionary innovation in an α-glucoside transporter from the yeast Saccharomyces eubayanus, we show that the ability to transport a novel substrate requires high-order interactions between many protein regions and numerous specific residues proximal to the transport channel. To reconcile the functional diversity of this family with the constrained evolution of this model protein, we generated new, state-of-the-art genome annotations for 332 Saccharomycotina yeast species spanning ~400 My of evolution. By integrating phylogenetic and phenotypic analyses across these species, we show that the model yeast α-glucoside transporters likely evolved from a multifunctional ancestor and became subfunctionalized. The accumulation of additive and epistatic substitutions likely entrenched this subfunction, which made the simultaneous acquisition of multiple interacting substitutions the only reasonably accessible path to novelty.

59 BASIC BIOLOGICAL SCIENCES↗