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DOE OSTI2024

Monodomain Liquid‐Crystal Elastomer Lattices for Broad Strain‐Rate Mechanical Damping

Designing structures that effectively dissipate energy across a broad range of mechanical loading rates, including those from compression, shock, and vibration, poses a significant engineering challenge. In this study, liquid‐crystal elastomers (LCEs), which possess anisotropic properties due to the alignment of their polymer backbone, are explored. As a result, LCEs exhibit a soft elastic response under mechanical loading, making them ideal for energy dissipation. Advances in additive manufacturing (AM) enable simple fabrication of foamlike dissipative structures with complex lattice geometries. Herein, direct ink write 3D printing, an extrusion AM method, is used to fabricate aligned, monodomain LCE lattice structures for broad strain‐rate mechanical damping. In this work, it is shown that these structures can dissipate strain energy in quasi‐static environments, comparable to traditional elastomeric lattices, and provide improved damping under high strain‐rate drop testing due to LCE soft elasticity. Additionally, under dynamic mechanical vibration, monodomain LCE lattices enhance damping at structural natural frequencies and provide high‐frequency attenuation. Finally, in these findings, a promising method is presented for fabricating mechanical damping devices that effectively dissipate energy across a broad range of loading rates.

3D printings↗

DOE OSTI2026

An Anisotropic Yield and Damage Material Model to Improve the Contact Pressure Analysis in a Biomass Shredding System

Size reduction systems used in biomass processing break biomass into smaller pieces by utilizing the kinetic energy from the sharp rotating blades. Abrasive and/or erosive wear caused by biomass comminution results in blade wear of the sharp edged cutters, deteriorating the process efficiency. Here, this study aims to optimize the blade design and improve the system efficiency by attempting to understand the interactions between the blades and biomass particles. Since real-time monitoring of these interactions is impractical during operation, mechanical simulations offer a viable alternative for investigating the shredding process. Yet, the irregular geometry and complex mechanical properties of biomass—such as the anisotropic nature of woodchips and their nonlinear fracture behavior—pose significant challenges for accurately simulating contact pressure. In this work an anisotropic yield material model, along with a damage initiation and evolution function, is applied to the woodchip particle to study the contact pressure on shredder blade, offering a scientific basis for improved blade design and process efficiency. This approach can be extended to other biomass processing systems with similar anisotropic feedstocks, making it a valuable tool for advancing sustainable biomass utilization.

09 - BIOMASS FUELS↗

DOE OSTI2025

Vector-level feedforward control of LPBF melt pool area using a physics-based thermal model

Laser powder bed fusion (LPBF) is an additive manufacturing technique that has gained popularity thanks to its ability to produce geometrically complex, fully dense metal parts. However, these parts are prone to internal defects and geometric inaccuracies, stemming in part from variations in the melt pool. Here, this paper proposes a novel vector-level feedforward control framework for regulating melt pool area in LPBF. By decoupling part-scale thermal behavior from small-scale melt pool physics, the controller provides a scale-agnostic prediction of melt pool area and efficient optimization over it. This is done by operating on two coupled lightweight models: a finite-difference thermal model that efficiently captures vector-level temperature fields and a reduced-order, analytical melt pool model. Each model is calibrated separately with minimal single-track and 2D experiments, and the framework is validated on a complex 3D geometry in both Inconel 718 and 316L stainless steel. Results showed that feedforward vector-level laser power scheduling reduced geometric inaccuracy in key dimensions by 62%, overall porosity by 16.5%, and photodiode root-mean-squared deviation by 38.5% on average. Overall, this modular, data-efficient approach demonstrates that proactively compensating for known thermal effects can significantly improve part quality while remaining computationally efficient and readily extensible to other materials and machines.

Additive manufacturing↗

DOE OSTI2024

Crack opening calculation in phase-field modeling of fluid-filled fracture: A robust and efficient strain-based method

The phase-field method has become popular for the numerical modeling of fluid-filled fractures, thanks to its ability to represent complex fracture geometry without algorithms. However, the algorithm-free representation of fracture geometry poses a significant challenge in calculating the crack opening (aperture) of phase-field fracture, which governs the fracture permeability and hence the overall hydromechanical behavior. Although several approaches have been devised to compute the crack opening of phase-field fracture, they require a sophisticated algorithm for post-processing the phase-field values or an additional parameter sensitive to the element size and alignment. Here, we develop a novel method for calculating the crack opening of fluid-filled phase-field fracture, which enables one to obtain the crack opening without additional algorithms or parameters. Here we transform the displacement-jump-based kinematics of a fracture into a continuous strain-based version, insert it into a force balance equation on the fracture, and apply the phase-field approximation. Through this procedure, we obtain a simple equation for the crack opening which can be calculated with quantities at individual material points. We verify the proposed method with analytical and numerical solutions obtained based on discrete representations of fractures, demonstrating its capability to calculate the crack opening regardless of the element size or alignment.

58 GEOSCIENCES↗

DOE OSTI2025

Strongly nonlinear wave propagation in elasto-plastic metamaterials: Low-order dynamic modeling

Nonlinear elastic metamaterials are known to support a variety of dynamic phenomena that enhance our capacity to manipulate elastic waves. Since these properties stem from complex, subwavelength geometry, full-scale dynamic simulations are often prohibitively expensive at scales of interest. Prior studies have therefore utilized low-order effective medium models, such as discrete mass-spring lattices, to capture essential properties in the long-wavelength limit. While models of this type have been successfully implemented for a wide variety of nonlinear elastic systems, they have predominantly considered dynamics depending only on the instantaneous kinematics of the lattice, neglecting history-dependent effects, such as wear and plasticity. Here, to address this limitation, the present study develops a lattice-based modeling framework for nonlinear elastic metamaterials undergoing plastic deformation. Due to the history- and rate-dependent nature of plasticity, the framework generally yields a system of differential-algebraic equations whose computational cost is significantly greater than an elastic system of comparable size. We demonstrate the method using several models inspired by classical lattice dynamics and continuum plasticity theory and explore means to obtain empirical plasticity models for general geometries, thereby gaining insight into the influence of microstructural plasticity on effective material performance, which can be used to improve the design of nonlinear mechanical metamaterials.

Dynamic simulation↗

DOE OSTI2026

Evaluation of simulated HPGe detector efficiencies in OpenMC compared to MCNP

In late 2023, the open-source radiation transport code OpenMC introduced a pulse-height tally (PHT) feature, enabling users to track the total energy deposited by individual photons in OpenMC cells. This function represents an important improvement of the OpenMC code because it allows users to simulate the response function of a gamma detector without relying on closed-source alternatives. Despite this, limited work has been published evaluating OpenMC as a radiation transport code for simulating gamma spectroscopy experiments. This study attempts to demonstrate the usefulness of OpenMC in this space by directly comparing its PHT output to MCNP (a trusted industry-standard Monte Carlo code). In the first half of this study, a radiation transport experiment is described in which a detector with a complex internal geometry is exposed to various gamma-emitting isotopes ( 133 Ba, 137 Cs, and 60 Co) over a range of distances. The setup of this experiment was modeled in MCNP with sufficient detail to capture the efficiency characteristics of a high purity germanium (HPGe) detector for the primary gammas of each isotope. After good agreement between the MCNP model and experiment was achieved, an identical model was produced in OpenMC to allow direct comparison between the full energy peak (FEP) values produced in OpenMC and MCNP. The results show strong agreement between OpenMC and MCNP across the full range of tested energies, with each model’s FEP values typically within 2% of each other and most FEP areas within 4% of experimental data. Worse agreement was seen between the Monte Carlo codes and experiment below 300 keV (an expected result). For the 662 keV line of 137 Cs, both codes were found in poor agreement with experiment and each other over the full range of distances tested (possibly indicating an error with the 137 Cs experimental data). Ignoring the anomalous results of the 662 keV line, all other data show good qualitative and quantitative agreement between MCNP and OpenMC. This result demonstrates the accuracy of OpenMC’s PHT feature for spectroscopic applications in which detector efficiency is a primary concern.

07 - ISOTOPES AND RADIATION SOURCES↗

DOE OSTI2026

Inverse Lieb materials: altermagnetism and more

The Lieb lattice, originally proposed for cuprate superconductors, has gained new attention in the emerging field of altermagnetism as a minimal analytical model for the latter. While the inverse Lieb lattice (ILL) was once considered purely theoretical, several materials with this motif have recently been discovered. Its unique geometry supports complex magnetic orders driven by geometric frustration, offering high tunability. In this work, we provide comprehensive insights into ILL magnetic phases and establish guidelines for identifying altermagnets. Using a Heisenberg model, we first construct phase diagrams to elucidate the mechanisms underlying experimental magnetic phases. We then bridge theory and experiment via density functional theory (DFT) calculations on existing ILL compounds, finding results consistent with experimental data. Notably, we identified a trend linking d-shell filling to magnetic order, where d x (x≤5) configurations show a propensity for altermagnetism. We also highlight Sr 2 CrO 2 Cr 2 OAs 2 as a promising metallic altermagnet with highly anisotropic J 2 exchange and a high Néel temperature (~600 K). Finally, our magnon spectra calculations confirm that chiral splittings correlate directly with anisotropies between inequivalent J 2 interactions.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Room temperature crystal field splitting of curium resolved by circularly polarized luminescence spectroscopy

Coordination of Cm(III) with a chiral decadentate ligand N,N,N',N'-tetrakis[(6-carboxypyridin-2-yl)methyl]-1,2-diaminocyclohexane (tpadac) generated complexes with strong luminescence allowing for the unprecedented measurement of well-resolved Cm(III) circularly polarized luminescence spectra. Quantitative resolution of the electronic structure of the [Cm(tpadac)][K] complexes was achieved at room temperature, highlighting the strength of the combination of luminescence and circularly polarized luminescence spectroscopies to unravel the fundamental electronic structure of Cm(III). These results are a clear demonstration that these spectroscopies are powerful yet simple tools for the fundamental understanding of electronic structure, which opens the door to future investigations of other Cm(III) complexes in geometries relevant to nuclear applications, and even other 5f-elements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Real-Time event reconstruction for Nuclear Physics Experiments using Artificial Intelligence

Charged track reconstruction is a critical task in nuclear physics experiments, enabling the identification and analysis of particles produced in high-energy collisions. Machine learning (ML) has emerged as a powerful tool for this purpose, addressing the challenges posed by complex detector geometries, high event multiplicities, and noisy data. Traditional methods rely on pattern recognition algorithms like the Kalman filter, but ML techniques, such as neural networks, graph neural networks (GNNs), and recurrent neural networks (RNNs), offer improved accuracy and scalability. By learning from simulated and real detector data, ML models can identify and classify tracks, predict trajectories, and handle ambiguities caused by overlapping or missing hits. Moreover, ML-based approaches can process data in near-real-time, enhancing the efficiency of experiments at large-scale facilities like the Large Hadron Collider (LHC) and Jefferson Lab (JLAB). As detector technologies and computational resources evolve, ML-driven charged track reconstruction continues to push the boundaries of precision and discovery in nuclear physics. In these proceedings, we highlight advancements in charged track identification leveraging Artificial Intelligence within the CLAS12 detector, achieving a notable enhancement in experimental statistics compared to traditional methods. Additionally, we showcase real-time event reconstruction capabilities, including the inference of charged particle properties, such as momentum, direction, and species identification, at speeds matching data acquisition rates. These innovations enable the extraction of physics observables directly from the experiment in real-time.

Gavalian, Gagik (ORCID:0000000267385457)↗

DOE OSTI2024

A variational method for the sheath potential of hypersonic leading edges with space-charge limitations

Electron transpiration cooling for the leading edges (LE) of hypersonic aircraft utilizes thermionic emission; however, space-charge effects limit the electron emission rate, potentially diminishing the efficiency of this cooling mechanism. We develop a variational weak form of the Poisson equation that describes the sheath potential and then numerically solve it using the finite element method. This formulation has two main benefits: (1) the space-charge limit condition can be incorporated as a constraint and (2) it allows for the analysis of three-dimensional geometries with complex boundary conditions. We demonstrate that the current emitted from the surface of an LE is generally a small fraction of the Child–Langmuir limit due to space charge. We then propose several methods to enhance the emitted current from the surface and to boost the cooling effect of thermionic emission. These include increasing the plasma density, applying a negative surface potential, and using fringe fields under suitable geometric conditions. For a LaB6 emitting LE, the total emitted current is shown to be minimal and independent of the temperature of a surface with floating potential. However, when a negative potential is applied and the surface is heated, the emitted current follows the Richardson–Dushman relationship up to a critical temperature, beyond which it remains constant. At an applied surface potential of −5 V, the critical temperature is around 1700 K.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Thermal Fluid Modeling Approaches in SAM for High Temperature Gas-Cooled Reactor Applications

This paper provides an overview of the unique modeling and simulation challenges and needs in the system and safety analysis of two common types of High Temperature Gas-cooled Reactor (HTGR) designs. The challenges are associated with the complex core geometry configurations and the change of the dominant heat removal mechanisms between normal operating conditions and decay heat removal transients. This requires that simulation tools utilize models with reasonable length scales and capture both the localized heat transfer and the core-scale heat transfer at the same time. To meet such analysis needs, different methodologies were developed. In conclusion, this includes adopting existing methods and further developing/improving them, as well as proposing innovative methods that leverage advanced computational frameworks such as the Multiphysics Object Oriented Simulation Environment (MOOSE).

HTGR↗

DOE OSTI2025

Numerical analysis of gas exhaust in Wendelstein 7-X using the direct simulation Monte Carlo method

The present work is focused on a 3D numerical assessment of the Wendelstein 7-X (W7-X) particle exhaust. For all the numerical simulations the direct simulation Monte Carlo solver of the DIVGAS workflow, has been employed. The complex 3D geometry of the sub-divertor region includes the pumping gap panel, supporting structures, cooling pipes as well as the cryo-vacuum pump. All the considered flow simulations correspond to the Standard magnetic configuration of W7-X. The main conclusions, which can be extracted from the present numerical analysis could be summarized as follows; The coupling between EMC3-EIRENE and DIVGAS, which considers the fact that the incoming neutral particle flux at the sub-divertor is based on realistic plasma background, has been demonstrated. Three plasma scenarios have been considered, for which is clearly seen that by increasing the heating power, the neutral pressure as well as the resulting pumping efficiency is increased. The obtained numerical results of the neutral pressure in the sub-divertor lie within a more general scan matrix, which assumes a wider range of incoming particle flux, namely 10 19 –10 24 (s −1 ). It has been observed that, the sub-divertor neutral pressure is proportional to the incoming neutral particle flux, with the effective pumping speed to be a constant of proportionality. The influence of switching off the cryo-vacuum pump on the sub-divertor pressure is rather modest and a weak increase of the neutral pressure in the sub-divertor is expected. Correlations of the sub-divertor pressure with the total incoming particle flux as well as the individual pumped flux at each of the AEH and AEP sections have been deduced. Moreover, it has been demonstrated that the influence of the incoming neutral particle flux on the albedo coefficient at the AEH and AEP pumping gaps is rather weak. All the above numerical findings will actively support the optimization of the W7-X particle exhaust, in view of future experimental campaigns.

DSMC method↗

DOE OSTI2024

Maximum a posteriori Ly α estimator (MAPLE): band power and covariance estimation of the 3D Ly α forest power spectrum

We present a novel maximum a posteriori estimator to jointly estimate band powers and the covariance of the three-dimensional power spectrum (P3D) of Ly $\alpha$ forest flux fluctuations, called MAPLE. Our Wiener-filter based algorithm reconstructs a window-deconvolved P3D in the presence of complex survey geometries typical for Ly $\alpha$ surveys that are sparsely sampled transverse to and densely sampled along the line of sight. We demonstrate our method on idealized Gaussian random fields with two selection functions: (i) a sparse sampling of 30 background sources per square degree designed to emulate the current Dark Energy Spectroscopic Instrument; (ii) a dense sampling of 900 background sources per square degree emulating the upcoming Prime Focus Spectrograph Galaxy Evolution Survey. Our proof-of-principle shows promise, especially since the algorithm can be extended to marginalize jointly over nuisance parameters and contaminants, i.e. offsets introduced by continuum fitting. Our code is implemented in JAX and is publicly available on GitHub.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2026

VoroClust: Scalable Clustering for Remote Sensing

Although supervised machine learning provides a powerful framework for image classification and segmentation, it requires comprehensive consistent datasets, which are not available for many remote-sensing applications. Remote-sensing datasets are expensive to collect, and each is acquired under different environmental conditions or with significant variations in system operating parameters. Unsupervised clustering algorithms analyze the structure of each dataset independently, rather than drawing on similarities with existing “training” examples, and are thus well suited for practical remote-sensing applications. We introduce VoroClust, a fast density-based unsupervised clustering algorithm applicable to high-resolution and high-dimensional data. VoroClust runs as fast as distance-based clustering methods, while capturing complex regional geometries at least as well as current-density-based methods. It uses a data-centered sphere cover to reduce computational demands, while still capturing data topology. It then propagates clusters outward from local peaks in density. We show that VoroClust provides fast state-of-the-art clustering for both high-resolution polarimetric synthetic aperture radar and high-dimensional hyperspectral imaging datasets.

42 ENGINEERING↗

DOE OSTI2025

Thermal Performance of Triply Periodic Minimal Surface Lattice Structures in Single-Phase Dielectric Fluid Cooling of Power Electronics

Additive manufacturing has transformed thermal management by enabling the production of complex, optimized geometries that conventional manufacturing methods cannot achieve. This study investigates the single-phase convective heat transfer performance of gyroid triply periodic minimal surface (TPMS) lattice structures with functional porosity. TPMS structures provide high surface area to volume ratios and are amenable to 3D printing. A gyroid numerical model was created and validated against an existing experimental study with a similar feature size to the investigated geometries. The TPMS structure has a periodic width of 1.6 mm, a length of 10 mm, and a height of 4 mm, with a functional porosity ranging from 0.5 to 0.8, decreasing with distance from the heated surface. Three different flow configurations were examined for an inlet fluid temperature of 70 °C. The inlet velocities range from 0.01 to 1.2 m/s, corresponding to a Reynolds number range of 10–900 with a heat flux of 50 W/cm 2 applied at the base. AmpCool ® AC-110 dielectric fluid (Prandtl number 59.5) was used as the coolant. Thermal performance and friction characteristics were studied for the three flow orientations. The parallel flow configuration was identified as the most efficient for heat removal. A detailed analysis of the numerical results highlights the underlying physics behind the thermal performance differences among the flow configurations.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Robust Containment Queries over Collections of Trimmed NURBS Surfaces via Generalized Winding Numbers

Here, we propose a containment query that is robust to the watertightness of regions bound by trimmed NURBS surfaces, as this property is difficult to guarantee for in-the-wild CAD models. Containment is determined through the generalized winding number (GWN), a mathematical construction that is indifferent to the arrangement of surfaces in the shape. Applying contemporary techniques for the 3D GWN to trimmed NURBS surfaces requires some form of geometric discretization, introducing computational inefficiency to the algorithm and even risking containment misclassifications near the surface. In contrast, our proposed method leverages properties of the 3D solid angle to solve the relevant surface integral using a boundary formulation with rapidly converging adaptive quadrature. Batches of queries are further accelerated by memoizing (i.e., caching and reusing) quadrature node positions and tangents as they are evaluated. We demonstrate that our GWN method is robust to complex trimming geometry in a CAD model, and is accurate up to arbitrary precision at arbitrary distances from the surface. The derived containment query is therefore robust to model non-watertightness while respecting all curved features of the input shape.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

EchemAMR (electro-chemical microsctructure scale models with adaptive meshing) [SWR-23-111]

A 3D microstructure resolving electrochemical transport and interfacial chemistry solver. Electrode microstructure plays an important role in determining the performance of an electrochemical system, e.g. lithium ion battery. EchemAMR is a microstructure scale model that solves the governing equations for ion transport, electrical current continuity, interfacial chemistry and structural mechanics. Complex microstructure geometries from imaging can be directly imported into EchemAMR. A volume fraction based description of the geometry on Cartesian grid with an immersed interface formulation enables simplified meshing and large-scale simulations with millions of degrees of freedom. EchemAMR has been tested against systems with analytic solutions for numerical convergence and highly resolved lithium ion battery microstructures. EchemAMR demonstrates excellent mass conversation and efficient scaling on heterogenous High-Performance Computing (HPC) with central and graphics processing units.

Sitaraman, Hariswaran↗

DOE OSTI2025

VoroClust

SAND2025-11465O VoroClust, also known as Voronoi Clustering, is a fast, density-based unsupervised clustering algorithm applicable to high-resolution and high-dimensional data. It operates as quickly as distance-based clustering methods while effectively capturing complex regional geometries, matching the performance of current density-based methods. VoroClust employs a data-centered sphere cover to reduce computational demands while preserving data topology. It propagates clusters outward from local density peaks. Although supervised machine learning is powerful for applications like image classification and segmentation, it requires comprehensive, consistent datasets, which many applications lack. Unsupervised clustering algorithms analyze the structure of each dataset rather than relying on similarities with other examples, making them well-suited for practical applications with insufficient or inappropriate data for supervised learning. 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.

Ebeida, Mohamed [Sandia National Lab. (SNL-CA), Li↗