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DOE OSTI2025

Data Structure Alchemy

In an increasingly more data-driven world, the project set out to uncover the first principles of data-structure design, chart the immense design space they form, and build automation that can synthesize an optimal structure, or even a whole storage engine, for any given workload, hardware platform, and cost target. Data structures are at the center of every computational system and are directly responsible for its performance. Two core technical thrusts were defined: 1) Mapping design spaces for key data-centric abstractions (filters, hash functions, storage-engine layouts, neural-network topologies, blockchain protocols, image layouts, etc.). 2) Developing search & synthesis algorithms, initially analytical cost models, later neural-guided bi-level optimisers that navigate sextillions of candidate designs in seconds and materialise the best one as ready‐to-run code. This report distills the key insights, accomplishments, and impact.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Organic Direct-Bonded-Copper-Based Rapid Prototyping for Silicon Carbide Power Module Packaging

Silicon carbide (SiC) power devices are playing ever- growing roles in high-power-density power electronics converters by offering benefits such as high voltage rating, fast transients, and high thermal performance. Organic direct-bonded copper (ODBC)-based packaging, due to its ductility and ease of han- dling, allows the possibility of a more flexible layout design that may better tap the potential of SiC benefits. In this work, an ODBC-based prototyping routine is developed that accelerates the iterations of packaging layout design with low cost. The properties of ODBC and its handling are briefly introduced, and tools and fabrication steps are explained. Following this routine, a 1.2-kV SiC half-bridge power module is designed and fabricated with the focus on sub-nanohenry ultra-low loop inductance. Simulation and experimental validation are also conducted.

25 ENERGY STORAGE↗

DOE OSTI2025

Flexible Fuel Electric Hybrid Glass Furnace Demonstration

The furnace contractor completed General Arrangement (GA) layouts and Piping and Instrumentation Diagrams (P&ID) for both furnaces during this reporting period. Preliminary equipment lists accompanied this work. Control system architecture in progress. Key furnace design elements and deliverables on track to be complete by end of phase. The facilities design and integration contractor completed a 3D scan and modeling of the facility. The work during this period focused on preliminary design with a focus on overall project scope and feasibility. This key work supports the overall project deliverables for 30% preliminary engineering and Preliminary Design Report (PDR) which are on track to be complete by the end of the phase. These deliverables are approximately 50% complete through the end of this reporting period. The batch house operations design contractor continues development of site plan and General Arrangement (GA) layout to support the 30% preliminary engineering and design package. This work is 60% complete by the end of this reporting period and is on track to be complete by the end of the phase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Spectrum Unfolding with the MC-15

The Multiplicity Counter 15 tube detector or MC-15 is an optimized detector designed for use in the field. It is composed of 15 3 He tubes embedded in high density polyethylene (HDPE). Recent work has explored expanding the use of the MC-15 beyond multiplicity counting to neutron dosimetry applications. Knowledge of the neutron energy spectrum information is required to use a detector as a neutron dosimeter. The MC-15 tube layout is shown in Figure 1. The unique layout makes it possible to use the detector for neutron spectroscopy via spectrum unfolding. Spectrum unfolding requires (1) energy dependence of the detector response, (2) a detector response matrix that precisely quantifies the response to mono-energetic neutrons, (3) an initial guess spectrum, (4) an unfolding algorithm, and (5) measured data (counts in the case of the MC-15). An energy dependent detector response matrix (DRM) can be constructed by considering either each of the three rows of 3 He tubes as a distinct detector or each individual tube as a distinct detector. The HDPE separating the 3 He in the MC-15 provides the distinct energy dependent response for the rows and individual tubes. In this report we detail the development of detector response matrices for the MC-15 and the application of the Los Alamos Unfolding Code (LUC) to both simulated and measured data. Three MC-15 orientations were studied: (1) standard orientation with the MC-15 front facing the source, (2) standard orientation with Cd sheet, (3) 90° orientation with the side of the MC-15 facing the source.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Compiling Quantum Circuits for Dynamically Field-Programmable Neutral Atoms Array Processors

Dynamically field-programmable qubit arrays (DPQA) have recently emerged as a promising platform for quantum information processing. In DPQA, atomic qubits are selectively loaded into arrays of optical traps that can be reconfigured during the computation itself. Leveraging qubit transport and parallel, entangling quantum operations, different pairs of qubits, even those initially far away, can be entangled at different stages of the quantum program execution. Such reconfigurability and non-local connectivity present new challenges for compilation, especially in the layout synthesis step which places and routes the qubits and schedules the gates. In this paper, we consider a DPQA architecture that contains multiple arrays and supports 2D array movements, representing cutting-edge experimental platforms. Within this architecture, we discretize the state space and formulate layout synthesis as a satisfiability modulo theories problem, which can be solved by existing solvers optimally in terms of circuit depth. For a set of benchmark circuits generated by random graphs with complex connectivities, our compiler OLSQ-DPQA reduces the number of two-qubit entangling gates on small problem instances by 1.7x compared to optimal compilation results on a fixed planar architecture. To further improve scalability and practicality of the method, we introduce a greedy heuristic inspired by the iterative peeling approach in classical integrated circuit routing. Using a hybrid approach that combined the greedy and optimal methods, we demonstrate that our DPQA-based compiled circuits feature reduced scaling overhead compared to a grid fixed architecture, resulting in 5.1X less two-qubit gates for 90 qubit quantum circuits. These methods enable programmable, complex quantum circuits with neutral atom quantum computers, as well as informing both future compilers and future hardware choices.

Physics↗

DOE OSTI2021

Lean-Stratified Combustion System with Miller Cycle for Downsized Boosted Application - Part 2

Automotive manufacturers relentlessly explore engine technology combinations to achieve reduced fuel consumption under continued regulatory, societal and economic pressures. For example, technologies enabling advanced combustion modes, increased expansion to effective compression ratio and reduced parasitics continue to be developed and integrated within conventional and hybrid propulsion strategies across the industry. Here, a high-efficiency gasoline engine capable for use in conventional or hybrid electric vehicle platforms is highly desirable. This paper is the second of two papers describing the multi-cylinder integration of a technology package combining lean-stratified combustion with Miller cycle for downsized boosted applications. The first paper describes the design, analysis and single-cylinder testing conducted to down-select the combustion system deployed to the multi-cylinder engine. This paper defines a light-duty engine package capable of achieving a 35% fuel economy improvement at US Tier 3 emission standards over a naturally aspirated stoichiometric baseline vehicle. A multi-mode combustion system was developed enabling highly efficient lean-stratified operation at light-load and stoichiometric Miller-cycle operation at mid- to high-loads. A central direct-injection four-valve layout was designed with high-tumble ports and a bowl-in-piston capable of stable operation under highly dilute mixtures when properly matched to fuel spray characteristics, injection strategy, and a high-energy ignition system. Boost system layout and base engine architecture were selected to minimize parasitics and maximize after treatment effectiveness. A multi-cylinder engine was developed and calibrated over a steady-state map. Results fed vehicle simulations over the EPA city and highway test cycles to predict the fuel economy improvement and tailpipe emissions potential. Fuel economy improvements over the baseline vehicle were projected at 42% and 39% for active-urea and passive-ammonia SCR after treatment systems respectively. Controls complexity to achieve regulatory compliance and the cost of the lean after treatment system were identified as the primary challenges to commercial viability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Liquid-Cooled Heat Sink Optimization for Thermal Imbalance Mitigation in Wide-Bandgap Power Modules

Power semiconductor die layout in substrates used in power modules is generally optimized for minimum electrical parasitics (e.g., stray inductance) by considering the minimum spacing between dies for thermal decoupling. The layout assumes sufficient heat spreading and transfer from dies to the cooling structure. For module designs using a direct substrate cooling method, the base plate is removed, leading to a steady-state thermal asymmetry in the power module due to insufficient heat spreading/transfer. This causes significant temperature differences among the devices. Such unintentional thermal asymmetries can lead to undesirable asymmetries in power conversion among semiconductor devices, which impact reliability. This article proposes a thermal imbalance mitigation method that uses evolutionary optimized liquid-cooled heat sinks to improve the thermal loading among devices.

Sahu, Raj↗

DOE OSTI2024

Predicting Instability and the Effect of Wind Loading on Single-Axis Trackers

As PV modules continue to trend toward larger, thinner, and more flexible forms they grow more susceptible to damage from dynamic wind loading. As a result, understanding the impact of wind on PV systems, particularly when mounted on solar-tracking hardware, and identifying robust, stable array layouts and stow strategies is becoming increasingly important for the PV community. In our ongoing DuraMAT project, we are developing an open-source software package, PVade (PV aerodynamic design engineering), to simulate the cascading fluid-structure interaction that occurs within solar-tracking arrays to enable researchers to test hardware, layout, and tracker control changes, leading to enhanced stability and a reduction in wind-driven damage. We will give an overview of the PVade software, highlighting recent user-interface and algorithm developments, before presenting the latest outcomes from our ongoing validation campaign in which we analyze and compare with experimental data obtained from a DuraMAT 1 project. From there, we will present simulated results from a larger, multi-row array and highlight relationships between varying tracker angles and stability as measured by different experimentally validated metrics.

fluid structure interaction↗

DOE OSTI2024

A Simulation and Optimization Framework for Managing Wind-Driven Loading on PV Systems

As PV modules continue to trend toward larger, thinner, and more flexible forms they grow more susceptible to damage from dynamic wind loading. As a result, understanding the impact of wind on PV systems, particularly when mounted on solar-tracking hardware, and identifying robust, stable array layouts and stow strategies is becoming increasingly important for the PV community. We are developing an open-source software package, PVade (PV aerodynamic design engineering), to simulate the cascading fluid-structure interaction that occurs within solar-tracking arrays to enable researchers to test hardware, layout, and tracker control changes, leading to enhanced stability and a reduction in wind-driven damage. We will give an overview of the PVade software and present the latest outcomes from our ongoing validation campaign in which we compare statistical structural responses with field data. From there, we will present simulated results from a larger, multi-row array and highlight the effect of varying tracker angles on stability as measured by both acceleration and deformation, focusing on the stability differences between positive and negative tilt angles.

fluid structure interaction↗

DOE OSTI2024

Simulating Wind-Driven Loading on PV Systems

As PV modules continue to trend toward larger, thinner, and more flexible forms they grow more susceptible to damage from dynamic wind loading. As a result, understanding the impact of wind on PV systems, particularly when mounted on compliant solar-tracking hardware, and identifying robust, stable array layouts and stow strategies is becoming increasingly important for the PV community. We are developing an open-source software package, PVade (PV aerodynamic design engineering), to simulate the cascading fluid-structure interaction that occurs within single-axis, solar-tracking arrays to enable researchers to test hardware, layout, and tracker control changes, leading to enhanced stability and a reduction in wind-driven damage. We will give an overview of the PVade software and present the latest outcomes from our ongoing validation campaign in which we compare time series and statistical structural responses with field data. From there, we will present simulated results from a larger, multi-row array and highlight the effect of varying tracker angles on stability and the differences between positive and negative tilt angles.

fluid↗

DOE OSTI2022

Mass Production of Microreactors: A Look at Potential Scenarios and Fabrication Facility Requirements

Microreactors may be able to be cost competitive in niche markets, but they are likely to be much more expensive than small modular reactors or large reactors in terms of levelized cost. The vision of microreactors being catered to larger markets relies heavily on their ability to be mass produced and cut costs. Since commercial nuclear reactors have not been mass produced before it is challenging to estimate what kind of manufacturing facilities will be needed, what they will cost, and how factory considerations influence the unit cost of microreactors. This summary attempts to imagine the various possible production layouts of microreactors and identify the different possible manufacturing facilities (factories) that might be required. Regulatory and economic considerations for these layouts and factories are then listed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Incorporating Wind Turbine Choice in High-Resolution Geospatial Supply Curve and Capacity Expansion Models

To achieve national decarbonization goals, U.S. annual deployment of wind energy will need to increase by at least fivefold compared to the recent past. Modeling and analysis frameworks can help inform where and how wind energy deployment might occur and thereby help enable the achievement of decarbonization goals. However, most prior wind energy modeling and analysis studies rely on generalized representations of wind energy technologies. Since wind energy technology advancements are expected to increase the competitiveness of wind energy, it is important to incorporate more detailed representations of turbine technology into wind energy modeling. Here we present a new method that incorporates wind turbine choice into the technology representation of land-based wind energy in long-term planning models. Our method integrates three previously published modeling and analysis capabilities: 1) bottom-up cost modeling to estimate future technology costs, 2) geospatial modeling to represent siting decisions, and 3) power sector modeling to evaluate potential deployment. We refer to this approach as a "customized turbine choice" methodology because it creates a composite turbine scenario by choosing from multiple wind turbine technologies—using site-specific optimized turbine layout and selecting the least-cost technology at each location. We demonstrate the capabilities of this new modeling pipeline by examining how the selection of four different wind turbine configurations might evolve from 2021 through 2040. Our results show that using our customized turbine choice methodology could lead to higher estimates for wind future deployment, which indicates that more simplified modeling might underestimate the role that wind energy could play in meeting decarbonization goals. Future research is needed to further explore the implications of turbine choice and to better inform technology researchers, original equipment manufacturers, and other wind industry stakeholders about the market potential of different wind turbine technologies.

17 WIND ENERGY↗

DOE OSTI2026

Alchemy: A Model-Based Approach for 2D to 3D Autonomous Nuclear System Design

Engineering design of nuclear power plant (NPP) piping and equipment systems frequently bypasses crucial 2D system planning, instead moving straight to 3D modeling. This often leads to designs that exceed building envelope constraints, forcing expensive and time-consuming redesigns. When 2D modeling is employed, it typically involves labor-intensive manual workflows that convert 2D drawings into 3D models, resulting in inefficiencies and errors across design iterations. These workflows further suffer from poor software interoperability and dependence on proprietary software ecosystems, thereby contributing to schedule delays and cost overruns. This paper presents Alchemy, an autonomous framework that transforms 2D system definitions into Industry Foundation Classes (IFC)-compliant 3D building information models (BIMs) for expediting nuclear facility design at the conceptual preliminary phase. Using a model-based approach, the framework treats the 2D system diagram as the central reference model employed to automatically generate all subsequent outputs, ensuring consistency between the system definition and the resulting physical design. A web-based interface enables engineers to define hierarchical system topologies including associated equipment, geometric properties, and connectivity requirements. A two-phase equipment layout optimization algorithm automatically computes collision-free spatial configurations within predefined building envelopes. An artificial intelligence (AI)-assisted pipe routing module then generates orthogonal, collision-free routing paths, allowing the user to select either an A* search-based method or an Ant Colony Optimization (ACO)-based method. All outputs are authored natively in IFC format, relying on open-source technologies and standardized formats in order to ensure extensibility and eliminate proprietary software dependencies. The proposed framework is validated on two representative pressurized-water reactor (PWR)-based case studies, for which it autonomously generates IFC-compliant 3D models in minutes, drastically reducing workflows that typically require hours of manual effort. The generated model demonstrates topologically correct equipment placement, physically plausible spatial relationships, and collision-free pipe routing consistent with known PWR loop configurations. This work represents a foundational step toward digital engineering for nuclear facility preliminary design, with future ongoing development targeting design code compliance and expanded system complexity.

97 - MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Demonstrating solarpilot ’s Python Application Programmable Interface Through Heliostat Optimal Aimpoint Strategy Use Case

solarpilot is a software package that generates solar field layouts and characterizes the optical performance of concentrating solar power (CSP) tower systems. solarpilot was developed by the National Renewable Energy Laboratory (NREL) as a stand-alone desktop application but has also been incorporated into NREL’s System Advisor Model (SAM) in a simplified format. Prior means for user interaction with solarpilot have included the application’s graphical interface, the SAM routines with limited configurability, and through a built-in scripting language called “LK.” This article presents a new, full-featured, python-based application programmable interface (API) for solarpilot, which we hereafter refer to as CoPylot. CoPylot enables python users to perform detailed CSP tower analysis utilizing either the Hermite expansion technique (analytical) or the SolTrace ray-tracing engine. CoPylot’s enables CSP researchers to perform analysis that was previously not possible through solarpilot’s existing interfaces. This article discusses the capabilities of CoPylot and presents a use case wherein we populate a model that obtains optimal solar field aiming strategies.

14 SOLAR ENERGY↗

DOE OSTI2026

Hydrodynamic Analysis and Optimization of Aquantis Marine Turbine: Cooperative Research and Development (Final Report)

The primary aim of this proposal is to improve the accurate prediction of hydrodynamic performance and dynamic load responses of the AQ10 floating axial-flow tidal turbine with a tri-cat mooring configuration. The validation of reduced-order modeling approaches with high-fidelity model will be implemented. Additionally, the frequency response domain, Response Amplitude Floating Wind (RAFT) toolbox plus an optimizer expanded for marine hydrokinetic turbines under the Submarine Hydrokinetic And Riverine Kilo-megawatt. Systems (SHARKS) program will be used for designing and exploring different key design parameters (platform dimension, mooring layout and its parameters) of next marine hydrokinetic (MHK) turbine generation.

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

Ensuring reliable connectivity to cellular-connected UAVs with up-tilted antennas and interference coordination

To integrate unmanned aerial vehicles (UAVs) in future large-scale deployments, a new wireless communication paradigm, namely, the cellular-connected UAV has recently attracted interest. However, the line-of-sight dominant air-to-ground channels along with the antenna pattern of the cellular ground base stations (GBSs) introduce critical interference issues in cellular-connected UAV communications. In particular, the complex antenna pattern and the ground reflection (GR) from the down-tilted antennas create both coverage holes and patchy coverage for the UAVs in the sky, which leads to unreliable connectivity from the underlying cellular network. To overcome these challenges, in this paper, we propose a new cellular architecture that employs an extra set of co-channel antennas oriented towards the sky to support UAVs on top of the existing down-tilted antennas for ground user equipment (GUE). To model the GR stemming from the down-tilted antennas, we propose a path-loss model, which takes both antenna radiation pattern and configuration into account. Next, we formulate an optimization problem to maximize the minimum signal-to-interference ratio (SIR) of the UAVs by tuning the up-tilt (UT) angles of the up-tilted antennas. Since this is an NP-hard problem, we propose a genetic algorithm (GA) based heuristic method to optimize the UT angles of these antennas. After obtaining the optimal UT angles, we integrate the 3GPP Release-10 specified enhanced inter-cell interference coordination (eICIC) to reduce the interference stemming from the down-tilted antennas. Our simulation results based on the hexagonal cell layout show that the proposed interference mitigation method can ensure higher minimum SIRs for the UAVs over baseline methods while creating minimal impact on the SIR of GUEs.

3GPP↗

DOE OSTI2024

Charge‐Programmable Photopolymers for 3D Electronics via Additive Manufacturing

Charge‐programmed 3D printing enables the fabrication of 3D electronics with lightweight and high precision via selective patterning of metals. This selective metal deposition is catalyzed by Pd nanoparticles that are specifically immobilized onto the charged surface and promises to fabricate a myriad of complex electronic devices with self‐sensing, actuation, and structural elements assembled in a designed 3D layout. However, the achievable property space and the material‐performance correlation of the charge‐programmed printing remain unexplored. Herein, a series of photo‐curable resins are designed for unveiling how the charge and crosslink densities synergistically impact the nanocatalyst‐guided selective deposition in catalytic efficiency and properties of the 3D printed charge‐programmed architectures, leading to high‐quality 3D patterning of solid and liquid metals. The findings offer a wide tunability of the structural properties of the printed electronics, ranging from stiff to extreme flexibility. Capitalizing on these results, the printing and successful application of an ultralight‐weight and deployable 3D multi‐layer antenna system operating at an ultrahigh‐frequency of 19 GHz are demonstrated.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Fibrous Materials for Flexible Li–S Battery

The lithium–sulfur (Li–S) battery is an attractive high-energy-density technology for future flexible and wearable electronics, but it is a challenge to simultaneously realize adequate flexibility, stability, and energy density. Recent studies show that fibrous materials are promising to achieve flexible batteries with high energy density, by taking advantages of their intrinsic flexibility, lightweight, large surface area, and cost-effectiveness. With a good tunability of the structure and function, fibrous materials can be suitable to construct various components of a working battery, including current collectors, buffer layers, interlayers, and solid-state electrolytes. In this review, we summarize the recent development of fibrous materials for flexible Li–S batteries, with an emphasis on the discussion of the synthesis and preparation of materials, design of fibrous structures and functionalities, and layout of battery cells for achieving high Coulombic efficiency, long cycle life, and good flexibility.

25 ENERGY STORAGE↗