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DOE OSTI2023

Multi-scale modeling of the electric field assisted sintering process

The electric field assisted sintering (EFAS) process involves tightly coupled physics that influence microstructural evolution in the particles being compacted. It is also an inherently multi-scale phenomenon, with the microstructure of the compact influencing the subsequent engineering-scale response of the sintering system. To improve understanding of how processing parameters influence microstructural evolution, we have developed a multi-scale modeling approach that couples a continuum-level model of the sintering system with a phase-field model for microstructural evolution of particles within the compact. The phase-field model couples the effect of chemical and electrical driving forces on microstructural evolution and includes the effect of charged defect segregation to surfaces and grain boundaries; this segregation leads to enhanced defect transport and heat generation at these interfaces in response to applied electric field. The effect of enhanced heat generation on particle neck growth and the influence of microstructural evolution on the engineering-scale model are demonstrated.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Development of Prototypical District-Scale Models: Preprint

The U.S. has set the climate goal to achieve net-zero greenhouse gas emissions by 2050. District-scale solutions, which include scale-specific opportunities for energy and emissions savings, can be investigated and implemented to help accelerate decarbonization and progress toward this goal. However, there is currently a lack of district-scale models of buildings and community energy systems that can be used to evaluate potential district-scale technologies and strategies across a range of representative community types. This initial work aims to define and develop prototype district models that can be adapted to support the planning, design, and operation of buildings and energy systems in districts considering the complexity and interactions of diverse building loads, weather impacts, distributed energy resources (e.g., PV, EV, electric and thermal energy storage), electric and thermal grid systems, and pricing signals. An overall workflow for developing these prototype district models is established. Stakeholders and potential users of the prototype district models provided technical feedback. The specifications of the selected high priority districts were defined and documented in a scorecard format. An example prototype district model was implemented with the URBANoptTM platform workflows. A case study was performed to demonstrate the model application.

district↗

DOE OSTI2023

Generation of Isocurvature from Curvature Inhomogeneities on Super-Horizon Scales

Here it is shown 1) how isocurvature inhomogeneities correlated on causally disconnected (super-horizon) scales are generated from curvature inhomogeneities which are known to be correlated on these scales 2) that super-horizon isocurvature generation is nearly inevitable for non-equilibrium chemical processes 3) that the amplitude of the compositional isocurvature correlations a) can be large for production of rare objects, b) falls off rapidly with separation c) falls off at scales below the horizon when these modes are generated. These two fall-offs results in an "isocurvature bump" in the power spectrum. Isocurvature generation is illustrated by the process of dark matter freeze-in, computed here with both separate universe modelling and linear perturbation theory. For freeze-in the most prominent isocurvature modes are inhomogeneities in the ratio of dark matter to standard model matter. Much smaller inhomogeneities in the ratio of baryons to standard model entropy are also produced. Previous constraints on freeze-in from Ly-$\alpha$ clouds limit the bump enhancement to $\lesssim10\%$ on comoving scales $\lesssim1\,$Mpc. Current observations are not sensitive to the isocurvature modes generated in viable freeze-in models. Results are obtained using a somewhat novel framework to describe cosmological inhomogeneities.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Reducing warpage in a hybrid large-scale additive manufacturing and compression molding process

In recent years, a hybrid manufacturing process, developed by combining extrusion-based large-scale additive manufacturing (AM) and compression molding (CM) techniques, has shown promising outcomes for producing structurally functional parts. The process can be used with both short fiber-reinforced composites and neat polymers and hence, even multi-material parts can be manufactured easily. This process offers the advantages of structural enhancement by having a desired fiber orientation using a large-scale AM process, as well as rapid manufacturing capability using a CM process. In the large-scale AM process, the alignment of fibers in the deposition direction enables significant improvement in the mechanical properties of the manufactured parts. However, the anisotropy resulting from the directional arrangement of fibers also introduces challenges related to warpage in the produced parts. This study aims to identify the causes of warpage and propose strategies to mitigate it. The research involves the use of preforms manufactured through the large-scale AM, which are then combined with the neat resin for CM manufacturing. A finite element-based numerical simulation model is developed, employing a sequentially coupled thermomechanical approach. Through a parametric study using the simulation models, optimization of printing direction and preform geometry is performed to minimize warpage. This contributes to the advancement and wider adoption of AM/CM hybrid manufacturing to produce structurally functional parts.

Jo, Eonyeon↗

DOE OSTI2025

Meso-scale modeling of UO2 nuclear fuel to high burnup

To improve the economics of light water reactors for commercial nuclear energy generation, utility operators are seeking to obtain regulatory approval to run UO2 fuel to higher levels of burnup. One potential impediment to obtaining this approval is the phenomenon of fuel fragmentation, relocation, and dispersal (FFRD). FFRD can result when fuel experiences a rapid temperature transient, such as that occurring during a Loss Of Coolant Accident (LOCA). FFRD has historically been most associated with the rim region in UO2 fuel pellets, where the phenomenon of fragmentation is also referred to as pulverization due to the small size of the fragments. More recent evidence suggests that the so-called “dark zone” (due to its appearance in micrographs) that can be observed in the mid-radial regions of high burnup fuel is also susceptible to FFRD. Although empirical fuel performance models have been developed that can adequately predict pulverization in the rim region under typical LWR conditions, a scientific understanding of what underlies fuel restructuring and subsequent FFRD is lacking even in the rim region, and no models are currently available for the behavior the dark zone. To address these challenges, the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has employed a multi-scale modeling approach to improve scientific understanding and develop new fuel performance models. In this talk, I will focus on meso-scale efforts, which form a crucial link between atomic-scale and engineering-scale models. Phase-field modeling combined with cluster dynamics is used to predict the restructuring process in the rim region. Phase-field fracture modeling, informed by atomistic simulations, is used to predict the onset of pulverization in the rim region. Combining these techniques together allows the extent of rim pulverization to be predicted. The formation and evolution of the dark zone has also been simulated with the phase-field method, using an improved approach to vacancy source term parameterization. The work shows the important impact of microstructure on fuel performance.

fracture↗

DOE OSTI2025

Across the Scales of the Nucleus: Understanding Short Range Correlations from Medium Modification to Probe Independence

The atomic nucleus presents an intricate system due to the non-linear forces described by Quantum Chromodynamics (QCD) that govern its structure. The range of scales involved is remarkable; the most massive nuclei weigh approximately five orders of magnitude more than the quarks that compose them. The nucleus can be analyzed at various levels, from quarks to hadrons to the nucleus as a whole. Short-Range Correlations (SRCs) within the nucleus play a significant role that spans these diverse scales. At the most fundamental level, SRCs influence the interaction between nucleons. The nucleon-nucleon (NN) interaction, arising from QCD, is crucial in determining nuclear properties. SRCs serve as valuable probes for measuring this NN interaction, as the nucleons within SRCs become effectively decoupled from the rest of the nucleus. Multiple experimental techniques, including electron scattering, have been employed to investigate the NN interaction through SRCs. However, our first project demonstrates that inclusive measurements alone are inadequate to constrain this interaction fully. Moving to the scale of the nucleus, SRCs contribute to the high-momentum tail of the nuclear spectral function. While the low-momentum region is characterized by nucleons exhibiting bulk properties, nucleons begin to pair into SRCs at higher momenta. Our research aims to bridge the understanding between the mean-field portion of the nucleus and its high-momentum SRC components. Additionally, SRCs affect the quark structure of protons, as evidenced by the EMC effect, which indicates that quarks behave differently when protons are embedded within a nucleus—an effect referred to as medium modification. This thesis explores the correlation between SRCs and medium modification across various experimental setups. Finally, we seek to establish an interpretation of the nuclear ground state. Accomplishing this requires demonstrating that our SRC observables are independent of the probe’s scale and scheme. The concluding project of this thesis illustrates how we utilize triple coincidence quasi-elastic scattering across a range of (Q2) values to develop a model-dependent framework for understanding SRC distributions within the nucleus’s ground-state wavefunction.

Denniston, A. W. Denniston [University of Tel Aviv↗

DOE OSTI2026

Robotics for Energy Infrastructure Construction on Earth and Beyond: Pilot Study Exploring Level 3-4 Semi-Autonomous Installation of a Reduced-Scale Photovoltaic Power Plant Prototype: Preprint

There is a growing need to build energy infrastructure at massive scale on both Earth and in space. On Earth, increasing electricity demand from applications such as AI data centers is driving rapid expansion of power systems, while in space, long-duration missions such as lunar operations require reliable and resilient energy infrastructure that can be deployed quickly. These needs outpace the capabilities of conventional construction methods. Robotic construction offers a path to faster, lower-cost, and more consistent deployment, yet most existing approaches focus on automating individual tasks rather than end-to-end assembly. The Industrialized Construction Innovation (ICI) team at the National Laboratory of the Rockies (NLR), in collaboration with the Colorado School of Mines, has been investigating robotics and automation strategies for rapid end-to-end energy infrastructure construction. This paper presents a pilot study demonstrating level 3-4 semi-autonomous, end-to-end robotic assembly of a reduced-scale photovoltaic power plant prototype under terrestrial conditions. The approach combines hardware redesign of photovoltaic components for robotic compatibility, discrete-event and physics-based robotic simulations in synthetic environments, and sim-to-real deployment to execute end-to-end robotic assembly of[NM1.1][NM1.2] tracking components, structural members, photovoltaic modules, and embedded electrical connections. The pilot identifies key limitations like tolerance management, perception and localization, end effector capability, fastening methods, and multi-physics simulation fidelity, that must be addressed to enable end-to-end robotic assembly of full-scale energy infrastructure. The study highlights how these insights inform scaling strategies for terrestrial energy infrastructure and adaptation to unstructured and extreme environments, including off-world scenarios such as robotic assembly of vertical tall lunar towers.

14 SOLAR ENERGY↗

DOE OSTI2023

Multi-scale modeling of the electric field assisted sintering process

36 - MATERIALS SCIENCE↗

DOE OSTI2021

High-Efficiency Conversion of Ionic Liquid-Pretreated Woody Biomass to Ethanol at the Pilot Scale

We report that with a diverse and widely distributed global resource base, woody biomass is a compelling organic feedstock for conversion to renewable liquid fuels. In California, woody biomass comprises the largest fraction of underutilized biomass available for biofuel production, but conversion to fuels is challenged both by recalcitrance to deconstruction and by toxicity toward downstream saccharification and fermentation due to organic acids and phenolic compounds generated during pretreatment. In this study, we optimize pretreatment and scale-up of an integrated one-pot process for deconstruction of California woody biomass using the ionic liquid (IL) cholinium lysinate [Ch][Lys] as a pretreatment solvent. By evaluating the impact of solid loading, solid removal, yeast acclimatization, fermentation temperature, fermentation pH, and nutrient supplementation on final ethanol yields and titers, we achieve nearly full conversion of both glucose and xylose to ethanol with commercial C5-utilizing Saccharomyces cerevisiae. We then demonstrate process scalability in 680 L pilot-scale fermentation, achieving >80% deconstruction efficiency, >90% fermentation efficiency, 27.7 g/L ethanol titer, and >80% ethanol distillation efficiency from the IL-containing hydrolysate post fermentation. This fully integrated process requires no intermediate separations and no intermediate detoxification of the hydrolysate. Using an integrated biorefinery model, current performance results in a minimum ethanol selling price of $\$$8.8/gge. Reducing enzyme loading along with other minor process improvements can reduce the ethanol selling price to $\$$3/gge. This study is the largest scale demonstration of IL pretreatment and biofuel conversion known to date, and the overall biomass-to-ethanol efficiencies are the highest reported to date for any IL-based biomass-to-biofuel conversion.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Dynamical System Scaling Application to Zircaloy Cladding Thermal Response During Reactivity-Initiated Accident Experiment

New fuel design and development currently requires 20 to 25 years to be qualified for use by the nuclear power industry. The thermal-hydraulics community has taken advantage of scaling theory to design reduced scale experiments that correctly preserve dominant key phenomena while quantifying distorted phenomena. These techniques can be leveraged in the design and analysis of fuel performance experiments to help reduce the timeline associated with fuel design and development. This study uses the Dynamical System Scaling (DSS) method to analyze cladding temperature data from the recent SETH-C experiment in the TREAT facility and accompanying BISON simulations to assess dynamic distortions occurring throughout the fast power excursion transient. The DSS analysis revealed that on the cool down from peak cladding temperature that the fuel radial power profile is the most sensitive modeling parameter with a heterogenous radial peaking factor corresponding to the lowest distortion compared to a uniform energy deposition. For the heat up to peak cladding temperature the heterogeneous radial power profile corresponded to the shortest process action. Finally, for the heat up to peak cladding temperature, the gap conductance model sensitivity was quantified using process action and shows that the default Light Water Reactor gap conductance model corresponded to the longest process action.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Local primordial non-Gaussianity from the large-scale clustering of photometric DESI luminous red galaxies

ABSTRACT We use angular clustering of luminous red galaxies from the Dark Energy Spectroscopic Instrument (DESI) imaging surveys to constrain the local primordial non-Gaussianity parameter fNL. Our sample comprises over 12 million targets, covering 14 000 deg2 of the sky, with redshifts in the range 0.2 < z < 1.35. We identify Galactic extinction, survey depth, and astronomical seeing as the primary sources of systematic error, and employ linear regression and artificial neural networks to alleviate non-cosmological excess clustering on large scales. Our methods are tested against simulations with and without fNL and systematics, showing superior performance of the neural network treatment. The neural network with a set of nine imaging property maps passes our systematic null test criteria, and is chosen as the fiducial treatment. Assuming the universality relation, we find $f_{\rm NL} = 34^{+24(+50)}_{-44(-73)}$ at 68 per cent (95 per cent) confidence. We apply a series of robustness tests (e.g. cuts on imaging, declination, or scales used) that show consistency in the obtained constraints. We study how the regression method biases the measured angular power spectrum and degrades the fNL constraining power. The use of the nine maps more than doubles the uncertainty compared to using only the three primary maps in the regression. Our results thus motivate the development of more efficient methods that avoid overcorrection, protect large-scale clustering information, and preserve constraining power. Additionally, our results encourage further studies of fNL with DESI spectroscopic samples, where the inclusion of 3D clustering modes should help separate imaging systematics and lessen the degradation in the fNL uncertainty.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

Continuous Fiber Bath Treatments at Pilot Scale: A Novel Testbed System

The technical demands on high performance textiles continues to expand, and the research community has answered the call with innovative fiber bath treatments for enhanced properties and sizings for improved composites. However, little translation to greater scale has been demonstrated. To fill this gap, a novel, multifunctional system has been developed to explore polymer fiber treatment methods, the deployment of nanoadditive coatings and other sizings, and smart processing methods at the pilot scale. Continuous tows of fibers can be passed through a temperature-controlled, crossflow bath with an immersion residence time exceeding 2 hours. The modular system is resistant to corrosive solutions, includes additional inline stations for washing and drying after processing, is equipped with a bevy of sensors, pumps, and valves monitored and controlled by a LabView program, and can be fully contained in a standard lab fume hood. This new testbed system, when coupled with high fidelity materials characterization methods, will enable rapid evaluation of new fiber treatment methods at pilot-scale.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Pilot Scale Testing of Lignite Adsorption Capability and the Benefits for the Recovery of Rare Earth Elements from Dilute Leach Solutions

Naturally occurring organic materials containing humic acids show a strong affinity towards rare earth elements (REE) and other critical elements. Leaching experiments on lignite coal waste produced from construction sand production revealed that the contained REEs were associated with the organic matter. Furthermore, adsorption studies revealed that the lignite waste was capable of extracting REEs from a model solution and increased the REE content of the lignite waste by more than 100%. As such, this study aimed to utilize the lignite waste to adsorb REEs from pregnant leach solutions and acid mine drainage sources having low REE concentrations and subsequently leach the lignite material to produce pregnant leach solutions containing relatively high amounts of REEs, which benefits the performance and economic viability of downstream separation and purification processes. An integrated flowsheet was developed based on this concept and tested at a pilot scale. The pregnant leachate solution (PLS) was generated from a heap leach pad containing 2000 tons of Baker seam coarse refuse. The pilot scale circuit was comprised of aluminum precipitation, adsorption using the waste lignite, and rare earth-critical metal (RE-CM) precipitation stages in succession. The results indicated that the aluminum precipitation stage removed over 88% and 99% of the Al and Fe, respectively. The adsorption stage increased the REE content associated with the waste lignite from 457 ppm to 1065 ppm on a whole mass basis. Furthermore, the heavy REE (HREE) content in the feedstock increased by approximately 250%, which raised the percentage of HREE in the REE distribution by 19 absolute percentage points. In addition to the REEs, concentrations of other critical elements such as Mn, Ni, and Zn also improved by 75%, 37%, and 250%, respectively. Bench-scale tests revealed that increasing the solids concentration in the waste lignite and PLS mix from 1% to 20% by weight enhanced the adsorption efficiency from 32.0% to 99.5%, respectively. As such, a new flowsheet was proposed which provides significantly higher REE concentrations in the PLS that can be fed directly to solvent extraction and/or oxalic acid precipitation and, thereby, enhancing process efficiency and economics.

58 GEOSCIENCES↗

DOE OSTI2025

Superclustering with the Atacama Cosmology Telescope and Dark Energy Survey. II. Anisotropic Large-scale Coherence in Hot Gas, Galaxies, and Dark Matter

Statistics that capture the directional dependence of the baryon distribution in the cosmic web enable unique tests of cosmology and astrophysical feedback. We use constrained oriented stacking of thermal Sunyaev–Zel’dovich (tSZ) maps to measure the anisotropic distribution of hot gas 2.5–40 Mpc away from galaxy clusters embedded in massive filaments and superclusters. The cluster selection and orientation (at a scale of ∼15 Mpc) use Dark Energy Survey (DES) Year 3 data, while expanded tSZ maps from the Atacama Cosmology Telescope Data Release 6 enable a ∼3× more significant measurement of the extended gas compared to the technique’s proof-of-concept. Decomposing stacks into cosine multipoles of order m , we detect a dipole ( m = 1) and quadrupole ( m = 2) at 8σ–10σ, as well as evidence for m = 4 signal at up to 6σ, indicating sensitivity to late-time non-Gaussianity. We compare to Cardinal simulations with spherical gas models pasted onto dark matter halos. The fiducial tSZ data can discriminate between two models that deplete pressure differently in low-mass halos (mimicking astrophysical feedback), preferring higher average pressure in extended structures. However, uncertainty in the amount of cosmic infrared background contamination reduces the constraining power. Additionally, we apply the technique to DES galaxy density and weak lensing to study for the first time their oriented relationships with tSZ. In the tSZ-to-lensing relation, averaged on 7.5 Mpc (transverse) scales, we observe dependence on redshift but not shape or radial distance. Thus, on large scales, the superclustering of gas pressure, galaxies, and total matter is coherent in shape and extent.

79 ASTRONOMY AND ASTROPHYSICS↗

NASA NTRS2011

Users Guide on Scaled CMOS Reliability: NASA Electronic Parts and Packaging (NEPP) Program Office of Safety and Mission Assurance

Reliability of advanced CMOS technology is a complex problem that is usually addressed from the standpoint of specific failure mechanisms rather than overall reliability of a finished microcircuit. A detailed treatment of CMOS reliability in scaled devices can be found in Ref. 1; it should be consulted for a more thorough discussion. The present document provides a more concise treatment of the scaled CMOS reliability problem, emphasizing differences in the recommended approach for these advanced devices compared to that of less aggressively scaled devices. It includes specific recommendations that can be used by flight projects that use advanced CMOS. The primary emphasis is on conventional memories, microprocessors, and related devices.

Scaled CMOS↗

DOE OSTI2022

Process Scale-Up of an Energy-Efficient Membrane Solvent Extraction Process for Rare Earth Recycling from Electronic Wastes

This study reports the process scale-up and long-term performance of an energy-efficient and cost-effective membrane solvent extraction (MSX) process for separation and recovery of high purity rare earth oxides (REOs) from scrap permanent magnets (SPMs). Here, the rare earth elements (REEs), including dysprosium, neodymium, and praseodymium, are recovered from SPMs using a neutral extractant, tetraoctyl diglycolamide (TODGA) embedded in a microporous polypropylene hollow fiber membrane module. The MSX process performance is demonstrated with bench scale module with membrane surface area of 1.4 m 2 to industrial scale modules with membrane surface area of up to 20 m2 to enable the processing of up to 1 ton month –1 of SPMs. The purity and the yield of the recovered REOs are >99.5 wt% and >95%, respectively. The average extraction rate of REOs is >10 g m –2 hr –1 . A skid of MSX system is assembled with a membrane area of 40 m 2 . The MSX skid successfully recovers REOs with a capacity of 300 kg REOs/month. Finally, it is determined that the organic phase containing the extractant maintains its performance up to 250 h. The results suggest that the MSX process is an economically viable and environmentally friendly process for separation and recovery of REOs from electronic wastes.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Atomic-Scale Modulation of Synthetic Magnetic Order in Oxide Superlattices

We report atomic-scale precision control of magnetic interactions facilitates a synthetic spin order useful for spintronics, including advanced memory and quantum logic devices. Conventional modulation of synthetic spin order has been limited to metallic heterostructures that exploit Ruderman–Kittel–Kasuya–Yosida interaction through a nonmagnetic metallic spacer; however, they face issues arising from Joule heating and/or electric breakdown. The practical realization and observation of a synthetic spin order across a nonmagnetic insulating spacer will lead to the development of spin-related devices with a completely different concept. Herein, the atomic-scale modulation of the synthetic spiral spin order in oxide superlattices composed of ferromagnetic metal and nonmagnetic insulator layers is reported. The atomically controlled superlattice exhibits an oscillatory magnetic behavior, representing the existence of a spiral spin structure. Depth-sensitive polarized neutron reflectometry evidences modulated spiral spin structures as a function of the nonmagnetic insulator layer thickness. Atomic-scale customization of the spin state can move the field one step further to actual spintronic applications.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2020

Simulation of mineral dissolution at the pore scale with evolving fluid-solid interfaces: review of approaches and benchmark problem set

This manuscript presents a benchmark problem for the simulation of single-phase flow, reactive transport, and solid geometry evolution at the pore scale. The problem is organized in three parts that focus on specific aspects: flow and reactive transport (part I), dissolution-driven geometry evolution in two dimensions (part II), and an experimental validation of three-dimensional dissolution-driven geometry evolution (part III). Five codes are used to obtain the solution to this benchmark problem, including Chombo-Crunch, OpenFOAM-DBS, a lattice Boltzman code, Vortex, and dissolFoam. These codes cover a good portion of the wide range of approaches typically employed for solving pore-scale problems in the literature, including discretization methods, characterization of the fluid-solid interfaces, and methods to move these interfaces as a result of fluid-solid reactions. A short review of these approaches is given in relation to selected published studies. Results from the simulations performed by the five codes show remarkable agreement both quantitatively--based on upscaled parameters such as surface area, solid volume, and effective reaction rate--and qualitatively--based on comparisons of shape evolution. This outcome is especially notable given the disparity of approaches used by the codes. Therefore, these results establish a strong benchmark for the validation and testing of pore-scale codes developed for the simulation of flow and reactive transport with evolving geometries. They also underscore the significant advances seen in the last decade in tools and approaches for simulating this type of problem.

58 GEOSCIENCES↗