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DOE OSTI2022

Impact of Gold Thickness on Interfacial Evolution and Subsequent Embrittlement of Tin–Lead Solder Joints

Although gold remains a preferred surface finish for components used in high-reliability electronics, rapid developments in this area have left a gap in the fundamental understanding of solder joint gold (Au) embrittlement. Furthermore, as electronic designs scale down in size, the effect of Au content is not well understood on increasingly smaller solder interconnections. As a result, previous findings may have limited applicability. The current study focused on addressing these gaps by investigating the interfacial microstructure that evolves in 63Sn-37Pb solder joints as a function of Au layer thickness. Those findings were correlated to the mechanical performance of the solder joints. Increasing the initial Au concentration decreased the mechanical strength of a joint, but only to a limited degree. Kirkendall voids were the primary contributor to low-strength joints, while brittle fracture within the intermetallic compounds (IMC) layers is less of a factor. The Au embrittlement mechanism appears to be self-limiting, but only once mechanical integrity is degraded. Sufficient void evolution prevents continued diffusion from the remaining Au.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Cross-sectoral impact of emerging technologies on U.S. manufacturing resilience and competitiveness

Introducing new technologies in one energy-intensive industry can affect how other industries operate and stay resilient, yet these cross-sector interactions are often underappreciated in conventional technology roadmaps. In practice, industrial systems do not evolve in isolation. They are linked through shared upstream and downstream dependencies, such as electricity and fuel supply, critical materials, transportation networks, and enabling infrastructure. As a result, large-scale technology deployment in one sector can reshape resource availability, infrastructure demand, and operational risk in others. These interdependencies mean that technology deployment decisions in one sector can create unintended bottlenecks or cascading benefits in others. Here, this article argues that a cross-sector, system-of-systems perspective is essential for evaluating and scaling emerging technologies in energy-intensive industries. By framing industrial transformation as an interconnected systems challenge rather than a set of isolated sectoral decisions, the study highlights how interdependence shapes technology feasibility, adoption pathways, and resilience outcomes. The article illustrates how cross-sector linkages can amplify both risks and benefits, and it emphasizes the importance of integrated planning approaches that account for shared dependencies, cascading impacts, and co-optimization opportunities. Adopting this broader perspective can support more robust technology roadmaps, improve strategic coordination across industries, and strengthen the long-term resilience of the industrial sector as a whole.

Nain, Preeti [Oak Ridge National Laboratory (ORNL)↗

DOE OSTI2025

Human–Earth system interactions under climate change

This special issue, titled ‘Focus on human–Earth system interactions under climate change,’ compiles cutting-edge research that deepens our understanding of the complex feedback mechanisms between anthropogenic activities and Earth system processes in the context of a changing climate (figure 1). The featured articles employ a diverse array of methodologies—including field studies, remote sensing, modeling, and socio-ecological analyses—to explore these interconnections. A unifying theme across these contributions is the imperative to bridge disciplinary divides, integrating physical Earth sciences with social sciences to fully capture the spectrum of human-Earth system interactions. Key topics addressed the impacts of human activities on natural systems, encompassing land-use change and water resource management on biogeochemistry, climate dynamics, and feedback on the climate system and socioeconomics from local to global scales under a changing climate.

Li, Huidong [Vanderbilt Univ., Nashville, TN (Unit↗

DOE OSTI2025

Microgrid Building Block Architecture, and Subcomponents Modeling and Demonstration in Controller Hardware-in-the-Loop

The recently proposed Microgrid Building Blocks (MBB) are ready-to-use components to build microgrids quickly, cheaply, and modularly. This work presents and demonstrates in controller hardware-in-the-loop (CHIL) three key subcomponents of an MBB architecture: power converter topology, control scheme, and communication framework. The addressed architecture aims for systems interconnection such as microgrid to grid and microgrid to microgrid. This paper studies each subcomponent in detail and validates the efficacy of the architecture through CHIL results.

Adib, Aswad [ORNL] (ORCID:000000020997056X)↗

DOE OSTI2025

Edge ML for CAN bus intrusion detection in AVs

Autonomous Vehicles (AVs) are revolutionizing transportation, but their reliance on interconnected cyber-physical systems exposes them to unprecedented cybersecurity risks. This study addresses the critical challenge of detecting real-time cyber intrusions in self-driving vehicles by leveraging a dataset from the Udacity self-driving car project. We simulate four high-impact attack vectors, Denial of Service (DoS), spoofing, replay, and fuzzy attacks, by injecting noise into spatial features (e.g., bounding box coordinates) to replicate adversarial scenarios. We develop and evaluate two lightweight neural network architectures (NN-1 and NN-2) alongside a logistic regression baseline (LG-1) for intrusion detection. The models achieve exceptional performance, with NN-2 attaining an AUC score of 93.15% and 93.15% accuracy, demonstrating their suitability for edge deployment in AV environments. Through explainable AI techniques, we uncover unique forensic fingerprints of each attack type, such as spatial corruption in fuzzy attacks and temporal anomalies in replay attacks, offering actionable insights for feature engineering and proactive defense. Visual analytics, including confusion matrices, ROC curves, and feature importance plots, validate the models' robustness and interpretability. This research sets a new benchmark for AV cybersecurity, delivering a scalable, field-ready toolkit for Original Equipment Manufacturers (OEMs) and policymakers. By aligning intrusion fingerprints with SAE J3061 automotive security standards, we provide a pathway for integrating machine learning into safety-critical AV systems. Our findings underscore the urgent need for security-by-design AI, ensuring that AVs not only drive autonomously but also defend autonomously. This work bridges the gap between theoretical cybersecurity and life-preserving engineering, offering a leap toward safer, more secure autonomous transportation.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Achieving 20.1% Efficiency in Organic Solar Cells Through Interconnected Fibrillar Networks via Local Molecular Stacking

ABSTRACT The performance of organic solar cells (OSCs) is governed by how molecular packing evolves into interconnected networks that facilitate exciton dissociation and charge transport. Using an all‐small‐molecule blend DR3TSBDT:Y6 as a model system, we study how local molecular stacking evolves into performance‐relevant morphology during solvent vapor annealing (SVA) and subsequent thermal annealing (TA). SVA promotes end‐to‐end stacking of amorphous acceptors to form interconnected fibrils, while TA compacts inter‐fibril spacing without disrupting favorable local order. Such molecular‐to‐morphological refinements broaden light absorption, enhance charge transport, and markedly improve device efficiency. Extending this approach to additional blend systems (D18:Y6, D18:L8‐BO, and DR3TSBDT:L8‐BO) yields similar structural evolution and performance gains, with the D18:L8‐BO system achieving up to 20.10% PCE. Our study establishes control over local stacking in amorphous acceptors into fibrillar networks as a general and effective route to realize high‐performance OSCs.

Wu, Junying↗

DOE OSTI2026

A Review of Distributed Wind Interconnection Technology and Standards

The objectives of this report are to discuss the uniqueness of power converters in distributed wind (DW), identify challenges in complying with existing standards, prioritize technological innovations to facilitate interconnection of DW energy systems, and, where necessary, propose potential clarifications or revisions to standards. This report evaluates IEEE 1547-2018, IEEE 1547.1-2020, and UL 1741 SB standards and their implications for DW. A standards review and interviews of DW industry stakeholders were conducted to identify challenges in the application of current standards to DW. The study concludes with a combination of recommendations of pathways towards facilitating DW product commercialization and DW interconnection, which draws on participation from multiple stakeholders in the space. These solutions can continue to be explored to improve DW standards compliance, improve the applicability of the standards to DW, reduce certification testing barriers, and ensure the safe and reliable operation of DW energy resources and electric power systems.

17 WIND ENERGY↗

DOE OSTI2022

Influence of the molecular weight and size distribution of PSS on mixed ionic-electronic transport in PEDOT:PSS

The commercially available polyelectrolyte complex poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS) is ubiquitous in organic and hybrid electronics. As such, it has often been used as a benchmark material for fundamental studies and the development of new electronic devices. Yet, most studies on PEDOT:PSS have focused on its electronic conductivity in dry environments, with less consideration given to its ion transport, coupled ionic-electronic transport, and charge storage properties in aqueous environments. These properties are essential for applications in bioelectronics (sensors, actuators), charge storage devices, and electrochromic displays. Importantly, past studies on mixed ionic-electronic transport in PEDOT:PSS neglected to consider how the molecular structure of PSS affects mixed ionic-electronic transport. Herein, we therefore investigated the effect of the molecular weight and size distribution of PSS on the electronic properties and morphology of PEDOT:PSS both in dry and aqueous environments, and overall performance in organic electrochemical transistors (OECTs). Using reversible addition–fragmentation chain transfer (RAFT) polymerization with two different chain transfer agents, six PSS samples with monomodal, narrow (D = 1.1) and broad (D = 1.7) size distributions and varying molecular weights were synthesized and used as matrices for PEDOT. We found that using higher molecular weight of PSS (Mn = 145 kg mol –1 ) and broad dispersity led to OECTs with the highest transconductance (up to 16 mS) and [μC*] values (~140 F cm –1 V –1 s –1 ) in PEDOT:PSS, despite having a lower volumetric capacitance (C* = 35 ± 4 F cm –3 ). The differences were best explained by studying the microstructure of the films by atomic force microscopy (AFM). We found that heterogeneities in the PEDOT:PSS films (interconnected and large PEDOT- and PSS-rich domains) obtained from high molecular weight and high dispersity PSS led to higher charge mobility (μOECT ~4 cm 2 V –1 s –1 ) and hence transconductance. Furthermore, these studies highlight the importance of considering molecular weight and size distribution in organic mixed ionic-electronic conductor, and could pave the way to designing high performance organic electronics for biological interfaces.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Synthesis of Ionic Ultramicroporous Polymers for Selective Separation of Acetylene from Ethylene

The design of highly stable and efficient porous materials is essential for developing breakthrough hydrocarbon separation methods based on physisorption to replace currently used energy-intensive distillation/absorption technologies. Efforts to develop advanced porous materials such as zeolites, coordination frameworks, and organic polymers have met with limited success. Here, a new class of ionic ultramicroporous polymers (IUPs) with high-density inorganic anions and narrowly distributed ultramicroporosity is reported, which are synthesized by a facile free-radical polymerization using branched and amphiphilic ionic compounds as reactive monomers. A covalent and ionic dual-crosslinking strategy is proposed to manipulate the pore structure of amorphous polymers at the ultramicroporous scale. The IUPs exhibit exceptional selectivity (286.1–474.4) for separating acetylene from ethylene along with high thermal and water stability, collaboratively demonstrated by gas adsorption isotherms and experimental breakthrough curves. Modeling studies unveil the specific binding sites for acetylene capture as well as the interconnected ultramicroporosity for size sieving. Finally, the porosity-engineering protocol used in this work can also be extended to the design of other ultramicroporous materials for the challenging separation of other key gas constituents.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Distinct Depth-Discrete Profiles of Microbial Communities and Geochemical Insights in the Subsurface Critical Zone

Microbial assembly and metabolic potential in the subsurface critical zone (SCZ) are substantially impacted by subsurface geochemistry and hydrogeology, selecting for microbes distinct from those in surficial soils. In this study, we integrated metagenomics and geochemistry to elucidate how microbial composition and metabolic potential are shaped and impacted by vertical variations in geochemistry and hydrogeology in terrestrial subsurface sediment. A sediment core from an uncontaminated, pristine well at Oak Ridge Field Research Center in Oak Ridge, Tennessee, including the shallow subsurface, vadose zone, capillary fringe, and saturated zone, was used in this study. Our results showed that subsurface microbes were highly localized and that communities were rarely interconnected. Microbial community composition as well as metabolic potential in carbon and nitrogen cycling varied even over short vertical distances. Further analyses indicated a strong depth-related covariation of community composition with a subset of 12 environmental variables. An analysis of dissolved organic carbon (DOC) quality via ultrahigh resolution mass spectrometry suggested that the SCZ was generally a low-carbon environment, with the relative portion of labile DOC decreasing and that of recalcitrant DOC increasing along the depth, selecting microbes from copiotrophs to oligotrophs and also impacting the microbial metabolic potential in the carbon cycle. Our study demonstrates that sediment geochemistry and hydrogeology are vital in the selection of distinct microbial populations and metabolism in the SCZ.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

EIC Hadron Beamline Vacuum Studies

Ninety percent of the EIC hadron ring vacuum chamber consists of cold-bore sections running through and interconnecting 4.55 K RHIC superconducting (SC) magnets. The EIC operating specification requires shorter bunches and 3x higher intensity beams which are not appropriate for the present RHIC stainless steel cold-bore beam tube. The intensity and emittance of the hadron beams will degrade due to interactions with residual gas or vacuum instabilities arising from the expected resistive-wall (RW) heating, electron clouds, and beam-induced desorption mechanisms. Without strategies to limit RW heating, major cryogenic system modifications are needed to prevent SC magnet quenches. The SC magnet cold-bore beam tubes will be equipped with a high RRR copper-clad stainless steel screen to significantly reduce RW heating and so the effect on the SC magnet cryogenic heat load and temperature. A thin amorphous carbon film applied to the beam-facing copper surface will suppress electron cloud formation. This paper discusses the vacuum requirements imposed by the EIC hadron beams and the plans to achieve the necessary vacuum and thermal stability that ensure acceptable beam quality and lifetime.

43 PARTICLE ACCELERATORS↗

DOE OSTI2021

Managing Solar Photovoltaic Integration in the Western United States: Resource Adequacy Considerations

This study examines the impact of reserve margin-based reliability assessment, as commonly used in capacity expansion models, on planning resource-adequate power systems under high penetrations of solar photovoltaics (PV). As a generation resource, PV is operationally different from the conventional dispatchable resources for which most capacity expansion models were designed. The question this study attempts to answer is whether large amounts of PV on a system (in this case, the Western Interconnection of North America) would bias the results of conventional reserve margin-based capacity expansion modeling towards an over- or under-provisioning of resource adequacy. This analysis used NREL’s Resource Planning Model (RPM) for capacity expansion modeling and NREL’s Probabilistic Resource Adequacy Suite (PRAS) for resource adequacy assessment. RPM uses a reserve margin requirement to enforce resource adequacy. PRAS, a collection of tools for studying the resource adequacy of power systems and the adequacy contributions of individual resources on a probabilistic basis, was used to compute multiple resource adequacy metrics across a number of simulated scenarios and system representations with differing regional detail. In all cases, including high PV penetrations (up to 33% annual generation from PV, interconnection-wide), RPM was able to produce resource-adequate systems as measured by normalized expected unserved energy and loss-of-load expectation results from PRAS. The accuracy of reserve margin approaches depends heavily on the underlying assumptions informing the capacity credit assigned to variable and energy-limited resources, particularly when such resources are abundant in the modeled system. RPM’s standard methodology for estimating variable and flexible resources’ capacity contributions, which is based on the top 100 hours of net load, did not appear to systematically undervalue or overvalue variable generation relative to a more rigorous equivalent firm capacity assessment using PRAS, although both over- and under-valuations were observed in specific scenarios. In the worst cases, the top 100 hour method underestimated the equivalent firm capacity of PV by two percentage points, and overestimated the equivalent firm capacity of PV by five percentage points. Calculating capacity contributions based on the top 10 hours of net load systematically underestimated equivalent firm capacities at more modest PV penetrations, but was often a better approximation of equivalent firm capacity than the existing 100-hour approach in scenarios with higher PV penetrations.

14 SOLAR ENERGY↗

DOE OSTI2024

Interconnected Nanoporous Polysulfone by the Self-Assembly of Randomly Linked Copolymer Networks and Linear Multiblocks

Porous materials have attracted considerable attention due to their versatile applications, especially in water purification. Interconnected nanoporous structures are distinguished by their high degree of porosity and resistance to clogging, as well as their insensitivity to nanostructural orientation. Previous works on randomly linked copolymer systems have shown that they can effectively produce disordered cocontinuous nanostructures, which upon removal of one component yield interconnected nanoporous materials. However, the cocontinuous nanomaterials previously developed using polystyrene (PS) and poly(d,l-lactic acid) (PLA) strands, and the resulting interconnected nanoporous PS monoliths, were far too brittle to enable practical use as membranes. Here, we study the self-assembly of randomly linked copolymer networks prepared using blocks of the engineering polymer polysulfone (PSU). A wide cocontinuous regime (spanning 40 wt %) was found for randomly end-linked copolymer networks (RECNs) constructed from PSU and PLA strands, via a combination of mechanical testing, gravimetry, small-angle X-ray scattering, and scanning electron microscopy. The PSU/PLA cocontinuous nanomaterial with symmetric composition showed 2.4 times higher Young’s modulus and ~100 times greater toughness than the corresponding PS/PLA sample. The interconnected nanoporous PSU fabricated after etching of PLA even exhibited 1.6 times greater toughness than PS/PLA prior to PLA removal. To facilitate the production of thin films of cocontinuous nanomaterials, we applied solution-processable randomly linked linear PSU/PLA multiblock polymers onto ultrafiltration membranes. Here, the interconnected nanoporous PSU thin film generated by etching PLA was found to effectively reject 50 nm diameter particles without significantly compromising permeability. This discovery presents a valuable addition to the existing techniques used to fabricate PSU membranes. In contrast to traditional methods, which are sensitive to processing conditions, produce a wide range of pore sizes, and offer limited adjustability of pore size, the current technique is anticipated to enable interconnected PSU membranes with more uniform and tailorable porosity.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Key Considerations for Adoption of Technical Codes and Standards for Battery Energy Storage Systems in Thailand

Battery storage is “technology that enables power system operators and utilities to store energy for later use. A battery energy storage system (BESS) is an electrochemical device that charges (or collects energy) from the grid or a power plant and then discharges that energy at a later time to provide electricity or other grid services when needed”. As countries in Asia consider the inclusion of BESS in their power systems to meet policy objectives, renewable energy goals, increase resilience, and expand energy access, there is an opportunity to learn from the experiences of other regions and jurisdictions that have developed more advanced storage markets and deployment methodologies. This report presents global best practices of codes, standards, and interconnection procedures developed to support the safe and reliable deployment of BESS. Several relevant case studies highlight current efforts to ensure safe operation of BESS and showcase potential pathways for adoption of relevant codes and standards. Specifically, this report is intended to support the Thailand Office of Energy Regulatory Commission (OERC) and other stakeholders in their efforts to develop technical codes and standards to govern the installation and operation of BESS; it may also be utilized as a guide for other countries as interest in the deployment of BESS technologies continues to grow.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Frequency Response and Congestion Management using Multi-Terminal HVDC Overlay

Continental level power system interconnections using a High Voltage direct current (HVDC) transmission lines have been considered to bring economic benefits such as interregional power exchange. This paper describes the modeling process and studies the technical benefits of having multiple HVDC lines, including a grid of HVDC lines (macrogrid) configuration, connecting the North American Eastern and Western electric power interconnections. The models developed provide steady state and stability analysis for multiple HVDC overlay topologies and provide technical benefit analysis in terms of frequency response and congestions management. The paper also provides a comparison of different HVDC topologies performance and their grid support in case of major disturbances

Tbaileh, Ahmad↗

DOE OSTI2020

Simulating Distributed Energy Resource Responses to Transmission System-Level Faults Considering IEEE 1547 Performance Categories on Three Major WECC Transmission Paths

This study performs a large quantity of transmission and distribution simulations for three regions in the Western Interconnection along with final transmission simulations informed by distribution simulation results. Results find that the type of ride-through implemented by distributed energy resources (DERs) is a significant factor to the overall power system response to transmission-level faults. This impact is particularly high for transmission-level faults that depress voltage levels for high numbers of substations (i.e., for cases that experience large regional voltage sags). Because of the programmed nature of the ride-through of IEEE 1547-compliant DERs, the potential for large reductions in real power injection is possible based on IEEE 1547 interpretation and specific implementation. In this study, we made a first attempt to determine the quantity of DERs affected by a variety of transmission-level faults as well as a granular response of distribution-simulated DERs to a few types of IEEE 1547-2003 interpretations and IEEE 1547-2018 voltage ride-through categories. The distribution-informed transmission studies show that the category of IEEE 1547 adherence, particularly with the new 2018 standard, can have a significant impact on the amount of DER-based generation lost following transmission-level fault events.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Impacts of Ternary-Pumped Storage Hydropower on U.S. Western Interconenction with Extremely High Renewable Penetrations

In recent years, ternary pumped storage hydropower (T-PSH), as one of the advanced PSH technologies, has attracted more attention from the industry. The interest is because of the capability of providing fast power support for the future electric grid with high penetration of renewable energy (RE). This paper focuses on studying the impact of T-PSH on frequency response of the U.S. Western Interconnection under different penetration levels of RE, which are from 20% to 80%. The detailed model of T-PSH is developed and implemented in the Western Interconnection grid model based on the GE Positive Sequence Load Flow (PSLF) platform, which can capture the unique dynamics of hydraulic short-circuit (HSC) mode and fast mode switching of T-PSH. To reveal the dynamic benefit from T-PSH, the frequency response of the Western Interconnection has been compared with and without T-PSH. In addition, a new solution is discussed that uses T-PSH to improve system stability issues caused by high RE penetration.

13 HYDRO ENERGY↗

DOE OSTI2021

An Overview of Issues Related to IEEE Std 1547-2018 Requirements Regarding Voltage and Reactive Power Control

The revised Institute of Electrical and Electronics Engineers (IEEE) 1547 Standard for Interconnection and Interoperability of Distributed Energy Resources with Associated Electric Power Systems Interfaces (IEEE Std 1547-2018) was published in April 2018. This standard is one of the foundational documents in the United States needed for integrating distributed energy resources (DERs), including solar energy systems, with the electric distribution grid. The revised standard contains 11 chapters (clauses) and 8 annexes that comprise 136 pages. The revision is significantly different from the 2003 version, and it contains new concepts and new technical requirements. Each clause specifies information or requirements that apply to certain aspects important to the interconnection of DERs to the electric power system. Implementing the requirements necessitates a careful study of the underlying technical concept and requires the appropriate information required to calculate relevant settings and configurations. Various stakeholders have different roles in implementing the standard, and portions of the standard are directed toward a specific audience who must possess specialized information and technical training to use and apply the requirements. This document aims to (1) summarize a specific portion of the standard as concisely as possible and (2) provide the reader with introductory knowledge and information to support the utilization of the requirements.

14 SOLAR ENERGY↗