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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Mixed-Integer Linear Programming Formulation with Embedded Machine Learning Surrogates for the Design of Chemical Process Families

In previous work, we introduced process family design. The main idea is to design a platform of common elements, and, allowing us to capture additional cost savings, simultaneously design a family of processes, and reducing both engineering and deployment timelines. We formulate this as an optimization problem, specifically a nonlinear generalized disjunctive program (GDP). We have proposed two approaches for reformulating and solving this problem: one based on full-discretization of the design space and one that uses Machine Learning (ML) surrogates to replace the nonlinear process models. Using ML surrogates to predict required system costs and performance indicators allows us to reformulate the nonlinearities in the GDP generate an efficient MILP formulation. In this work, we apply the ML surrogate approach to two case studies. One case study involves designing a family of carbon capture systems to cover a set of different flue gas flow rates and inlet CO 2 concentrations, where we consider the absorber and stripper as common unit module types. The second case study focuses on a water-desalination process, where we design a family of these processes for a variety of salt concentrations and flow rates. In both of these case studies, we demonstrate a scalable optimization approach that enables the design of multiple processes simultaneously, reducing the time-to-market and overall costs by maximizing the cost savings due to both economies of scale and economies of numbers.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Graph-based design of irregular metamaterials

In the field of metamaterial research, random structures offer a novel and less conventional approach compared to traditional periodic designs. Designing random metamaterials is challenging when it comes to ensuring intercon- nectivity, which is essential for manufacturability. This study introduces an innovative framework for generating random metamaterials using graph al- gorithms, ensuring connectivity and adaptability across various base shapes, including cylinders, triangles, pyramids, and cubes. By employing graph algorithms, our framework enhances the intuitiveness and efficiency of de- sign representation and manipulation, streamlining the design process. The framework generates families of designs that exhibit a wide range of prop- erty magnitudes that can be adjusted intuitively by modifying the input parameters. The rapid design process allows many designs to be generated, offering the user a multitude of solutions around the target property range. The designs can be effectively implemented in various fields and subjected to diverse analytical studies, including static, dynamic, and eigenfrequency assessments. We illustrate computational results for two key properties (stiff- ness and acoustic impedance), showcasing the method’s effectiveness through examples ranging from rod-based to cube-based designs. Here, the framework not only advances metamaterial research but also creates new opportunities for innovation in fields requiring customized material properties.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Open-Source Offshore Airfoil Summary (V.1.0)

The Open-Source Offshore (OSO) airfoils have been developed for research purposes for offshore wind turbines, offering a set of airfoils that align with modern turbine design requirements and industry design practices without proprietary constraints on research use. The eventual airfoil family will target the IEA 22 MW reference wind turbine, which was originally developed with the FFA airfoils. The two airfoils summarized in Table 1 (OSO-21-WT1 and OSO-30-WT1) started development as part of a family of airfoils being designed to target the IEA 22 MW wind turbine. The criteria used to design these airfoils are summarized in Table 1, which aim to encapsulate requirements of modern airfoils for offshore wind turbine applications, and were developed with feedback from industry and research experts. The airfoils were designed using XFOIL and candidate airfoils were then analyzed in RFOIL, which is considered more accurate than XFoil for high lift predictions of thicker airfoils. The design process for a preliminary family of airfoils is available, including a more detailed explanation of the design requirements and metrics similar to those used for these airfoils. Most of the design criteria are met for these two airfoils, with two exceptions. For both airfoils, the L/D Roughness Loss metric is exceeded (42% > 40% goal) and the desired lift coefficient margin over the design value (“CL_Margin”) was moderately exceeded (0.43 > 0.3) while smooth-stall characteristics (computed) were achieved. Note that all of the metrics were computed using RFOIL, and like other new airfoils, these will need to be experimentally validated at a range of Reynolds numbers. The airfoil coordinates will be shared publicly on Sadia National Laboratories’ public Github repository:

17 WIND ENERGY↗

DOE OSTI2025

Targeted Chemical Looping Materials Discovery by an Inverse Design

Chemical looping with oxygen uncoupling (CLOU) materials is actively sought for combustion of carbonaceous materials to achieve complete conversion and capture of carbon dioxide. These materials may play a vital role in reducing atmospheric carbon via negative carbon output. However, there is no one‐size‐fits‐all approach as different operating conditions and feedstocks may require different CLOU materials. As a result, the exploration and discovery of high‐performance CLOU materials can be a slow process. To address this challenge, a high‐throughput inverse machine learning workflow that identifies optimum materials from perovskite oxides for a given set of targets is developed—temperature and Gibbs free energy of oxygen formation. The model is trained on high‐throughput density functional theory calculations of CLOU materials and inverts the materials design process using a genetic algorithm to produce realistic substituted SrFeO 3‐δ compositions as output. Using the inverse model, it is able to identify several interesting new families of CLOU materials: Sr 1‐ x A x Fe 1‐ y B y O 3‐δ (e.g., A = Ca or K; B = Mg, Bi, Mn, Ni, Co, Cu, or Zn). These materials have shown promising properties, and some of them even outperform the benchmark material in terms of oxygen release kinetics under relevant CLOU operating conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Design of a Preliminary Family of Airfoils for High Reynolds Number Wind Turbine Applications

For the past 30 years, offshore wind turbines exhibited a continual pattern of growth that is expected to continue as the industry pushes for higher efficiency. Current designs for the next generation of wind turbines are so large that the chordwise Reynolds number of the blades is well beyond the design range of existing open-source airfoil families. This paper presents a preliminary family of new airfoils designed specifically for the needs of these next-generation offshore turbines, ranging from 21% thick to 30% thick with operating Reynolds numbers between 12 million and 18 million. These airfoils are intended to be alternative to the FFA airfoils that are commonly used on reference turbines such as the IEA 15MW and 22MW designs. In this work, airfoil performance metrics and design targets are developed, the design process is outlined, an optimization scheme is presented, and finally the airfoils and their simulated performance are compared to existing baselines. Lift to drag ratios in a clean condition were improved by up to 49.3% from the baseline FFA airfoil, and rough condition lift to drag ratio was improved by up to 9.3%. It is estimated that the cumulative improvements provided by this airfoil family would result in an approximately 1% increase of Annual Expected Power (AEP) for the 22 MW turbine compared to the current baseline.

airfoils↗

DOE OSTI2025

EMPOWERED Distributed Energy Resources Permit Accelerator Pilot

This report summarizes the EMPOWERED Distributed Energy Resources (DER) Permit Accelerator Pilot project. Its primary objective was to streamline the design, installation, permitting, and inspections of targeted Distributed Energy Resource (DER) solutions. Streamlining these processes is critical to strengthening and accelerating the adoption of DER solutions nationwide. Moreover, streamlined processes help expedite the clean energy transition and expand energy resilience by improving understanding and capability among key stakeholders like property owners, code officials, and the general workforce. The project team accomplished this by developing and deploying a set of design and permitting guides for simple DER solutions, which they rolled out via a permitting pilot program. The project team developed nine permitting and inspection guides for simple DER solutions, as follows: 1. Single-Family and Duplex: Electric Vehicle Service Equipment (EVSE), and Storage, Solar + Storage (each in two code cycles) 2. Multi-family and Office: EVSE, Storage, Solar + Storage (each in two code cycles) 3. A permitting process guide to support the implementation of the permitting guides. The guides cover key code requirements via plan review and field inspection checklists for code officials and building owners to follow to streamline the permitting and inspections process for DER solutions. Following the development of the initial set of guides, the project team formed two cohorts, each made up of four jurisdictions, to participate in the Permit Accelerator Pilot. Each cohort received training and technical assistance to support them in incorporating the guides into use. The project successfully engaged jurisdictions in two disparate US regions: Chelsea, Somerville, Natick, and Norwood in metro Boston; and Pima County, Town of Gilbert, Flagstaff, and Sedona in Arizona. Feedback gathered from the project was valuable in refining the guides to better address jurisdictional needs. After the pilot period, the project team developed final versions of the guides based on extensive feedback from the cohorts and from external technical peer review. Feedback included needs and barriers related to implementation, as well as detailed technical improvements from external peer review. The final guides were presented in a series of webinars with a national reach, with 192 attendees from 35 states in the live session of the final webinar, and the final guides are posted online and available for use nationwide. Key findings: • The most receptive jurisdictions were those adjacent to other jurisdictions that had already adopted similar initiatives. The least receptive jurisdictions were those in the midst of adopting new code cycles. • The most common barrier to jurisdictional adoption of new guidelines were internal administrative and process delays, more so than technical barriers. • The main technical barrier to adoption proved to be the concern of fire hazard risks posed by energy storage systems. There is some apprehension in the code enforcement community about the safety of the batteries. Education coordinated with fire and safety services will help alleviate concerns and increase confidence in the acceptance of innovative technologies. • Opportunities to further leverage and advance the guides and related resources include outreach, education, and jurisdictional support; updates to the resources to align with code cycle changes and local requirements; and advancements supporting emerging technologies.

14 SOLAR ENERGY↗

NASA NTRS1972

Development of beam leaded low power logic circuits

The technologies of low power TTL and beam lead processing were merged into a single product family. This family offers the power and thermal advantages of low power(54L), while providing the additional reliability advantages of beam leads. The reduction in the power and heat levels also allows the system designer to take advantage, through beam lead, multichip assemblies, of increased package density to reduce system size and weight.

Smith, B. W.↗

DOE OSTI2025

Cardinal: Seismic and Geoacoustic Array Processing

Data collected via seismic and infrasound array deployments are leveraged in the geosciences to detect and characterize a myriad of natural and anthropogenic sources. These deployments consist of numerous sensors placed in a predetermined configuration to amplify signal strength and improve the efficacy of array processing techniques used to measure signal directionality and waveform coherence. High‐fidelity feature extraction is often predicated on interstation distance as well as the frequency content and wavelength of an incident signal. Numerous array processing softwares analyze data in sequential frequency bands to obtain a more detailed characterization of a signal. However, current algorithms are limited in their ability to determine optimal array configuration for each band. We introduce an open‐source Python code, called Cardinal, to process seismic and infrasound array data in discretized time–frequency space with the option of applying an adaptive array design to determine optimal subarray configuration for each frequency band. To reduce computational time, the array processing step can be run in parallel using multithreading. Furthermore, the software has the capability to aggregate array processing results from different time–frequency pixels to produce separate sets of detections, or families, with added utility via the application of an adaptive semblance threshold, which aids in isolating signals‐of‐interest from coherent background noise. Upon appropriate configuration, Cardinal exhibits the potential to combine distinct seismic and infrasound phases into separate families.

Adaptive Array↗

DOE OSTI2026

Mechanistic implications of excited high-spin states, spin–spin coupling, and differential [2Fe–2S] + cluster temperature relaxations in the electron-bifurcating NfnABC from Thermococcus sibiricus

Electron bifurcation (EB) is a mechanism of biological energy transduction in which multiple oxidation–reduction (redox) reactions are thermodynamically coupled within a single enzyme, enabling the enzyme to harness the excess free energy from an exergonic process to drive an endergonic process. Because of this unprecedented chemistry, there is interest to translate EB principles to artificial and bioengineered systems, but a hurdle is that knowledge pertaining to the fundamental design principles of EB enzymes remains scarce. Here, we investigated the fundamental physical and electronic properties of electron transfer sites in a spectroscopically uncharacterized member of the BfuABC family of EB enzymes, the NADH-dependent reduced-ferredoxin:NADP + oxidoreductase from Thermococcus sibiricus (Tsi NfnABC). Cryo-EM structures of Tsi NfnABC previously demonstrated that it contains twelve redox cofactors: two flavins (one FAD and one FMN), eight [4Fe–4S] clusters, and two [2Fe–2S] clusters. The FMN, one [4Fe–4S] cluster, and one [2Fe–2S] cluster comprise the bifurcating active site termed the electron-bifurcating flavobicluster (BF-FBC), which is found in all BfuABC family members. By using electron paramagnetic resonance spectroscopy, we identified spectral signatures originating from interactions between the FMN radical and [4Fe–4S] + cluster in the BF-FBC and observed temperature dependent behavior of the BF-FBC's [2Fe–2S] + cluster indicative of moderately slow spin–lattice relaxation. Additionally, we uncovered numerous spectral features corresponding to half-integer, S > ½ spin states of [4Fe–4S] + clusters, including one attributable to the consequences of lysine-ligation of a [4Fe–4S] cluster unique to NfnABC. We contextualize these findings to electron transfer theory and NfnABC's structure. Our insights further the understanding of how enzymes are designed to exert control over electron transfer to conduct thermodynamically challenging reactions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Probing multi-dimensional composition spaces in search of strong metallic alloys

Refractory complex concentrated alloys (RCCA) offer exceptionally high-temperature strength compared to pure metals and dilute alloys, but predictive theory for RCCA design is lacking. We present large-scale molecular Dynamics (MD) simulations of crystal plasticity to explore alloy compositions for maximum mechanical strength, focusing on Fe-Ta-W and Nb-Ta-Mo-W alloy families modeled with Embedded Atom Model (EAM) and Spectral Neighbor Analysis Potentials (SNAP). To efficiently guide the search for strong alloy compositions, we employ iterative optimization using Gaussian process regression. Many simulated RCCA compositions exhibit pronounced cocktail strengthening, with strengths surpassing their strongest constituent metal, tungsten. Contrary to expectations, the highest strength is found on binary edges of the RCCA composition space. Detailed analyses of atomistic simulations reveal that, similar to pure BCC metals, plastic response in RCCA is primarily governed by screw dislocations. However, at large strains, dislocation multiplication and interactions (Taylor hardening) become the dominant mechanisms contributing to RCCA strength.

Materials science↗

DOE OSTI2026

Selectivity mechanisms of ion intercalation in Prussian blue analogs

Prussian blue analogs (PBAs) are a family of materials with facile, reversible, and selective ion transport capability for various ions via electrochemical intercalation, owing to their vacancy structure. The large tunable compositional space of PBAs allows for manipulation of intercalation behavior and selectivity by controlling structural vacancy level through choice of transition metal centers and modifications to the synthesis process. However, a lack of understanding of the mechanisms of ion selectivity hinders the material’s design process. Here, for this work, we investigated the origins of ion selectivity using a model PBA, copper hexacyanoferrate, and focused on eight technologically and biologically prominent ions, for which we determined a sequence of selectivity: Rb + > K + > Na + > Ba 2+ > Sr 2+ ≈ Ca 2+ > Mg 2+ > Li + . We provide electrochemical, structural, and redox evidence of strong correlation between the ion identity, the dominant charge-compensating redox, and preferred occupancy site. Specifically, using synchrotron anomalous X-ray diffraction (AXRD), we reveal that monovalent ions exhibit significant association with the corner sites of the unit cell and iron redox, whereas divalent ions display affinity toward the center site with higher ratios of copper redox. Informed by selectivity results, we applied CuHCFe to Li purification and achieved 99.9% purity. Our findings demonstrate an approach to elucidating ion intercalation behavior in order to distinguish and manipulate material properties to optimize separation performance.

Prussian blue analog↗

DOE OSTI2026

2D in-Plane Ordered MXene Nanosheets Derived from (Mo 2/3 Er 1/3 ) 2 AlC Rare-Earth i-MAX for Energy Storage Applications

MXenes have become one of the most versatile families of two-dimensional (2D) materials due to their high conductivity, hydrophilicity, and remarkable electrochemical performance. This has stimulated intense efforts to design and synthesize MXenes, including structurally unique in-plane ordered 2D MXenes called i-MXenes. Here, we have synthesized the quaternary rare earth (RE)-based i-MAX phase (Mo 2/3 Er 1/3 ) 2 AlC using an arc melting method, and the corresponding 2D i-MXene was then obtained through a LiF/HCl soft etching process. Literature studies have shown that Al and the RE element are etched out during the etching process, leading to the formation of pure vacancy-ordered Mo1.33C 2D i-MXene. However, our investigation reveals that upon exposure to a fluorine solution, the i-MAX phase forms RE fluoride impurities, which are challenging to remove through HCl−DI water washing and persist in the final product, resulting in impure Mo 1.33 C@Er i-MXene. These results were confirmed by various characterizations such as X-ray diffraction, Raman spectroscopy, X-ray photoelectron spectroscopy, and scanning transmission electron microscopy. Although the Mo 1.33 C@Er electrode showed a 24-fold increase in specific capacitance compared to its parent i-MAX phase, it still exhibited a high charge-transfer resistance arising from the insulating nature of RE fluoride byproducts, which adversely influence the overall capacitance behavior of the synthesized 2D Mo 1.33 C@Er i-MXenes. This study contributes to identifying pathways for the preparation of pure 2D i-MXenes from RE-based i-MAX phases and developing improved synthesis methods. With additional process optimization, the 2D i-MXene holds a strong potential for electrochemical energy storage applications. Additionally, the electronic structures of Mo 1.33 C were theoretically studied using first-principles density functional theory calculations, which revealed that pristine Mo 1.33 C is metallic, and this metallic nature is preserved even with −O, −F, and mixed functionalization.

chemical structure↗

DOE OSTI2025

Isoreticular Tolerance and Phase Selection in the Synthesis of Multi‐Module Metal–Organic Frameworks for Gas Separation and Electrocatalytic OER

Abstract Although metal–organic frameworks are coordination‐driven assemblies, the structural prediction and design using metal‐ligand interactions can be unreliable due to other competing interactions. Leveraging non‐coordination interactions to develop porous assemblies could enable new materials and applications. Here, we use a multi‐module MOF system to explore important and pervasive impact of ligand‐ligand interactions on metal‐ligand as well as ligand‐ligand co‐assembly process. It is found that ligand‐ligand interactions play critical roles on the scope or breakdown of isoreticular chemistry. With cooperative di‐ and tri‐topic ligands, a family of Ni‐MOFs has been synthesized in various structure types including partitioned MIL‐88‐acs ( pacs ), interrupted pacs (i‐ pacs ), and UMCM‐1‐muo. A new type of isoreticular chemistry on the muo platform is established between two drastically different chemical systems. The gas sorption and electrocatalytic studies were performed that reveal excellent performance such as high C 2 H 2 /CO 2 selectivity of 21.8 and high C 2 H 2 uptake capacity of 114.5 cm 3 /g at 298 K and 1 bar.

Xiao, Yuchen [Department of Chemistry University o↗

DOE OSTI2025

Isoreticular Tolerance and Phase Selection in the Synthesis of Multi‐Module Metal–Organic Frameworks for Gas Separation and Electrocatalytic OER

Xiao, Yuchen [Department of Chemistry University o↗

NASA NTRS1972

Determination of mean surface position and sea state from the radar return of a short-pulse satellite altimeter

Using the specular point theory of scatter from a very rough surface, the average backscatter cross section per unit area per radar cell width is derived for a cell located at a given height above the mean sea surface. This result is then applied to predict the average radar cross section observed by a short-pulse altimeter as a function of time for two modes of operation: pulse-limited and beam-limited configurations. For a pulse-limited satellite altimeter, a family of curves is calculated showing the distortion of the leading edge of the receiver output signal as a function of sea state (i.e., wind speed). A signal processing scheme is discussed that permits an accurate determination of the mean surface position--even in high seas--and, as a by-product, the estimation of the significant seawave height (or wind speed above the surface). Comparison of these analytical results with experimental data for both pulse-limited and beam-limited operation lends credence to the model. Such a model should aid in the design of short-pulse altimeters for accurate determination of the geoid over the oceans, as well as for the use of such altimeters for orbital sea-state monitoring.

Barrick, D. E.↗

DOE OSTI2025

Design and Analysis of an Integral MPPT Control Law for Wave Energy Conversion Systems

In this paper, we propose an integral-based maximum power point tracking (MPPT) algorithm for point absorber wave energy conversion (WEC) systems. A permanent magnet synchronous generator (PMSG) is coupled to the point absorber and its drive implements the proposed MPPT control. While the rotating frame of reference of the PMSG implements power control, the slower mechanical frequency of the incident waves are processed with an additional transformation that yields another set of dc dynamics. The computed dc power in the new reference frame, which is focused on slow wave dynamics, is input to the MPPT control law that tunes the emulated resistance of the machine drive to extract peak power from the wave absorber device. We derive a stability condition for the proposed controller and validate our control design on a simulated 10kW system.

wave energy, maximum power point tracking (MPPT), ↗

DOE OSTI2025

Braiding for the win: Harnessing braiding statistics in topological states to play quantum games

Nonlocal quantum games provide proof of principle that quantum resources can confer an advantage at certain tasks. They also provide a compelling way to explore the computational utility of phases of matter on quantum hardware. In a recent paper [O. Hart et al., Phys. Rev. Lett. 134, 130602 (2025)], we demonstrated that a toric code resource state conferred advantage at a certain nonlocal game, which remained robust to small deformations of the resource state. In this paper we demonstrate that this robust advantage is a generic property of resource states drawn from topological or fracton ordered phases of quantum matter. To this end, we illustrate how several other states from paradigmatic topological and fracton ordered phases can function as resources for suitably defined nonlocal games, notably the three-dimensional toric-code phase, the X-cube fracton phase, and the double-semion phase. The key in every case is to design a nonlocal game that harnesses the characteristic braiding processes of a quantum phase as a source of contextuality. We unify the strategies that take advantage of mutual statistics by relating the operators to be measured to order and disorder parameters of an underlying generalized symmetry-breaking phase transition. Additionally, by connecting the win probability to twist products, we show that success at the game serves as a many-body entanglement witness. Namely, if the players implement a perfect quantum strategy on large length scales, the quantum state they share cannot be connected to a trivial product state via a constant-depth local unitary circuit. Lastly, we massively generalize the family of games that admit perfect strategies when codewords of homological quantum error-correcting codes are used as resources.

Fractons↗

DOE OSTI2025

Robot-based Additive Manufacturing of Lego-type Modular Molds for Wind Blades

The objective of this project is to reduce the cost and lead time of horizontal wind turbine blade mold tooling and blade transportation, while maintaining the highest standards of blade quality. The solution involves a smart-design family of modular molds that are easily transportable to fabrication sites near the place of service. Key innovations include the use of additive manufacturing (AM) to integrate conformal thermal management channels, offering enhanced control over the thermal profiles tailored to specific blade materials. This approach enables in-situ quality assurance during mold fabrication, significantly improves mold life, and allows for reuse across multiple production cycles. Ultimately, the solution aims to optimize both tooling and transportation costs, contributing to the scalability of wind turbine blade production. A significant barrier to scaling up the production of large wind turbine blades lies in the high costs associated with tooling and the transportation of blades. Traditional molds are expensive, bulky, and difficult to transport, adding considerable lead time and cost to the overall manufacturing process. Additionally, transporting blades to distant locations for final assembly further exacerbates these challenges. The project aims to address these inefficiencies by demonstrating a modularized, additive-manufactured mold that meets all necessary blade specification requirements, specifically for blade lengths between 120m and 150m.

17 WIND ENERGY↗