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At least 181 records · Page 10

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DOE OSTI2025

Feature Based Qualification of 17-4PH Stainless Steel to Evaluate Location-Specific Variability in Wire Arc Additive Manufacturing

Qualifying large-scale metal additive manufacturing (M-AM) technologies such as wire arc additive manufacturing (WAAM) can be challenging. This is especially significant in precipitation hardened martensitic stainless steels like SS 17-4PH, where thermal histories induce location-specific microstructural variability and property anisotropy. The Department of Defense (DOD) and the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center (GVSC) Ground Vehicle Materials Engineering (GVME) aim to build robust and qualified large-scale M-AM workflows that could reduce the time and cost through quick and informed evaluation, testing, and development of feedstock, processes, and parts. The report presents the findings from the collaborative efforts between Oak Ridge National Laboratory (ORNL) and the U.S. Army GVSC GVME. The aim of this project was to develop a geometric feature-based qualification framework for WAAM of SS 17-4PH components. This report outlines selection methodology of representative build geometries, optimization of WAAM process parameters, in-situ monitoring, microstructure-property evaluation, thermal simulations, as well as data visualization techniques incorporated in this project. The results from this project demonstrate a clear understanding of thermal history dependent phase evolution and consequent location-specific property variations in WAAM of SS 17-4PH. These results in conjunction with the data-driven methodologies used in this project are expected to reduce qualification timelines, improve predictability, and accelerate the development of reliable feature-based qualification strategies for part production via large-scale M-AM technologies.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Geophysical Signatures of Crack Network Coalescence in Rocks at Multiple Length Scales

The main goal of the research project was to identify the geophysical signatures of fracture growth in natural rocks by utilizing novel geophysical techniques. The research objectives were to (a) investigate the potential for geophysical methods to determine when cracks initiate, the types and locations of propagated cracks, and the coalescence of networks of cracks in natural rocks at multiple scales, (b) determine how damage at the microscale evolved into damage at the macroscale and then link the microscopic and macroscopic observations, (c) quantify crack coalescence in rocks under realistic stress conditions using coupled mechanical-geophysical-optical visualization, and (d) identify the precursors in geophysical signals to crack coalescence. The following research thrusts were explored to achieve the research objectives: (1) uniaxial compression testing of rock specimens with and without a set of pre‐existing flaws and (2) triaxial compression testing of natural rock specimens. These thrusts allowed for exploring fracturing in rocks under realistic in situ environments and at multiple scales. This project provided educational opportunities for nine graduate and undergraduate students and resulted in 27 peer-reviewed publications. This first research thrust focused on investigating the micromechanics of fractures in rocks through uniaxial compression testing combined with advanced geophysical and imaging techniques, specifically acoustic emission (AE) monitoring, ultrasonic imaging, and 2-dimensional Digital Image Correlation (2D-DIC). By examining damage processes under time-independent and time-dependent loading conditions, insights into damage localization, crack initiation, and fracturing mechanisms were gained. It was observed that the AE signals and the strain-based measurements directly reflect the state of damage in the rock specimen and could be used to identify the cracking levels, such as the crack initiation (CI) and crack damage (CD), and the mode of deformation. A novel calibration apparatus was developed to enhance the accuracy of AE sensors, allowing for the estimation of key parameters such as magnitude, source dimension, stress drop, and radiated seismic energy associated with the fractures. The findings highlighted significant variations in the temporal evolution of AE source parameters during the primary, secondary, and tertiary stages of creep, identifying tensile cracking as the primary deformation mode. The second research thrust focused on enhancing the understanding of fracturing processes in natural rocks through triaxial compression testing, real-time AE monitoring, and ultrasonic monitoring. We investigated the impact of various factors such as fracture propagation regimes, injection parameters, rock types, and pre-existing conditions on the hydraulic fracture (HF) behavior using scaled true-triaxially loaded specimens of Barre granite and Lyons sandstone. Custom sensor housing facilitated concurrent active and passive monitoring to analyze hydro-mechanical responses and microseismicity associated with different HF scenarios. A coupled investigation of passive microseismicity and active signal attributes permitted a detailed comprehension of the various HF processes (aseismic deformation, fracture initiation and propagation, fluid permeation, and leak-off) and their dependence on the specific rock type. The findings of this research demonstrated the effectiveness of AE monitoring techniques in providing valuable insights into the impact of various factors on the behavior and dynamics of HF processes. The advancements in monitoring techniques, offering a more thorough and precise approach, represent a significant step towards optimizing HF practices and ensuring sustainable resource extraction.

58 GEOSCIENCES↗

DOE OSTI2026

Filtration Performance of Simulated 200 West Area Waste Feeds

This report describes the scaled experimental system and approach used to examine dead-end filtration performance of representative 200W waste feeds. The scaled system, which was originally designed and assembled to test Tank Side Cesium Removal (TSCR) system performance with higher-than-expected solid loadings in 2021 (Schonewill et al. 2021), was repurposed to conduct the current experiments at ~1/145 of full scale (based on throughput). Six experimental runs were conducted with five different 200W waste feed simulants: three using a DEF module scaled for TSCR and three using a DEF module scaled for the 200W process modules (based on the current design for the Advanced Modular Pretreatment System). Each experiment was run continuously for multiple days with an operating approach prototypic of the full-scale system. Staff performing the experimental runs monitored performance, obtained data from calibrated process instruments, and collected samples for observation and analysis. The measured data are presented with a focus on assessing DEF performance – specifically, the filters’ differential pressure response to the five waste simulants, frequency and efficacy of backwashing, and baseline recovery between experimental runs; data related to ion exchange column performance are also discussed in cases where the opportunity arose. The experimental campaign demonstrated that the DEFs satisfied their primary function of protecting the ion exchange column from solid intrusion for all the representative simulants used. The filters readily handled solids loadings of =500 ppm (and even greater), especially the modules scaled to the 200W process modules. Adjustments to the processing flow rate and reductions in feed temperature were observed to affect the rate of differential pressure increase on the filters, but neither adversely affected the ability of the DEFs to perform their primary function. Backflushing reliably recovered filter performance in all runs, although it did not prevent irreversible fouling for one simulant. The run that exhibited irreversible fouling established that both the quantity and the nature of the solids being filtered need to be considered when projecting filter performance.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Mid-IR UAV-based sensing platform with deep learning to Identify and Quantify Gaseous Emission in Gas Flares

This report details the development and evaluation of a Mid-Infrared (Mid-IR) Unmanned Aerial Vehicle (UAV)-based sensing platform integrated with deep learning algorithms for the identification and quantification of gaseous emissions in gas flares. The project, spearheaded by Omega Optics, Inc., aimed to address environmental monitoring challenges by leveraging advanced photonic technologies and autonomous UAV operations. The research focused on designing, optimizing, and fabricating photonic crystal waveguides and grating couplers to enhance the sensitivity and accuracy of gas detection. A comprehensive drone-based system was developed, featuring a miniaturized sensor, GPS module, and microcontroller communication network for real-time gas concentration monitoring. The system's adaptive sampling algorithm, implemented using the Robot Operating System (ROS), enables autonomous detection and localization of gas emission sources. Preliminary results demonstrate the platform's capability to detect and monitor gas emissions with high precision, cost-effectiveness, and scalability. Future work will expand upon this foundation by introducing 3D wind model-based learning for dynamic environmental conditions and further enhancing the user interface and data processing algorithms to support broader environmental monitoring applications. Overall, this project represents a significant step forward in UAV-based environmental sensing technologies, offering robust solutions for detecting and mitigating the impacts of gaseous emissions on public health and safety.

47 OTHER INSTRUMENTATION↗

DOE OSTI2024

Numerical Simulation of Biogenic Fluid Catalytic Cracking (BFCC) Regenerators at Different Scales with MFIX-Exa

Catalytic Fast Pyrolysis (CFP) is a process that converts biomass into liquid intermediates suitable for transportation fuels by rapidly heating it in the presence of a catalyst, aiming to produce stable oils with reduced oxygen content. During CFP, the catalyst can become deactivated by the accumulation of coke, a carbon-rich deposit formed from the decomposition of biomass components. Unlike in petroleum refining, regenerating coked catalysts from biomass pyrolysis requires specific approaches due to the different chemical nature of the coke formed. An experimental technique, Temperature Programmed Oxidation (TPO), was used to study the de-coking process by gradually increasing temperature while monitoring the production of CO and CO2, which provides data for kinetic modeling. Utilizing data from TPO experiments, coke combustion kinetic model was developed to describe the rate of coke removal at different temperatures, allowing for simulation of regeneration processes. Then kinetic model is integrated into MFIX-Exa for the simulation of Biogenic Fluid Catalytic Cracker (BFCC) regenerator at different scales, enabling analysis of catalyst flow, temperature distribution, and regeneration efficiency under various operating conditions.

biogenic fluid catalytic cracking↗

DOE OSTI2024

Assessment and Usage of In-Situ Monitoring Data for American Society of Mechanical Engineers Part Qualification

In-situ monitoring and anomaly detection are important components for qualification of directed energy deposition (DED) additive manufacturing (AM) processes and components. The use of in-situ monitoring requires an understanding of anomalies that can be identified during the process and how those anomalies correlate to mechanical properties of the component post-production. There is also a need to qualify the algorithms and software used to interpret the process signals for DED AM. There is no single process signal that can be used with a single algorithm that will identify all anomalies that will translate to a defect in a process. The process signals are affected by changes in material, location, resolution, acquisition rate, component geometry, and the machine itself. It is observed that multiple process signals are required to identify relevant features that can be correlated to mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Real-Time FPGA Implementation For Frequency Sweep Interferometry In The LBNF Complex

The Long Baseline Neutrino Facility (LBNF) will deliver a 2.4 MW muon neutrino beam from Fermilab to the Deep Underground Neutrino Experiment (DUNE), requiring unprecedented precision in beamline alignment to achieve DUNE's neutrino oscillation measurement goals. Vertical misalignments of beamline components as small as 0.5 mm can contribute 6-7\% uncertainty in predicted neutrino flux, necessitating sub-0.1 mm alignment monitoring capabilities. The Horn Location Sensor (HLS) system employs frequency sweep interferometry (FSI) in a distributed hydrostatic leveling network to achieve the required precision under harsh radiation conditions up to 5000 kRad/year. Traditional FSI implementations suffer from laser sweep nonlinearities that degrade resolution and require computationally intensive post-processing corrections using gas reference cells. This work presents a real-time FPGA-based implementation of the HLS data acquisition and processing system using a sweep tracker interferometer for dynamic sweep linearization. The system utilizes a PYNQ-Z2 FPGA with programmable logic implementing parallel 16k-point FFT processing across four channels, synchronized by the sweep tracker signal to eliminate post-processing requirements. Spectral performance testing demonstrates significant improvements in peak sharpness compared to traditional fixed-frequency digitization. The FPGA implementation enables real-time displacement monitoring with processing speeds orders of magnitude faster than software-based approaches, essential for the operational requirements of LBNF's eventual distributed sensor network. This advancement in real-time FSI processing directly supports DUNE's precision neutrino physics program by providing the rapid feedback necessary for maintaining stringent beamline alignment tolerances during high-power beam operations.

Rossel, A. Jacob [Fermilab; Unlisted]↗

DOE OSTI2025

Leveraging FPGA Advantages for Quicker Data Processing for LBNF

Rossel, Jacob↗

DOE OSTI2026

Advanced Facility Design and AI/ML Enabled Safeguards to Establish Secure, Economical Recycling of Fast Reactor Fuels (Final Scientific/Technical Report)

The project, "Advanced Facility Design and AI/ML Enabled Safeguards to Establish Secure, Economical Recycling of Fast Reactor Fuels," represents a significant advancement in nuclear fuel recycling technology. It integrates cutting-edge multimodal sensor fusion, machine learning (ML), and digital twin (DT) technologies to address challenges in material safeguarding, process optimization, and regulatory compliance for pyroprocessing facilities. This research has significantly enhanced the understanding of pyrochemical fuel recycling processes by developing innovative tools and methodologies. The Multimodal Safeguards Monitoring Unit (MSMU) combines electroanalytical techniques, Raman spectroscopy, and differential thermal analysis (DTA) to enable high-fidelity, near-real-time material accountancy measurements. Machine learning techniques, such as Long Short-Term Memory (LSTM) autoencoders, are utilized to detect anomalies in material balances and sensor data, improving the reliability of safeguards monitoring. Additionally, digital twin technology has been established to provide real-time system-level monitoring and diagnostics, integrating physics-based models with sensor data to optimize process safety and efficiency.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

EMP, Attachment 2: Data Management Plan

This Data Management Plan (DMP) is an attachment to the Pacific Northwest National Laboratory Environmental Radiological Air Monitoring Plan (EMP). PNNL is a U.S. Department of Energy Office of Science national laboratory. Radioactive effluent monitoring and environmental surveillance for PNNL operations in Washington State are the responsibility of the PNNL Environmental Protection and Regulatory Programs division and are conducted by the Environmental Radiation Task staff. This DMP describes the data management processes for PNNL radioactive air emissions (stack) monitoring and environmental radiological ambient air surveillance activities.

40 CFR 61 Subpart H↗

DOE OSTI2025

Thermochemical Properties of a Water-Soluble Zr(IV)-Flavonolate Complex for Fluoride Sensing

Detection of fluoride in water samples is critical for monitoring many chemical, environmental, and biological processes, however, these measurements often rely on costly instrumentation. Here, this situation has motivated the design of simple to use, fieldable fluoride sensors. Previously, a fluorometric sensor based on (EDTA)Zr(H 2 O) 2 (EDTA = ethylenediamine-N,N,N′,N′-tetraacetate) and 3-hydroxyflavone (FlvH) was reported for fluoride detection in ethanol-H 2 O mixtures. Herein, we report the synthesis and characterization of the previously proposed Zr(IV)-flavonolate complex as the dimethylammonium salt, [(EDTA)Zr(Flv)][NMe 2 H 2 ] (Flv = 3-hydroxyflavonolate), and detail its utility for aqueous fluoride sensing. This species exhibits an intense blue fluorescence upon excitation with near-UV light (λ ex = 390 nm; λ em = 460 nm) that is quenched in the presence of NaF (100 mM acetate buffer, pH = 5) with good sensitivity (LOD = 20.9 nM; [F – ] from 10 –8 to 10 –4 M) under neat aqueous conditions. The equilibrium constant (K eq = 1.26 ± 0.00184 × 10 8 M –2 ) and free energy (Δ$G^°_{\textrm{rxn}}$ = –11.0 kcal mol –1 ) were determined under the conditions used for fluoride sensing, indicating a highly favorable reaction with F – in water. Finally, we developed paper-based sensing strips for qualitative fluoride sensing by immobilizing the sensor in a deposited gel enabling good selectivity and reduced interference due to slower ion diffusion.

aqueous chemistry↗

DOE OSTI2025

Raman Digital Twin of Monolayer Janus Transition Metal Dichalcogenides

Monolayer transition metal dichalcogenides (TMDs) are a key class of two-dimensional (2D) materials with broad technological potential. Their Janus counterparts exhibit unique properties due to broken out-of-plane symmetry and further enrich the functionalities of TMDs. However, experimental synthesis and identification of Janus TMDs remain challenging. It is thus highly desirable to have a rapid, simple, and in situ characterization technique to monitor, in real time, the conversion process from the parent to Janus structure. Raman spectroscopy stands out for such a task as it is a powerful, nondestructive, and very commonly used tool to characterize 2D materials both in situ and ex situ. To realize the full potential of Raman spectroscopy on rapid characterization of Janus TMDs, we present a computational “Raman digital twin” library for various monolayer Janus TMDs in both 2H and Td phases. We focus on group-6 TMDs: MoS 2 , WS 2 , MoSe 2 , WSe 2 , MoTe 2 , WTe 2 and their Janus variants: MoSSe, MoSTe, MoSeTe, WSSe, WSTe, and WSeTe. Using first-principles density functional theory (DFT), we calculate their vibrational properties and predict distinct Raman fingerprints. These phonon and Raman signatures reflect each material’s structural symmetry and atomic composition, enabling clear identification via Raman spectroscopy. Our theoretical work supports experimental efforts by providing benchmarks for material identification, structural analysis, and quality control. In conclusion, the computational library expedites the discovery and development of Janus 2D materials, facilitating tighter integration between theoretical predictions and experimental validation.

Chalcogenides↗

DOE OSTI2024

RhizoNet segments plant roots to assess biomass and growth for enabling self-driving labs

Abstract Flatbed scanners are commonly used for root analysis, but typical manual segmentation methods are time-consuming and prone to errors, especially in large-scale, multi-plant studies. Furthermore, the complex nature of root structures combined with noisy backgrounds in images complicates automated analysis. Addressing these challenges, this article introduces RhizoNet, a deep learning-based workflow to semantically segment plant root scans. Utilizing a sophisticated Residual U-Net architecture, RhizoNet enhances prediction accuracy and employs a convex hull operation for delineation of the primary root component. Its main objective is to accurately segment root biomass and monitor its growth over time. RhizoNet processes color scans of plants grown in a hydroponic system known as EcoFAB, subjected to specific nutritional treatments. The root detection model using RhizoNet demonstrates strong generalization in the validation tests of all experiments despite variable treatments. The main contributions are the standardization of root segmentation and phenotyping, systematic and accelerated analysis of thousands of images, significantly aiding in the precise assessment of root growth dynamics under varying plant conditions, and offering a path toward self-driving labs.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2026

Fermilab Booster loss modelling and rebalancing using Bayesian methods

To meet PIP-II upgrade requirements, Fermilab Booster losses need to be reduced by 50% compared to present levels. So far, simulations are not good enough to predict loss patterns. Thus, an extensive Booster tune up will be necessary to achieve required performance. In this paper we present an effort to build a data-driven loss model using Bayesian techniques, and subsequently to rebalance losses for higher trip margins. We first created several sets of spatially and temporally isolated orbit and optics knobs, and trained Gaussian process models for each beam loss monitor as well as beam current. Novel techniques of uncertainty constraints and approximate GP fitting were introduced to handle safety and timing requirements. We then performed single and multi-objective tuning using scalarized objectives comprised of critical beam loss locations. We achieved significant rebalancing of losses, increasing margins by 25%, as well as an overall improvement in transmission efficiency of 0.4%. Automated data collection is being developed so that more accurate surrogate models can be trained over time.

Kuklev, N. [Fermilab]↗

DOE OSTI2025

Fermilab Booster loss modelling and rebalancing using Bayesian methods

Fermilab Booster is being upgraded for the PIP-II project to support 20Hz ramp rate at higher intensities. Loss trip limits determine the achievable peak power. To meet PIP-II requirements, losses need to be halved as compared to current levels. Losses primarily occur at injection and transition crossing, with both gradually increasing and threshold-like intensity-dependent behaviors. The existing simulation models are not yet good enough for quantitative loss predictions. In practice, it will be necessary to tune up the Booster using iterative methods and operator intuition. In this paper we present an effort to systematically model Booster losses using active learning (Bayesian exploration) techniques, and subsequently to rebalance them for higher trip limit margins. We first created several sets of spatially and temporally isolated orbit and optics knobs, and trained Gaussian process models for each beam loss monitor as well as beam current. This is a complex task due to safety and timing requirements – we discuss mitigations such as uncertainty constraints and approximate fitting. Once models are stable, we perform large-scale single and multi-objective tuning using scalarized objectives made up of critical beam loss locations. Our results demonstrate significant rebalancing of losses, increasing trip margins, as well as an overall improvement in beam transmission efficiency. We are exploring how to combine existing simulations with experimental data and automate the collection procedure so that more advanced surrogate models can be created over time.

Kuklev, Nikita [Fermilab]↗

DOE OSTI2024

Digital-Twin-Enabling Technologies for Online Condition Monitoring of Nuclear Power Plant Components

Online condition monitoring is an area of active research that may enable optimized scheduling, maintenance, and safety of nuclear power plant components, reducing unnecessary derates while simultaneously improving operational capacity. Digital twins (DTs) are one avenue to conduct online condition monitoring and are currently being explored by national laboratories and universities alike. DTs for online condition monitoring are, in essence, state concurrent models that emulate a physical process which predicts a parameter and compares it against a measured value. A DT’s goal is to provide additional insights by combining and interpreting various sources of information for preventative maintenance scheduling optimization or early fault detection. DTs for condition monitoring are projected to be valuable for meeting requirements under 10 CFR 50.55a, “Codes and Standards,” and 10 CFR 50.65, “Requirements for Monitoring the Effectiveness of Maintenance at Nuclear Power Plants”. However, DT technologies are still under significant development, and the process for developing a DT for condition monitoring has not been formalized. Therefore, in this work, we present an initial framework for developing a DT, discuss and review the various challenges and considerations for DT deployment, and identify the opportunities that a DT can improve. The presented framework is intended to help developers formulate a strategy when approaching DT development for condition monitoring. In conclusion, a DT use case for a reactor coolant pump is presented to demonstrate the proposed framework.

advanced sensor instrumentation↗

DOE OSTI2025

Upgrade to Fixed and Translating Scintillation-based Loss Detector System in the Fermilab Drift Tube Linac

The closed-off structure of the Fermilab Drift Tube Linac precludes a robust array of instrumentation from directly monitoring the H- beam that is accelerated from 750 keV to 116 MeV. To improve beam tuning and operational assessment of Drift Tube Linac performance, scintillator-based loss monitors were previously installed along the exterior of the first two accelerating cavities to assess low energy beam losses. Here we present a recent upgrade to the loss monitor system, including significant improvements in analog signal processing to address baseline-interfering noise; digitization of the signals to enable regular operational use and tuning; and a new remote operation upgrade of the translating loss monitor with precise positioning of the loss monitor along its nine-foot track. Data from the fixed and translating detectors collected under varying beam conditions validate the utility of the upgrade.

Chen, E. V. [Fermilab]↗

DOE OSTI2025

Upgrade to Fixed and Translating Scintillation-Based Loss Detector System in the Fermilab Drift Tube Linac

The closed-off structure of the Fermilab Drift Tube Linac precludes a robust array of instrumentation from directly monitoring the H- beam that is accelerated from 750 keV to 116 MeV. To improve beam tuning and op-erational assessment of Drift Tube Linac performance, scintillator-based loss monitors were previously installed along the exterior of the first two accelerating cavities to assess low energy beam losses. Here we present a recent upgrade to the loss monitor system, including significant improvements in analog signal processing to address baseline-interfering noise; digitization of the signals to enable regular operational use and tuning; and a new remote operation upgrade of the translating loss monitor with precise positioning of the loss monitor along its nine-foot track. Data from the fixed and translating de-tectors collected under varying beam conditions validate the utility of the upgrade.

Chen, Erin V. [Fermilab] (ORCID:0000000215467899)↗