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DOE OSTI2025

LLRF System Analysis for the Fermilab PIP-II Superconducting LINAC

PIP-II is a superconducting linac that is in the initial acceleration chain for the Fermilab accelerator complex. The RF system consists of a warm front-end with an RFQ and buncher cavities along with 25 superconducting cryo-modules comprised of cavities with five different acceleration \(β\). The LLRF system for the linac has to provide field and resonance control for a total of 125 RF cavities. Various components of the LLRF system have been tested with and without beam at the PIP-II test stands. The LLRF system design is derived from the LCLS-II project with its self-excited loop architecture used in the majority of the cryo-modules. The PIP-II beam loading at 2 mA is much higher than the LCLS-II linac. The control system architecture is analyzed and evaluated for the operational limits of feedback gains and their ability to meet the project regulation requirements for cavity field amplitude and phase regulation.

Varghese, P. [Fermilab] (ORCID:0009000925131983)↗

DOE OSTI2025

Advancing 1D thermo-hydraulic tools for large cryogenic facilities

The Cryogenic Division at Fermilab develops large-scale cryogenic systems for particle accelerators and superconducting magnet test facilities. To support design and diagnostics, a Python-based code was created to calculate pressure drops in components such as valves and pipes. This paper presents recent enhancements to the code, including new heat transfer functions that improve the accuracy of thermal and hydraulic predictions. The first application models pressure and temperature changes in Proton Improvement Plant PIP-II relief pipes, aiding pipe sizing and protecting relief valves. The second example analyses heat load evolution in a pipe carrying sub-atmospheric helium, helping interpret temperature sensor data and understand gas return behavior to cold compressors. These improvements significantly expand the tool's capabilities, offering a practical resource for designing and troubleshooting cryogenic systems under dynamic thermal and flow conditions.

Beckwith, R. [Fermilab]↗

DOE OSTI2024

Test Stand Functional Requirements for Testing MQXFA Magnets and Q1/Q3 Cryostat Assemblies (Rev.3)

This document specifies test stand requirements for testing the High Luminosity LHC (HL-LHC, or HiLumi LHC) MQXFA magnets and LQXFA/B cryostat assemblies. Total of 12 (3 pre-series, 7 series production and 2 re-work) of these cryostat assemblies are expected to be fabricated and delivered to CERN by the U.S. HL-LHC Accelerator Upgrade Project (US HL-LHC AUP) as part of the U.S. contributions to the LHC High Luminosity Upgrade. These cryostat assemblies are the quadrupole magnetic components of the HL-LHC Q1 (LQXFA) and Q3 (LQXFB) inner triplet optical elements in front of the interactions points 1 (ATLAS) and 5 (CMS). One LMQXFA cold mass is installed in each cryostat assembly and each cold mass consists of two MQXFA quadrupole magnets. MQXFA, LMQXFA and LQXFA/B functional requirements are specified in [1,2,3].MQXFA magnets will be tested at BNL Vertical Magnet Test Facility (VMTF) and 12 cryostat assembly tests planned at Fermilab’s Horizontal Magnet Test Facility (HMTF). This document specifies the test stand functional requirements for testing MQXFA magnets and LQXFA/B cryostat assemblies.

43 PARTICLE ACCELERATORS↗

DOE OSTI2026

Power Electronic Development Challenges for High Power Density Integrated Electric Drive Applications

The ever-increasing demand for compact, efficient, and high-performance traction drive systems for transportation applications has accelerated the development of integrated electric drives. In these systems, the electric machine and inverter are integrated within a single housing, offering significant advantages in electrical performance, volume, weight, cost, and overall system efficiency. Despite these benefits, such high levels of integration introduce a new set of challenges, particularly in power electronic design and component selection. This article presents an in-depth investigation of a highly integrated electric drive architecture with an internal stator-mounted inverter, highlighting key design considerations and trade-offs aimed exclusively at maximizing system power density.Based on a comprehensive review of the literature, the power density of a voltage-source-inverter-driven electric drive is primarily governed by the volumetric contributions of the power modules, heat sinks, and DC-link capacitors. Accordingly, this work focuses on the optimization of these three critical components to enhance the inverter's overall power density. The proposed design achieves a power density of 100 kW/L, demonstrating the effectiveness of the presented approach for next-generation integrated electric drive systems.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Progress in developing a superconducting accelerator for efficient eBeam and X-ray production

The PIP-II Accelerator is an 800 MeV superconducting Linac in the injection chain of the Fermilab accelerator complex. The LLRF systems for the 125 cavities which include a few normal conducting cavities in the warm front-end section, use a variety of LLRF hardware components and sub-systems that are part of the timing and synchronization system. This includes a master oscillator and phase averaging reference line, a beam pattern generator to enable beam transfer between non-harmonic RF systems and beam loading compensation systems synchronized to a start of beam trigger. The timing signals are based on a 650 MHz clock with manchester encoded event information and data provided over optical fiber. The timing and synchronization systems and their performance parameters will be described here.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Assembly of the MOLLER Toroidal Magnets at Jefferson Lab

The MOLLER experiment at the Thomas Jefferson National Accelerator Facility (JLab) aims to precisely measure the weak interaction between electrons. This experiment leverages the 12 GeV electron beam and will run for three years. A crucial component of MOLLER is a system of five uniquely shaped water-cooled toroidal magnets. These magnets, possessing seven-fold symmetry, are designed to focus particles by separating electrons scattered off hydrogen in a liquid hydrogen target. The five magnets separate electrons scattered off electrons (Møller scattering) and protons (elastic e-p scattering) within target into approximately circular rings at the detector. Here, this paper presents the assembly process for these five toroidal magnets, detailing critical steps including epoxy application, pin insertion, soldering and brazing, coil assembly, and alignment, all performed to meet stringent magnet specifications. Additionally, it discusses challenges encountered during construction and highlights lessons learned, offering insights for future magnet development projects.

Lamont, Joseph [Thomas Jefferson National Accelera↗

DOE OSTI2025

Redis-Based Streaming Architecture for Accelerator Beam Instrumentation DAQ Systems

The Fermilab Acceleraor Division, Beam Instrumentation Department, is always adopting modern and current software methodologies for complex DAQ architectures. This paper highlights the Redis Adapter (RA) as the key software component enabling high performance, modular communication between digitizers and distributed control systems by leveraging Redis and containerization. The RA provides a unified, efficient interface between Redis based data streams and consumer systems. In the legacy architecture, digitized data flowed through the custom, UDP based Distributed Data Communication Protocol in the middle layer. In the current system, DDCP remains the ingestion path, while the RA serves as the decoupling layer. The proposed system replaces old VME digitizers with a SOM-based digitizer that communicates with Redis using the RA. The RA acts as both a performance-critical bridge and a protocol-agnostic adapter, ensuring compatibility with legacy control frameworks while enabling future scalability and modularity. This restructuring of the middle layer also helps the system achieve high throughput, reduce latency, and simplify the data path. Finally, we will demonstrate how RA is utilized in our two core products to deliver both legacy compatibility and future flexibility.

Joshi, S. [Fermilab]↗

DOE OSTI2025

Exascale workflow applications and middleware: An ExaWorks retrospective

Exascale computers offer transformative capabilities to combine data-driven and learning-based approaches with traditional simulation applications to accelerate scientific discovery and insight. However, these software combinations and integrations are difficult to achieve due to the challenges of coordinating and deploying heterogeneous software components on diverse and massive platforms. Here, we present the ExaWorks project, which addresses many of these challenges. We developed a workflow Software Development Toolkit (SDK), a curated collection of workflow technologies that can be composed and interoperated through a common interface, engineered following current best practices, and specifically designed to work on HPC platforms. ExaWorks also developed PSI/J, a job management abstraction API, to simplify the construction of portable software components and applications that can be used over various HPC schedulers. The PSI/J API is a minimal interface for submitting and monitoring jobs and their execution state across multiple and commonly used HPC schedulers. We also describe several leading and innovative workflow examples of ExaWorks tools used on DOE leadership platforms. Furthermore, we discuss how our project is working with the workflow community, large computing facilities, and HPC platform vendors to address the requirements of workflows sustainably at the exascale.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Elucidating texture and grain morphology contributions to the micromechanical response of additively manufactured Inconel 625

Microstructural variation of additively manufactured (AM) metal components in comparison to wrought counterparts makes certification for critical applications a challenge. Microscale simulations leveraging modern computational tools may be used to supplement testing of AM microstructures, thus accelerating certification by reducing the number of experiments needed. However, as micromechanical response is closely tied to critical properties like fatigue-life and fracture, utilization of these simulations with macroscale experimental data alone is insufficient. One means to attain microscale experimental data is in situ diffraction data collected from synchrotron X-ray sources. In this work, such data were collected during in situ compression of AM Inconel 625 superalloy. Interpretation of experimental results was assisted by massive (8M element) complementary micromechanical simulations performed on sets of virtual microstructures generated using cellular automata. Together, micromechanical data from diffraction experiments and simulations were used to probe the effects of textured “track” microstructures generated during laser powder bed fusion and directional strength-to-stiffness on micromechanical response. Though fiber-averaged directional strength-to-stiffness ratios were expected to dominate given the high elastic anisotropy of the material, the combination of small variations in texture and specific grain configurations unique to AM microstructures lead to significant variability in micromechanical response after yield. The findings emphasize the importance of high-fidelity microstructural representation that captures key texture components and AM-specific morphology for property prediction of AM metals.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Accelerating multigrid with streaming chiral SVD for Wilson fermions in lattice QCD

A modification to the setup algorithm for the multigrid preconditioner of Wilson fermions in lattice QCD is presented. A larger basis of test vectors than that used in regular multigrid is calculated by the smoother and truncated by singular value decomposition on the chiral components of the test vectors. The truncated basis is used to form the prolongation and restriction matrices of the multigrid hierarchy. This modification of the setup method is demonstrated to increase the convergence of linear solvers on an anisotropic lattice with m π ≈ 239 MeV from the Hadron Spectrum Collaboration and an isotropic lattice with m π ≈ 220 MeV from the MILC Collaboration. The lattice volume dependence of the method is also examined. Increasing the number of test vectors improves speedup up to a point, but storing these vectors becomes impossible in limited memory resources such as GPUs. To address storage cost, we implement a streaming singular value decomposition of the basis of test vectors on the chiral components and demonstrate a decrease in the number of fine level iterations by a factor of 1.7 for m q ≈ m crit

Iterative methods↗

DOE OSTI2024

Mini-99 Experiment Design and Target Assembly

Qualification of nuclear fuels requires an understanding of a myriad of fuel performance variables, which requires time-consuming irradiations in test reactors. Accelerating burnup accumulation to reduce the irradiation time has historically been accomplished by increasing the 235 U enrichment in integral fuel tests, which inherently couples the fuel’s temperature and fission heat generation. Separate effects irradiation testing of nuclear fuel, using the MiniFuel target in the Oak Ridge National Laboratory’s (ORNL’s) High Flux Isotope Reactor (HFIR), offers an approach for decoupling fuel temperature and fission rate by reducing the quantity of the fuel and relying primarily on gamma heating in the surrounding components to drive fuel temperatures. However, if the fission rate is high enough, the fuel temperature will still vary over time as the fission heating changes, primarily due to poor heat conduction between the fuel and the surrounding components. This work details the design, analysis, and fabrication of a MiniFuel target which utilizes sodium bonding to improve the heat rejection from the fuel specimen, enabling the testing of higher 235 U enrichments (~8wt.%) to further accelerate burnup accumulation without prohibitively large temperature variations throughout the course of the irradiation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Proposal for a proton-bunch compression experiment at IOTA in the strong space-charge regime

The longitudinal compression of intense proton bunches with strong space-charge force is an essential component of a proton-based muon source for a muon collider. This paper discusses a proton-bunch compression experiment at the Integrable Optics Test Accelerator (IOTA) storage ring at Fermilab to explore optimal radio frequency (RF) cavity and lattice configurations. IOTA is a compact fixed-energy storage ring that can circulate a 2.5-MeV proton beam with varying beam parameters and lattice configurations. The study will aim to demonstrate a bunch-compression factor of at least 2 in the IOTA ring while examining the impact of intense space-charge effects on the compression process.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Proposal for a Proton-Bunch Compression Experiment at IOTA in the Strong Space-Charge Regime

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Measurement of Close-in Ground Motion from an Underground Chemical Explosion

Understanding the geophysical response near an underground explosion is crucial for generating insights into the source and emplacement conditions that produce distinct observations in monitoring scenarios occurring at greater distances. Recently, Shot A of the Low Yield Nuclear Monitoring (LYNM) Physics Experiment 1 (PE1) series was conducted at the Nevada National Security Site to provide ground truth for subsurface explosion signal models. This experiment resulted in measuring near-source ground motion at distances ranging from 70 to 1000 m/kt with a 99% success rate, yielding high-fidelity knowledge of the near-field response that can serve as benchmarks for future numerical modeling and experiment planning. However, technical challenges exist in observing near-source phenomena while safeguarding sensitive data acquisition components from the detrimental effects of ground motion in the subsurface. This report outlines tools and techniques to address challenges associated with observing near-source accelerations and within the tunnel drift of the PE1 test bed. Additionally, we describe key systems designed with both modern advancements and legacy guidance to maximize the collection of high-quality ground motion data, which may be applied to constitutive and computational models, leading to new or improved understanding of the near- and far-field signals produced by underground explosions.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2025

NRIC Annual Report FY 2025

The National Reactor Innovation Center (NRIC), established in August 2019, is a national United States (U.S.) Department of Energy (DOE) program. NRIC’s mission is to partner with industry and national laboratories to bridge the gap between concept, demonstration, and commercialization of advanced nuclear technology. NRIC accomplishes this through building or enhancing existing DOE infrastructure to support testing of components and systems that are key to successfully deploying advanced nuclear technology. NRIC’s vision is that by 2028, NRIC will be partnered with industry and accelerating the demonstration and deployment of advanced nuclear technology using DOE national laboratory infrastructure and expertise. NRIC will establish four new experimental facilities and two large reactor test beds for integrated technology demonstrations and experimentation by 2028 and complete two advanced nuclear technology tests by 2030. Achieving this vision will enable urgently needed abundant and affordable clean energy both domestically and internationally. NRIC’s success will inspire our nation and the global community to embrace the promising contribution of innovative nuclear reactor technologies to the clean energy economy and re-establish the U.S. as the global leader in advanced nuclear energy. NRIC is tasked with expediting the development of advanced nuclear energy technologies by bringing together private-sector technology developers and the world-class capabilities of the DOE national laboratory system. Through this program, the U.S. private sector is given access to the physical infrastructure available at DOE national laboratories to test and demonstrate their reactor concepts. NRIC works closely with the DOE-Nuclear Energy (NE) program that grants access to technical, regulatory, and financial support for commercializing nuclear energy. NRIC builds upon these new reactor concepts and technology successes to effectively strengthen U.S. nuclear leadership.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Accelerated Lifetime Testing of Main Shaft Seals for Tidal Turbine Rotors

This document will briefly discuss the observations and results from an NREL conducted accelerated lifetime testing of the main shaft seal for the Verdant Power fifth generation Gen5 underwater Tidal Energy Converter (TEC) turbine, which successfully performed at the RITE project in 2020-2021. In order to evaluate a 5-year Service Interval ( SI) for this component, testing at NREL operated the main shaft seal nearly continuously for over 135 (text says 130 days on page 5 and 125 days on page 7 and 137 days on page 11) days at a rotational velocity of 160 rpm while the test stand recorded water pressure, barrier fluid pressure, temperature, and number of cycles., representing ~ 40% of the SI. An additional separate test was conducted to measure the aging behavior of the rubber drive rings. The water pressure reservoir was held constant as 29 psi. Barrier fluid pressure remained relatively constant throughout the duration of the test but was seen to sink to as low as 10.1 psi. No barrier fluid leakage was observed throughout the test. A sudden failure occurred within the seal after the power to test machine was interrupted for a scheduled building maintenance procedure. Upon restarting, the main shaft seal lost all ability to prevent water ingress. The exact cause is not known but is believed to be either a seal assembly issue or a change in the alignment of the seal components during or following the power outage. Following seal disassembly, significant wear was seen on one of the graphite sealing rings. Based on these results it is recommended that a follow-on TEAMER be conducted to rectify protocol and assembly issues to further evaluate SI of this component. The support and participation of Verdant Power Inc, Dovetail Solutions LLC and Garlock Manufacturing Inc were instrumental in understanding the results. NREL thanks them for their significant effort.

13 HYDRO ENERGY↗

DOE OSTI2025

Acceleration of Power System Dynamic Simulations Using a Deep Equilibrium Layer and Neural ODE Surrogate

The dominant paradigm for power system dynamic simulation is to build system-level simulations by combining physics-based models of individual components. The sheer size of the system along with the rapid integration of inverter-based resources exacerbates the computational burden of running time domain simulations. Here, in this paper, we propose a data-driven surrogate model based on implicit machine learningspecifically deep equilibrium layers and neural ordinary differential equationsto learn a reduced order model of a portion of the full underlying system. The data-driven surrogate achieves similar accuracy and reduction in simulation time compared to a physics-based surrogate, without the constraint of requiring detailed knowledge of the underlying dynamic models. This work also establishes key requirements needed to integrate the surrogate into existing simulation workflows; the proposed surrogate is initialized to a steady state operating point that matches the power flow solution by design.

Neural ordinary differential equations↗

DOE OSTI2025

Operation at Reduced Atmospheric Pressure and Concept of Reliability Redundancy for Optimized Design of Insulation Systems

Electrified transportation is calling for insulation design criteria that is adequate to provide elevated levels of power density, power dynamics and reliability. Increasing voltage levels are expected to cause accelerated intrinsic and extrinsic aging effects which will not be easily predictable at the design stage due to a lack of suitable modeling. Designing reliable insulation systems would require finding solutions able to control accelerated aging due to an unpredictable increase of intrinsic stresses and the onset of extrinsic stresses as partial discharges. This paper proposes the concept of reliability redundancy for the insulation design of aerospace electrical asset components, which is also validated at lower-than-standard atmospheric pressure. The principle is that extrinsic-aging-free design might be achieved upon determining the aging stress or abnormal service stresses distribution and being sure that aging will not generate conditions that can incept extrinsic aging (partial discharges) during operation life. However, such information is never, in practice, fully available to insulation system designers. Hence, especially in critical applications such as electrified aircraft, aerospace, and combat ships a further level of reliability should be added to a partial-discharge-free design, which can consist of the use of corona-resistant materials and/or of life models able to consider the accelerated aging effect of partial discharges (or any other type of extrinsic-accelerated aging factor). Innovative life modeling considering both extrinsic and intrinsic aging stresses, insulating material testing to estimate model parameters, and a metric for quantifying the extent of corona (or partial discharge) resistance can lead to establishing feasibility and limit conditions for optimized or fully reliability-redundant design. It is shown in the paper that if an extrinsic-aging-free design is not feasible, and it is therefore replaced by a redundant design, a further level of reliability redundancy can be provided by effective condition monitoring plans.

Montanari, Gian Carlo↗