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DOE OSTI2024

Bridging Hydrological Ensemble Simulation and Learning Using Deep Neural Operators

Ensemble-based simulation and learning (ESnL) has long been used in hydrology for parameter inference, but computational demands of process-based ESnL can be quite high. To address this issue, we propose a deep neural operator learning approach. Neural operators are generic machine learning algorithms that can learn functional mappings between infinite-dimensional spaces, providing a highly flexible tool for scientific machine learning. Our approach is built upon DeepONet, a specific deep neural operator, and is designed to address several common problems in hydrology, namely, model parameter estimation, prediction at ungaged locations, and uncertainty quantification. Here we demonstrate the effectiveness of our DeepONet-based workflow using an existing large model ensemble created for an eastern U.S. watershed that is instrumented with 10 streamflow gages. Results suggest DeepONet achieves high efficiency in learning an ML surrogate model from the model ensemble, with the modified Kling-Gupta Efficiency exceeding 0.9 on holdout test sets. Parameter inference, carried out using the trained DeepONet surrogate model and genetic algorithm, also yields robust results. Additionally, we formulate and train a separate DeepONet model for physics-informed, seq-to-seq streamflow forecasting, which further reduces biases in the pre-trained DeepONet surrogate model. While this study focuses primarily on a single watershed, our approach is general and may be extended to enable learning from model ensembles across multiple basins or models. Thus, this research represents a significant contribution to the application of hybrid machine learning in hydrology.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Multistage Stochastic optimization for mid-term integrated generation and maintenance scheduling of cascaded hydroelectric system with renewable energy uncertainty

The uncertainties resulting from the escalating penetration of renewable energy resources pose severe challenges to the efficient operation of modern power systems. Hydroelectricity is characterized by its flexibility, controllability, and reliability, and thus becomes one of the most ideal energy resources to hedge against such uncertainties. This paper studies the mid-term integrated generation and maintenance scheduling of a cascaded hydroelectric system (CHS) consisting of multiple cascaded reservoirs and hydroelectric units. To precisely describe the mid-term water regulation policies, the hydraulic coupling relationship and water-energy nexus of CHS are incorporated into the proposed optimization model. The uncertainties of natural water inflow and the power outputs of wind/solar energy generation are taken into consideration and captured via a stochastic process modeled by a scenario tree. A multistage stochastic optimization (MSO) approach is developed to coordinate the complementary operations of multiple energy resources, by optimizing the mid-term water resource management, generation scheduling, and maintenance scheduling of CHS. The proposed MSO model is formulated as a large-scale mixed-integer linear program that presents significant computational intractability. To address this issue, a tailored Benders decomposition algorithm is developed. Two real-world case studies are conducted to demonstrate the capability and characteristics of the proposed model and algorithm. The computational results show that the proposed MSO model can exploit the flexibility of hydroelectricity to efficiently respond to variable wind and solar power, and reserve water resources for the generation in peak months to reduce the consumption of fossil fuel. Furthermore, the proposed solution approach also exhibits promising computational efficiency when handling large-scale models.

13 HYDRO ENERGY↗

DOE OSTI2025

Application of Flex-QA Arrays in HTS Magnet Testing

Flexible PCB quench antennas have been very useful in providing high-quality high-resolution data in low temperature superconducting magnet tests. Similar multi-sensor arrays have been employed recently to cover a high temperature superconductor magnet tested at FNAL. In the present work, data taking conditions and magnet features to support the analysis framework are discussed. Then observations made during complete magnet powering cycles are described and analysis of quench antenna data are presented. Based on results, improvements to instrumentation and data taking are debated. Views on the future of flexible quench antenna sensors for HTS magnet diagnostics and operational support are shared.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Application of Flex-QA Arrays in HTS Magnet Testing

Stoynev, S.↗

DOE OSTI2025

ASEAN Technical Exchange Workshop for System Operators, Regulators, and Policymakers

This presentation provides an in-depth exploration of power system planning, cross-border electricity trading, and battery energy storage systems (BESS), offering actionable insights for system operators, regulators, and policymakers. The first section delves into power system planning and analysis, focusing on capacity expansion models and resource adequacy studies, including their role in optimizing system efficiency, managing emissions, and addressing system reliability risks. Key considerations, such as integration of transmission into generation planning and the forecasting versus optimization of customer distributed energy resources (DER) technologies, are explored. The session highlights critical trade-offs in spatial granularity and model runtimes, as well as the feasibility of aligning distribution investments with capacity expansion efforts. The second section examines cross-border electricity trading, with an emphasis on resource adequacy concepts such as reliability targets, loss of load expectation (LOLE), and planning reserve margins (PRM). Case studies on reserve market design and coordination across US regions provide insights into improving reserve deliverability and managing interregional power balance and congestion. This section also addresses market-to-market congestion management, including advanced strategies for high-voltage direct current (HVDC) optimization and ancillary service delivery. Finally, the presentation covers the rapid evolution of Battery Energy Storage Systems (BESS), highlighting their operational growth, regulatory frameworks, and use cases in grid flexibility, energy storage, and reliability. The discussion focuses on the benefits of BESS for system stability, resilience, and integration of renewable energy, offering insights into its role as a vital component in the transition toward a more sustainable and flexible grid. Key performance parameters, such as throughput, round-trip efficiency, and state of charge, are also examined.

25 ENERGY STORAGE↗

DOE OSTI2026

Potential of Data Center Controls in Grid Services

The rapid proliferation of large data centers brings both challenges and opportunities for grid reliability. The data center resources and their potential flexibility have the potential to contribute resources to grid operations. Through capabilities like energy shifting and resource coordination, data centers can help reduce their net demand on the transmission network, as well as provide additional grid services to support reliable operation on the grid. While transient and long-term grid planning and operations are the scenarios that draw most attention, the quasi-steady state timeseries (QSTS) operation of data centers and grid bring interesting scenarios that can help evaluate the data center controls to aid grid services. This work is focused on modeling data centers for QSTS applications – incorporating the AI data center load profiles and building on the PNNL digital twin model for the thermal management loads to enable simulation studies to reveal the impact of data center controls on grid performance. This includes the integration of a QSTS battery and natural gas generator model to incorporate local resource impacts to the system. The simulation study is performed with a modified IEEE 24-Bus transmission system. Scenarios are focused on evaluating the data center load impacts on the transmission system and leveraging both data center and local generation controls to mitigate those impacts and provide additional grid services. The data center controls revealed the ability to contribute to two main kinds of grid services: preventing congestion on a weak grid by coordinating the data center resources with the collocated BESS and onsite generation; and the ability to help the grid operations during stressed times of operation like during a contingency. Leveraging these and other capabilities has the potential to help data centers become grid responsive assets, aiding in both their integration into the power system and grid reliability.

power grid simulation↗

DOE OSTI2026

Digital Twin User Guide for Chelan County Public Utility District

This user manual offers a comprehensive guide for developing a Digital twin (DT) of a Kaplan turbine at Chelan County Public Utility District (Chelan PUD) using neural networks. As variable renewable generation expands, hydropower units must operate with optimal efficiency and stability. For Kaplan machines, this flexibility is achieved through coordinated control of guide vane (wicket gates) opening and runner blade pitch, which amplifies the plant’s inherent nonlinear behavior and challenges traditional physics-only modeling. The efficiency of the Kaplan turbine varies with different combinations of the guide vans (wicket gate) opening and the blade angle. Each guide van opening and blade angle has a corresponding highest efficiency point, forming a cam relationship that represents the optimal combination.The discharge of a hydraulic turbine is controlled by the opening angle of the guide vans. Therefore, for each value of head, there is a certain guide van opening and blade angle that corresponds to the highest efficiency. For a given head, different combinations of the guide van opening and blade angle have different efficiencies. Therefore, coordinate cam curves are used to describe the relationship between the wicket gate opening and blade angle with different water head. To address these challenges, the manual details a data-driven modeling and learning workflow centered on structured neural networks. The approach is designed to forecast critical operational variables—discharge flow, net head, penstock (or scroll-case) pressure, and generator electrical outputs—by leveraging real-time inputs such as the generator power control setpoint, exciter field current and field voltage, together with hydromechanical commands (e.g., gate position and, when available, runner blade-pitch angle). The neural models are trained and validated on operational data from a Kaplan unit operated by Chelan PUD, demonstrating that the structured NN architecture can learn the coupled gate–blade–electrical dynamics. The result is a robust DT that improves situational awareness and supports data-informed decision-making for Chelan PUD’s Kaplan turbine operations.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

An open control sequence specification to scale building demand flexibility via analytics software

For over two decades, researchers and practitioners have showcased the ability of large commercial buildings to provide grid services by shedding or shifting load. Various utility demand response (DR) and virtual power plant (VPP) programs throughout the United States are presently utilizing these demand-side resources. However, growth of these programs have been limited, in part due to the high cost necessary to integrate the DR control strategies into the building automation system (BAS). Implementing these strategies involves adjusting control sequences, necessitating dozens of hours of customized programming per building, limiting their adoption to large organizations and progressive owners. Recent efforts by researchers and industry have demonstrated the capability of energy management and information systems (EMIS), originally designed for fault detection and diagnostics, to interface with existing BAS and perform supervisory control to optimize building operations. While these approaches are quickly being adopted by industry, demand flexibility (DF) control strategies remain limited in product offerings. One of the challenges is the lack of documented best-practice DF sequences, despite the rich literature on field implementations. This paper develops a new open-specification for a zone-based temperature adjustment shed strategy for commercial building HVAC systems, describing the specification’s implementation in two EMIS tools in both experimental and field settings. Both implementations successfully reduced electric load by at least 40% on average during the called event, while maintaining temperature limits. This study’s detailed process from specification to deployment shows the potential for scalability as well as highlights challenges related to integration with heterogeneous BAS products.

Granderson, Jessica↗

DOE OSTI2024

Laboratory Evaluation of Commercial Utility Microgrid Controller Test Results

The functional requirements of many microgrid controllers (MGCs) are expanding and evolving to meet growing utility and community needs. At a high level, the utility microgrid controller serves resilience and reliability use cases by coordinating transitions between grid-connected and islanded states and by managing the system during island operations. This includes control scenarios that require the microgrid controller to use flexible microgrid boundaries, maintain energy balance, coordinate with peer systems, and manage grid-forming (GFM) and grid-following (GFL) distributed energy resources (DER). In order to evaluate these functional enhancements, microgrid controller test plans must also be developed to ensure that the implemented controllers provide adequate performance. This report provides MGC test plans for both island operation and transition functions. The functions covered in this report include feeder level energy management, island constraint management, secondary voltage and frequency control, black start, and synchronized reconnection. This second edition update also includes results from applying the tests to a commercial utility microgrid controller. These results evaluate the performance and reliability of the controller under various operational scenarios. It identifies specific areas where the controller excels and highlights gaps that need to be addressed for future enhancements. The application of these test plans on real-world system behavior provides insights on commercial equipment readiness for field deployment. These test cases can be applied to utility-managed microgrid controllers that exclusively manage utility-owned equipment; the tests also apply to third-party managed microgrid controllers that coordinate with utility- and customer-owned equipment. The report can also be used by technology developers and project developers in industry to evaluate control strategies and performance characteristics for community microgrid controllers.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Modeling the Potential Impact of Storage on the US Power Sector in a Multisector Dynamic Context

The electric power sector is expected to grow in size, importance, and complexity around the world as economies expand and electric supply technologies and demand patterns evolve in significant ways. At the same time the electric power sector may see substantial increases in VRE generating technologies which can add variability and uncertainty to the diurnal and seasonal profile of electric supply. With these forces in play, the emergence of modular, flexible electricity storage technologies may have profound impacts on the operation of electric power systems. Here we reduce a storage modeling gap in MSD models by incorporating grid-based electricity storage into the electric sector dynamics of the Global Change Analysis Model-USA (GCAM-USA) with improved power sector representation. We find a potentially significant role for storage technologies in the future of the U.S. power system, with storage capacity ranging from 7.7 to 14.7 GW in 2050 and 13.9 to 31.6 GW in 2100 across several techno-economic scenarios. We also find that storage can help to smooth variability in residual load arising from evolving electricity demands and the introduction of high shares of VRE to the electric grid. This reduces reliance on high-cost peaking generators, improves system-wide capacity factors, and limits curtailment of VRE.

Patel, Pralit L.↗

DOE OSTI2025

Modelling pulsed field magnetization of iron-based bulk superconductors

Abstract Bulk superconductors can be used as super-strength quasi-permanent magnets capable of providing magnetic flux densities considerably superior to conventional permanent magnets. This makes them attractive for several engineering applications that rely on strong magnetic fields like rotating machines, NMR/MRI and magnetic drug delivery systems. Recently, the authors reported a record trapped magnetic field in an iron-based bulk superconductor: 2.83 T was trapped in potassium-doped barium iron arsenide (Ba, K)Fe 2 As 2 (or Ba122) at 5 K. Of particular significance is that the strength and temporal stability of this magnetic field exceeds the requirements of MRI machines, indicating iron-based bulks can now perform at levels demanded by engineering applications. One crucial challenge for their practical use, however, is the need to apply and remove an external magnetic field to magnetize them. Pulsed field magnetization (PFM) shows great promise as a practical method of magnetizing bulks, but the process generates heat in the bulk that is detrimental to its superconducting performance and ability to act as a super-strength magnet. In this paper, coupled electromagnetic–thermal numerical models are used to simulate the PFM of iron-based bulk superconductors. Here we focus on the recent-record-breaking, fine-grain polycrystalline K-doped Ba122 bulks. The impact that the specific J c ( B ) characteristics and thermal properties of the Ba122 material—all of which have been experimentally measured from state-of-the-art samples—have on the magnetic flux dynamics and thermal behaviour during PFM, including the final trapped field, is investigated. We show that because the thermal properties are similar to those of REBa 2 Cu 3 O 7 −δ bulks, a similar response to pulsed fields is obtained. A maximum trapped field of ∼0.81 T (∼43.3% of the maximum trapped field capability under ideal, field-cooling conditions) was simulated at 5 K, with a magnetization efficiency of ∼54%. The modelling framework provides a fast and flexible tool for optimising the practical PFM process at different operating temperatures to maximise the trapped field in state-of-the-art Ba122 bulks and to guide the design of future experiments.

bulk superconductors↗

DOE OSTI2024

Valuing EV Managed Charging for Bulk Power Systems

When and where electric vehicle (EV) charging occurs has significant implications for power systems supporting widespread EV adoption, especially with high shares of wind and solar generation. This study extends previous works by leveraging detailed simulation models for EV adoption, EV use, EV charging, and bulk power system operations, and by linking them with methods for describing charging flexibility at both the individual vehicle and aggregate levels. This technical potential study focuses on how the value of EV managed charging (EVMC) changes depending on charging flexibility type (within-charging session or within-week scheduling), dispatch mechanism (direct load control or one of several price-based mechanisms), and managed charging participation rate. We show that naively aggregating EV charging flexibility from individual vehicles into megawatt-scale resources grossly overestimates the flexibility of the fleet, because such aggregate models can unrealistically pair, e.g., one already-fully-charged vehicle's ability to increase load with another already-charging vehicle's ability to accept more charge, effectively requesting a charging rate that is infeasible for the latter vehicle. We find per-vehicle bulk system value is highest at low participation rates for all dispatch mechanisms. Factoring in production cost savings, avoided firm capacity savings, and combustion-related power sector emissions savings, we estimate the value of EVMC at low participation rates (5%) to be $33/vehicle-year to $69/vehicle-yr for within-session charging flexibility and $40/vehicle-yr to $120/vehicle-yr for within-week charging flexibility in an envisioned 2038 New England power system and monetary value reported in 2016 U.S. dollars. At 100% participation, per-vehicle value declines to $25/vehicle-yr to $31/vehicle-yr for within-session charging flexibility and to $29/vehicle-yr to $36/vehicle-yr for within-week charging flexibility; however, 100% participation yields the highest total system savings.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Uniting Theory and Experiment to Deliver Flexible MOFS for Superior Methane (NG) Storage

The objective of the project was to use previous insights developed through synthesis and quantitative modeling of rigid metal–organic frameworks (MOFs) in an established synergistic theoretical/experimental team to create, modify, and evaluate flexible MOFs (FlexMOFs) for natural gas (NG) storage and release at practically useful pressures and transform the NG storage economy. The goal was reduced pressure absorbed natural gas (ANG) FlexMOF storage at operating pressures less than 100 bar with physisorption exploiting the favorable thermodynamics and kinetics of flexible porous material opening in response to adsorption. Hydrogen behavior in this context was also considered. The specific aim of the project was to design and develop a standard computational modeling methodology for, first, detailed atomistic retrodiction of FlexMOF gating behavior and ultimately prediction of the effects of functionalization and/or substitution on structural transitioning. The project was also geared towards the establishment of the interaction of methane with the framework and binding sites using modeling and the FlexMOF will be both internally and external validated as a SMART metric. This has value to the scientific community both from the obvious standpoint of providing a better understanding of the promising test case systems (CdIF-13 and the MIL-53(Al) series of MOFs), but also in providing an avenue of obtaining insight into these FlexMOF systems in general, which is of particular interest given the tendency of structure-function correlation to lag behind synthesis methodology (making the latter a hit or miss proposition for applications). This gap remains significant for FlexMOF systems whose gate opening behaviors complicate computational examination. The computational methodologies are relatively inexpensive in terms of both money and computational resources enhancing the general viability of these methodologies. The ultimate gain to the public will be in the application of these techniques to design systems for natural gas storage and use to cut down on green-house emissions.

03 NATURAL GAS↗

DOE OSTI2024

Probabilistic Hydropower Flexibility Valuation: Case Studies for Boating Flow Regime

The optimal scheduling of hydropower generation holds significant importance to power system operation. The unique requirements of environmental constraints and the power system, depending on their respective objectives, demand distinct flow patterns. While power system stakeholders strive to optimize revenue in electricity markets, stakeholders from boating recreation seeks to identify flow ranges that optimize the boating experience. In pursuit of a win-win solution, this study aims to reconcile the interests of various stakeholders in hydropower scheduling. The maximum revenue from day-ahead electricity market is explored through an optimization process considering both plant operation constraints, boating flow constraints, water availability, and market prices. Results of real world case studies at a river in California show that the proposed approach can achieve dual objectives: maximizing market revenue while addressing boating recreation necessities. In addition, as the accuracy of electricity price forecasting and flow forecasting increase, the optimal revenue becomes increasingly advantageous to hydropower plant operators.

13 HYDRO ENERGY↗

DOE OSTI2025

Scalable Data Center Capacity for DOE's AI Prototype: A Rapidly Available Gigawatt Data Center for DOE

The multilaboratory Gigawatt Data Center working group was commissioned to identify approaches to rapidly establish federal data centers with scalable capacities up to 1,000 MW. These state-of-the-art facilities will serve as hubs for interdisciplinary collaboration, industry partnerships, and transformative applications of artificial intelligence. The proposed strategic shift includes facilitating multilaboratory collaboration, prioritizing operational efficiency, expanding public–private partnerships, optimizing investments, ensuring long-term contractual flexibility, supporting open science and secure data enclaves, and exploiting high-speed national networks. Owing to their extensive experience and best practices, the US Department of Energy national laboratories are uniquely positioned to lead this initiative. We recommend conducting a feasibility analysis to rapidly identify the optimal sites for this initiative, and the effort will likely involve private industry for design, construction, financing, and operational integration. We also propose establishing multiple geographically diverse sites to ensure energy resilience, high operational reliability, and a diverse user base, thereby effectively addressing the nation’s critical needs.

42 ENGINEERING↗

DOE OSTI2026

EXERGETIC: De-Risking Next-Generation Resilient Geothermal Hybrids via At-Scale Evaluation Using Virtual Emulation Digital Twin Environment for Efficient Operation

The DOE-GTO-funded project, award number 5.1.2.12, entitled "EXERGETIC - De-risking Next Generation Resilient Geothermal Hybrids via at-Scale Evaluation Using a Virtual Emulation Digital Twin Environment for Efficient Operation," advances the solution to these challenges by developing and validating a geothermal co-emulation environment implemented at the National Laboratory of the Rockies (NLR)'s Advanced Research on Integrated Energy Systems (ARIES) platform. This framework enables the de-risking of next-generation geothermal and geothermal hybrid systems through high-fidelity modeling, real-time digital emulation, advanced control strategies, and techno-economic assessment. The project focused on geothermal hybrid configurations that integrate geothermal power plants with concentrated solar power and underground thermal energy storage, enabling enhanced efficiency, flexibility, and grid support capabilities. The main goal of this project was the development of a geothermal digital co-emulation environment to demonstrate the technical and economic value of geothermal hybrid systems and their contribution to grid stability and flexibility. The EXERGETIC framework combined physics-based models, controls, and real assets at ARIES, including digital real-time simulators (DRTS), a 20-MW-scale controllable grid interface (CGI), and a 2-MW conventional generator. Detailed transient models were developed for the key subsystems of a hybrid geothermal plant, including parabolic trough solar collectors, reservoir thermal energy storage (RTES), and a binary Organic Rankine Cycle (ORC) power plant. The ORC model explicitly captured thermal inertia and off-design operation and integrated control strategies to dynamically respond to electric load profiles. The models were validated against published experimental and numerical studies, demonstrating strong agreement and confirming the accuracy and robustness of the modeling approach. The resulting digital twin represents geothermal-solar-storage systems at multiple scales (1 MW to 100 MW) and enables realistic emulation of grid-connected operation. The control architecture allows the geothermal resource to provide stable baseload generation, while solar and stored thermal energy supply flexible, dispatchable support during periods of high demand or variable grid conditions. A key contribution of the EXERGETIC project is the demonstration that geothermal hybrid systems can be designed to be active grid assets rather than passive baseload generators. Using the ARIES platform, the digital twin was evaluated under multiple grid scenarios, including load following, voltage support at the distribution level, and frequency response at the transmission level. Results show that hybrid geothermal systems can respond effectively to dynamic grid conditions, providing inertia-like behavior, primary frequency support, and voltage regulation through coordinated control. In addition to the performance and grid services capability analysis of geothermal and hybrid geothermal systems, the EXERGETIC project also focused on scalability and techno-economic analysis of geothermal hybrid plants. In particular, for the scalability analysis, machine-learning (ML)-based surrogate models were trained using data generated from the geothermal digital twin under different grid-connected scenarios and plant capacities. These ML models demonstrated strong interpolation and extrapolation capabilities across plant sizes, accurately reproducing both steady-state and transient responses with very low errors. Regarding the techno-economic analysis, plant performance results were integrated with cost models for hybrid geothermal systems, and the levelized cost of electricity (LCOE) was used as the main economic metric to evaluate system performance across a range of system capacities, solar shares, solar multiples, and storage durations. Results indicate that economies of scale significantly reduce geothermal LCOE as plant capacity increases, with large-scale systems (25-100 MW) achieving substantially lower costs than small plants. Hybridization with solar thermal energy and storage further improves economic performance by increasing capacity utilization and enabling flexible dispatch. In addition, thermal storage plays a critical role in reducing LCOE by maximizing geothermal, solar, and stored energy resources. In summary, the results from this project demonstrate that geothermal hybrid systems represent a promising alternative for increasing the energy conversion efficiency of geothermal technologies, contributing to the preservation of geothermal resources, and supporting the transition of geothermal plants from traditional baseload resources into flexible, resilient, and cost-competitive energy conversion technologies.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.

42 ENGINEERING↗

DOE OSTI2025

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

42 ENGINEERING↗