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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Automation of Laser Plasma Focused Ion Beam Microscopy for Next-Gen Energy Materials

Automation can revolutionize the use of ultrafast laser ablation and plasma-focused ion beam (PFIB) techniques for high-throughput, reproducible cross-sectioning and various sample preparation in materials characterization. As these methods become essential for analyzing complex energy materials and next-generation devices, efficient, standardized workflows are needed to minimize variability and enhance precision. This work highlights our advancements in developing automated processes for sample preparation that integrates machine learning, workflow optimization, and large-scale data acquisition to improve efficiency and scalability in applications such as electrolyzers, photovoltaic cells, and microelectronics. To streamline cross-sectioning and lamella fabrication, we have implemented fully automated workflows that standardize laser ablation and PFIB milling sequences. These workflows incorporate pre-programmed protocols for material removal, alignment, and thinning, reducing user intervention and ensuring consistency across different sample types. Machine learning algorithms further enhance automation by predicting optimal milling strategies and adapting parameters based on material properties and sectioning requirements. This approach significantly improves throughput while maintaining the structural integrity of prepared samples for high-resolution imaging and analysis, including transmission electron microscopy. Beyond sample preparation, our automation platform enables the acquisition of large, high-resolution datasets through serial sectioning, image alignment, and 3D reconstruction. These automated routines facilitate multi-scale characterization, capturing structural and compositional details from the nanoscale to the device level. By reducing variability and increasing efficiency, our automated approach enhances defect analysis, failure diagnostics, and process optimization, accelerating advancements in materials research and device engineering.

36 MATERIALS SCIENCE↗
DOE OSTI2025

TRANSP integrated modeling code for interpretive and predictive analysis of tokamak plasmas

This paper provides a comprehensive review of the TRANSP code, a sophisticated tool for interpretive and predictive analysis of tokamak plasmas, detailing its major capabilities and features. It describes the equations for particle, power, and momentum balance analysis, as well as the poloidal field diffusion equations. The paper outlines the spatial and time grids used in TRANSP and details the equilibrium assumptions and solvers. Various models for heating and current drive and radiation, including updates to the NUBEAM model, are discussed. The handling of large-scale events such as sawtooth crashes and pellet injections is examined, along with the predictive capabilities for advancing plasma profiles. The integration of TRANSP with the ITER Integrated Modeling and Analysis Suite (IMAS) is highlighted, demonstrating enhanced data access and analysis capabilities. Additionally, the paper discusses best practices and continuous integration techniques to enhance TRANSP's robustness. The suite of TRANSP tools, designed for efficient data analysis and simulation, further supports the optimization of tokamak operations and coupling with other tokamak codes. Continuous development and support ensure that TRANSP remains a major code for the analysis of experimental data for controlled thermonuclear fusion, maintaining its critical role in supporting the optimization of tokamak operations and advancing fusion research.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Discovering $\mu$Hz gravitational waves and ultra-light dark matter with binary resonances

In the presence of a weak gravitational wave (GW) background, astrophysical binary systems act as high-quality resonators, with efficient transfer of energy and momentum between the orbit and a harmonic GW leading to potentially detectable orbital perturbations. In this work, we develop and apply a novel modeling and analysis framework that describes the imprints of GWs on binary systems in a fully time-resolved manner to study the sensitivity of lunar laser ranging, satellite laser ranging, and pulsar timing to both resonant and nonresonant GW backgrounds. We demonstrate that optimal data collection, modeling, and analysis lead to projected sensitivities which are orders of magnitude better than previously appreciated possible, opening up a new possibility for probing the physics-rich but notoriously challenging to access $\mu\mathrm{Hz}$ frequency GWs. We also discuss improved prospects for the detection of the stochastic fluctuations of ultra-light dark matter, which may analogously perturb the binary orbits.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Ultra-high Bandwidth, Ultra-high Dynamic Range X-Ray Shock Characterization via Photonic Integrated Circuit

Nuclear weapon component assessment tests at the Z Machine rely on accurate X-ray yield measurements for model validation, design and analysis of component survivability, and source optimization. Yield measurement devices currently used do not provide the requisite certainty to enable accurate and efficient data analysis of test results, which leads to an increase in Z-shots required for evaluation, longer device development times, and higher operation costs. Additionally, current X-ray flux detectors lack high temporal resolution at the tails. Similarly, shock measurement techniques used for component assessment often lack the ability to spatially resolve wave behavior thereby limiting the ability to measure shock propagation dynamics needed to design the next generation of ND components. Here we present the development of a photonic micro-calorimeter and shock sensor consisting of meter-long waveguide spirals that are optomechanically coupled to X-ray absorbing layers to characterize yield and shock propagation at nanosecond timescales.

42 ENGINEERING↗
DOE OSTI2025

BATMODS-lite [SWR-25-108]

Battery Analysis and Training Models for Optimization and Design Studies (BATMODS) is a Python package with an API for pre-built battery models. The original purpose of the package was to quickly generate synthetic data for machine learning models to train with. However, the models are generally useful for any battery simulations or analysis. BATMODS-lite includes the following: 1) A library and API for pre-built battery models 2) Kinetic/transport properties for common battery materials

Randall, Corey [National Laboratory of the Rockies↗
DOE OSTI2024

Reductive Analysis with Compiler-Guided Large Language Models for Input-Centric Code Optimizations

Input-centric program optimization aims to optimize code by considering the relations between program inputs and program behaviors. Despite its promise, a long-standing barrier for its adoption is the difficulty of automatically identifying critical features of complex inputs. This paper introduces a novel technique, reductive analysis through compiler-guided Large Language Models (LLMs), to solve the problem through a synergy between compilers and LLMs. It uses a reductive approach to overcome the scalability and other limitations of LLMs in program code analysis. The solution, for the first time, automates the identification of critical input features without heavy instrumentation or profiling, cutting the time needed for input identification by 44× (or 450× for local LLMs), reduced from 9.6 hours to 13 minutes (with remote LLMs) or 77 seconds (with local LLMs) on average, making input characterization possible to be integrated into the workflow of program compilations. Optimizations on those identified input features show similar or even better results than those identified by previous profiling-based methods, leading to optimizations that yield 92.6% accuracy in selecting the appropriate adaptive OpenMP parallelization decisions, and 20-30% performance improvement of serverless computing while reducing resource usage by 50-60%.

Input-Centric Optimization↗
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 OSTI2025

High-Temperature Aquifer Thermal Energy Storage (HT-ATES) Projects in Germany and the Netherlands—Review and Lessons Learned

Aquifer thermal energy storage (ATES) is a concept that can help to address heating and cooling needs through the use of the subsurface as a seasonal thermal energy storage (STES) system. Over 2800 ATES systems have been deployed with storage temperatures typically below 25 °C and only a few with higher temperatures (>40 °C), which would increase the energy density and utility of the stored thermal fluids. Until now, only a few high-temperature aquifer thermal energy storage (HT-ATES) projects have been initiated and are still in operation. These HT-ATES projects have encountered a range of technical and non-technical challenges. This study reviews ten such projects: four in Germany and six in the Netherlands. The non-technical issues include public acceptance, a lack of regulatory framework for these systems, managing overlapping uses of the subsurface, managing changes with the providers and off-takers of thermal energy, and obtaining financing to implement these projects. Common technical issues include geological factors such as incomplete characterization of the subsurface and reservoir heterogeneity; geochemical issues such as mineral scaling, corrosion, and biofouling; lower than expected thermal recovery; and issues with system design and reliability. This review highlights benefits and challenges faced by HT-ATES projects with the goal to use the lessons learned to improve the siting, design, development, and operation of such systems. Recommendations include improved initial subsurface site characterization, use of coupled process models to optimize system design and predict system performance, cascaded uses of stored thermal energy to better utilize the stored heat, monitoring networks to provide feedback on system performance, and expanded system scale to allow for continued operation even when maintenance of some system components is required. Techno-economic modeling and risk analysis could be used to optimize such HT-ATES project design and identify key factors that will affect sustained economic viability. In addition, design flexibility is important for these systems to allow for changing conditions regarding the supply and demand of thermal energy. Adopting these findings should improve the performance and reduce the risks for future HT-ATES projects worldwide.

15 - GEOTHERMAL ENERGY↗
DOE OSTI2026

Optimizing Energy Use in Pulp & Paper with DOE’s Energy Intensive Industries Resources

The U.S. pulp and paper industry is the third-largest energy consumer in manufacturing, accounting for roughly 10% of sector energy use. Improving energy efficiency reduces operating costs and strengthens competitiveness. To support this effort, the U.S. Department of Energy (DOE), through Oak Ridge National Laboratory (ORNL), launched the Energy Intensive Industries (EII) Initiative. A two-year pilot across 45 industrial sites identified more than 4 trillion Btu/year in potential energy savings. This presentation outlines plans for a follow-up technical assistance program tailored to pulp and paper mills. Available resources include a cost-savings scoping tool, implementation planning guidance, and technical support for applying advanced methods such as Pinch Analysis for integrated process-utilities optimization. The session introduces key Pinch Analysis principles and highlights case studies demonstrating measurable improvements. ORNL also seeks industry feedback on barriers to efficiency improvements, including technology gaps and resource needs. DOE’s broader objective is to accelerate productivity and economic competitiveness across U.S. energy-intensive industries.

Kamath, Dipti [ORNL] (ORCID:0000000278739994)↗
DOE OSTI2024

Optimizing Carbon Capture, Transport, and Storage: Overcoming Challenges with Machine Learning and Cost-Benefit Analysis

Carbon Capture, Utilization, and Storage (CCUS) is a critical strategy for reducing CO₂ emissions and mitigating climate change. However, its widespread deployment faces numerous challenges across the capture, transport, and storage phases. These challenges include the technical complexity of predicting subsurface behaviors during CO₂ injection, ensuring long-term storage integrity, optimizing transportation networks, and balancing the economic and environmental trade-offs. Addressing these issues requires an integrated approach combining advanced subsurface modeling with system-level analyses to assess costs, risks, and benefits. This presentation provides an overview of studies conducted by the National Energy Technology Laboratory (NETL) to tackle these challenges. NETL’s efforts encompass cutting-edge research in subsurface fluid behavior machine learning predictions, alongside the development of innovative tools for system optimization and economic evaluation. By bridging technical expertise and strategic analysis, NETL aims to advance the deployment of CCUS technologies to support global decarbonization efforts. Presented at the Carnegie Mellon University CEE IESS Student Seminar October 4, 2024.

Shih, Chung Yan↗
DOE OSTI2026

A Flexible Quasi-Static Mooring Design Optimization Method for Floating Structures

This paper presents a flexible and efficient design method for optimizing the mooring systems of floating structures. Mooring system optimization is challenging because of the strong nonlinearity of mooring system behavior and the many technical constraints that must be satisfied. Furthermore, different mooring configurations can have very different design spaces. While some successful examples of mooring design optimization exist in the literature, developing an optimization approach that can work across various mooring design problems is a larger challenge. We present such a method based on a flexible parameterization that allows a wide variety of mooring designs to be described by a list of variables, a quasi-static mooring model that provides efficient evaluation of a mooring design without directly considering mooring system dynamics, and an optimization framework that generates, evaluates, and adjusts the mooring design while considering user-specified constraints such as offset limits, strength safety factors, and seabed contact limits. We demonstrate the design optimization framework on four mooring design problems, each for a different type of mooring system. We compare the use of different design modes to simplify the optimization problem, showing that they can reduce the computation time by up to 75%. We also compare different optimization algorithms and find that the resulting computational speed can vary by up to 51 times. We perform a sensitivity study on one design and find that the local sensitivity of anchoring radius to water depth has a positive correlation of 0.29, but the global sensitivity shows large nonlinearities. Lastly, we perform a coupled dynamic analysis on one of the optimized designs and find that the predicted mean platform motions and mooring line tensions are within 1% of dynamic results and the extreme motions and tensions are within 14%. Lastly, we show that a DEA-Chain-Polyester mooring configuration is cost-optimal for the given design problem of the demonstrations, which aligns with general industry practice.

16 TIDAL AND WAVE POWER↗
DOE OSTI2026

Optimizing fluvial flood mitigation strategies: A multi-objective approach for cost-effective and socially-aware infrastructure feasibility analysis

Effective levee planning must balance capital cost, risk reduction, and community priorities. These objectives are rarely optimized together. This study presents a feasibility phase, simulationin-the-loop framework that couples terrain-based flood modeling with a socially aware multiobjective optimizer. Flood risk is measured as Expected Annual Exposed Population (EAEP), obtained by integrating exposure over Annual Exceedance Probability (AEP) nodes, mirroring the Hydrologic Engineering Center's Flood Damage Reduction Analysis (HEC-FDA) expected-annual formulation but with people rather than dollars. Exposure per scenario is computed by overlaying binary inundation masks with a population surface at the tract level. Distributional fairness is encoded through a Group Benefit Share (GBS) constraint that requires high-SVI tracts to receive at least a baseline share of annualized benefits. Capital cost is represented by a height-dependent unit-cost model suitable for screening. This study addresses the two-objective problem, minimize cost and expected annual exposure subject to the GBS constraint, using Non-Dominated Sorting Genetic Algorithm II (NSGA-II) and leveraging Pareto front for feasibility phase decision making. Implemented with terrain-based flood modeling, GeoFlood, for rapid scenario evaluation, the framework is demonstrated in Southeast Texas. The results reveal clear trade-offs among cost, risk, and social benefits and identify non-dominated levee height configurations that satisfy the benefit-share floor. The contributions are a scalable decision support method that operationalizes expected annual population-based risk, embeds enforceable benefit-sharing guarantees, and uses lightweight simulation to explore large design spaces before higher fidelity design stages.

Flood mitigation↗
DOE OSTI2026

Towards Scaling Law Analysis For Spatiotemporal Weather Data

Compute-optimal scaling laws are relatively well studied for NLP and CV, where objectives are typically single-step and targets are comparatively homogeneous. Weather forecasting is harder to characterize in the same framework: autoregressive rollouts compound errors over long horizons, outputs couple many physical channels with disparate scales and predictability, and globally pooled test metrics can disagree sharply with per-channel, late-lead behavior implied by short-horizon training. We extend neural scaling analysis for autoregressive weather forecasting from single-step training loss to long rollouts and per-channel metrics. We quantify (1) how prediction error is distributed across channels and how its growth rate evolves with forecast horizon, (2) if power law scaling holds for test error, relative to rollout length when error is pooled globally, and (3) how that fit varies jointly with horizon and channel for parameter, data, and compute-based scaling axes. We find strong cross-channel and cross-horizon heterogeneity: pooled scaling can look favorable while many channels degrade at late leads. We discuss implications for weighted objectives, horizon-aware curricula, and resource allocation across outputs.

Kiefer Jr, Alexander [ORNL] (ORCID:000000025398874↗
DOE OSTI2024

A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process

Recent progress in sensing techniques and data analytics tools have significantly accelerated the development of Wire Arc Additive Manufacturing (WAAM) systems. This data centric approach emphasizes leveraging available data throughout the production process to optimize performance. Integration of extensive data analysis provides the opportunity to improve precision, reduce waste, and enhance the quality of produced parts. This method relies on AI/ML models and optimization techniques, which are developed using the data collected from various sources, including in-situ sensors, ex-situ imaging, and manufacturing process parameters. The quality and diversity of this data, along with the alignment between different data streams (achieved through spatiotemporal registration) are critical for the successful development of AI/ML and optimization models. In this work, we present a spatiotemporally registered dataset generated during the WAAM process of deposition of a rectangular block. The dataset includes the comprehensive description of deposition process, process parameters, in-situ collected welding characteristics, acoustic data, and X-Ray Computed Tomography analysis data for the build. Dataset A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process has arisen under UT-Battelle, LLC’s Prime Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy (DOE) to manage and operate the Oak Ridge National Laboratory. UT-Battelle, LLC will not assert any rights under United States law or under the Prime Contract it has in the dataset against any user of the dataset, including any copyrights or patent rights. UT-Battelle, LLC requests that attribution to the dataset is provided as academically appropriate.

42 ENGINEERING↗
DOE OSTI2025

A co-registered in-situ and ex-situ dataset from wire arc additive manufacturing process

Recent progress in sensing techniques and data analytics tools have significantly accelerated the development of Wire Arc Additive Manufacturing (WAAM) systems. This data-centric approach emphasizes leveraging sensor data available throughout the production process to optimize performance. Integration of extensive data analysis provides opportunities for improving precision, reducing waste, and enhancing the quality of produced parts. This method relies on AI/ML models and optimization techniques, which are developed using the data collected from various sources, including in-situ sensors, ex-situ imaging, and manufacturing process parameters. The quality and diversity of this data, along with the alignment between different data streams (achieved through spatiotemporal registration) are critical for the successful development of AI/ML and optimization models. In this work, we present a spatiotemporally registered dataset generated during the WAAM process of deposition of a rectangular block. The dataset includes a comprehensive description of the deposition process, process parameters, welding characteristics and acoustic data collected in-situ, and X-Ray Computed Tomography data of the build.

42 ENGINEERING↗
DOE OSTI2025

Domain Decomposition for Integer Optimal Control with Total Variation Regularization

Total variation integer optimal control problems admit solutions and necessary optimality conditions via geometric variational analysis. In spite of the existence of said solutions, algorithms which solve the discretized objective suffer from high numerical cost associated with the combinatorial nature of integer programming. Hence, such methods are often limited to small and medium-sized problems. We propose a globally convergent, coordinate descent–inspired algorithm that allows tractable subproblem solutions restricted to a partition of the domain. Our decomposition method solves relatively small trust-region subproblems that modify the control variable on a subdomain only. Given nontrivial subdomain overlap, we prove that a global first-order necessary optimality condition is equivalent to a first-order necessary optimality condition per subdomain. We additionally show that a sufficient decrease is achieved on a single subdomain by way of a trust-region subproblem solver using geometric measure–theoretic arguments, which we integrate with a greedy patch selection to prove convergence of our algorithm. In conclusion, we demonstrate the practicality of our algorithm on a benchmark large-scale, PDE-constrained integer optimal control problem and find that our method is faster than the state of the art.

domain decomposition↗
DOE OSTI2025

SpectraCodec: A Hilbert curve-based method for encoding metadata in mass spectra for machine learning applications (SpectraCodec) v1

Machine learning approaches to mass spectrometry (MS) data analysis require structured metadata for optimal performance. However, current MS file formats necessitate external metadata sources, creating integration challenges that impede analytical workflows. Here, we present a novel approach for encoding metadata directly within mzML files using one-hot encoding of ASCII characters mapped via Hilbert space-filling curves. This strategy embeds metadata in the first spectrum's m/z-intensity space, ensuring persistence with the primary data, eliminating the need for external metadata files, and maintaining compatibility with existing MS software. We demonstrate that the Hilbert curve mapping efficiently utilizes the two-dimensional spectral space while maintaining robust data recovery. This method offers a practical solution for machine learning applications in mass spectrometry by ensuring metadata and spectral data remain unified through all stages of analysis.

Bowen, Benjamin [Lawrence Berkeley National Labora↗
DOE OSTI2025

Toward a sustainable circular economy of multilayer plastic films: Life cycle and techno-economic assessment with a focus on end-of-life treatment and multiple recovery cycles

This study presents a life cycle assessment (LCA) and techno-economic analysis (TEA) of end-of-life technologies for treating polyethylene–polyamide barrier film waste, focusing on quality degradation across recovery cycles. Novel treatment methods are experimentally validated, while others are drawn from literature and industry consultations. A displacement approach, assuming no quality loss, is first applied. Results show that solvent-based recycling via the solvent-targeted recovery and precipitation (STRAP) process outperforms alternatives across environmental indicators, reducing global warming potential (GWP) by 40% compared to landfilling. Incineration performs worst in most categories, particularly eutrophication (80% higher than landfilling), due to nitrogen emissions. Experimentally validated downcycling (pelletizing) proves more economically viable. The assumption of infinite recoverability is overly optimistic. To address this, we propose a mathematical framework accounting for a finite number of recovery cycles. This refined model shows reduced GWP and cost savings for solvent recovery, making its benefits less pronounced than initially estimated. Sensitivity and uncertainty analyses reveal strong dependence on recovered material quality and solvent recovery efficiency, underscoring the need for optimized process design. Finally, hotspot analysis identifies greenhouse gas emissions from the polyamide supply chain as the dominant GWP contributor. In conclusion, the results underscore potential trade-offs across pathways and show that solvent-based recovery’s sustainability depends heavily on process conditions.

36 MATERIALS SCIENCE↗