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DOE OSTI2025

Soft X-Ray Tomography Has Evolved into a Powerful Tool for Revealing Cell Structures

Over the past three decades, soft X-ray tomography (SXT) has rapidly evolved from a proof-of-concept microscopy method into a high-throughput quantitative imaging modality. This advancement enables researchers to address central questions in cell biology. Despite its relatively short developmental period compared to light and electron microscopy, SXT has emerged as a powerful imaging technology. It enables measuring chemical changes in cellular organelles, analyzing three-dimensional structures of whole cells and creating digital cellular models to study cell motility. We discuss the unique nature of SXT to visualize cells without fixation or labeling, enabling quantitative analyses of organelle chemical composition. We explore SXT microscopes available worldwide, SXT segmentation software, and the diverse cell types studied using this technique. We conclude with emerging directions in SXT imaging, including a brief discussion of recent discoveries that are highly influential and likely to become integral to cell biology textbooks.

Weinhardt, Venera↗

DOE OSTI2026

Roadrunner

SAND2026-17073O Roadrunner software provides a comprehensive platform for simulating the mechanical behavior of crystalline materials under various loading conditions, allowing users to investigate the effects of dislocation slip hardening and damage evolution. Developed as a fork of the Multiphysics Object Oriented Simulation Environment (MOOSE) software from Idaho National Laboratory, Roadrunner is optimized for high-performance computing and can simulate large-scale problems, enabling researchers to explore complex scenarios. Its applications include material design and optimization in aerospace and automotive industries, investigation of failure mechanisms in structural materials, and development of predictive models for crystalline materials under various loading conditions. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Lim, Hojun [Sandia National Lab. (SNL-CA), Livermo↗

DOE OSTI2024

Improving Cost and Efficiency of the Scalable Solid Oxide Fuel Cells Power System

The objective of this project was to design and develop a 20kW range small-scale solid oxide fuel cells (SOFC) power system for applications such as data centers and commercial buildings. The original plan included a 5,000 hours demonstration and a Techno-Economic Analysis (TEA) which were dropped as part of project termination. The original project plan was to use a stack with a cross-flow cell design which had previously been tested for 500 hours at a community college in Malta, NY. However, it was decided to move to the advanced R-SOFC co-flow cell developed under Department of Energy Award DE-FE0031971. The advanced cell design has the advantage of a larger active area for the same manufacturing footprint which results in fewer required cells for the same stack power, hence a higher volumetric power density (kW/L) and lower cost per kW than the original cross-flow cell design. A full SOFC system Simulink model was developed and calibrated with testing data from a fuel cell stack and BOP (balance of plant) components. The simulation results from the calibrated model showed an acceptable match with the experimental data. A structural analysis conducted for various load scenarios indicated no high stress areas for all spatial directions. Major electrical system components were acquired, built and successfully tested. System sensors were verified and validated against controls. Safety checks, a diagnostic check, PID tuning, and control software commissioning tasks were also conducted. The power electronics prototype was delivered and trial testing completed. Balance of Plant component testing and simulation work was conducted to characterize Reformer-Heat Exchanger heat transfer and backpressure and reformer catalyst methane conversion and product selectivity. Simulations were conducted to design the Anode and Cathode fluid passages and size the air-air and fuel-fuel heat exchangers. A Burner operation map was created from test data and the Anode Gas Recirculation blower was tested to evaluate its durability. The SOFC system used a horizontal style design where components sit directly on a casting with a direct connection to the skid. This design has efficient packaging and a small footprint with approximate dimensions of 750 mm x 700 mm x 1700 mm. An SOFC system was built and successfully tested at the Malta, NY facility The system for over 500 hours under load of which over 300 hours was at full load of 20 kW.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Standardized Protocol for Real-Time APIs as Required by Title 23 CFR 680.116(c)

Improving the ability of drivers to easily locate working and available chargers is key to improving the public charging experience. Electric vehicle charging providers who are recipients of federal funds through the National Electric Vehicle Infrastructure (NEVI) Formula Program, Charging and Fueling Infrastructure (CFI) Discretionary Grant Program, and other funding programs as identified under Title 23 of the U.S. Code must deploy and maintain an application programming interface (API) to access information about charging stations they operate.1 This includes information about individual charging ports, pricing, and availability in accordance with the Federal Highway Administration’s National Electric Vehicle Infrastructure Standards and Requirements, 23 CFR 680.116(c), herein referred to as the minimum standards (Federal Highway Administration 2023). Specifically outlined in the minimum standards, states and other designated recipients are required to ensure that charging station information including location, connector type, power level, real-time status, and real-time price to charge are available free of charge to third-party software developers through an API. These requirements are intended to enable effective communication with consumers about available charging stations and help consumers make informed decisions about trip planning, including when and where to charge. This document provides a standardized protocol for how to structure data, data update frequency, and practices for making the data required to be shared via API usable for improving public transparency and the customer experience. These are recommendations only and do not modify the Federal Highway Administration’s minimum standards in any way.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Robust Dark Energy Constraints with the Dark Energy Spectroscopic Survey (Final Technical Report)

This project developed and applied advanced theoretical, computational, and data-analysis methodologies to extract robust and precise cosmological constraints from the Dark Energy Spectroscopic Instrument (DESI). The work focused on maximizing the scientific return of DESI through optimized survey strategy, novel higher-order clustering statistics, improved modeling of small-scale structure, and rigorous mitigation of observational systematics. Over the award period, the project made substantial contributions to DESI science planning, produced new methods for bispectrum and three-point correlation function analyses, advanced constraints on primordial non-Gaussianity, and delivered widely used software tools. The project also played a major role in training graduate students and a postdoctoral researcher who contributed directly to DESI key projects. The results have significantly enhanced the cosmological reach of DESI and provide a strong foundation for future surveys such as DESI-II and Stage-V experiments.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

Enabling Next Generation Reaction Injection Molding (RIM) for Lightweight Structures

Replacing metal components in trucks, trailers, and buses with lightweight polymer composites is challenging due to high temperatures and complex manufacturing. The Reaction Injection Molding (RIM) process using Dicyclopentadiene (DCPD) resin offers a solution by producing robust parts with excellent stiffness, impact strength, and resistance properties. Simulations are essential for optimizing this process, predicting defects, and improving quality. However, most commercial software is tailored for thermoplastics, requiring thermoset users to generate their own datasets. In this project, a material data card for DCPD was developed to perform RIM simulations. Design of Experiments (DOE) was used to identify key factors affecting filling, curing, and warpage, aiming to minimize cycle time and defects. The simulations explored varying injection gate parameters (size, location, number) and process conditions (mold/resin temperature, injection/curing pressure). Results showed that gate design significantly impacts filling behavior and defects. A single central gate provided balanced flow with fewer defects, while two corner gates led to more defects. Additionally, lower injection pressure increased filling time, while higher mold temperature accelerated curing but led to more warpage. This optimization framework aims to enhance DCPD part performance and promote sustainable manufacturing by reducing waste and energy consumption. This research has been performed in collaborations with McClarin Composites. The research outcome has been submitted to the Journal of Manufacturing Processes.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Overview of MARS: The Multimodal Advanced Radiography Station at the High-Flux Isotope Reactor

Neutron imaging is a powerful tool used for inspecting internal structures and studying macroscale particle dynamics. This work is performed at the Multimodal Advanced Radiography Station (MARS), which is the cold-neutron imaging beamline at the High-Flux Isotope Reactor at Oak Ridge National Laboratory. Herein is a summary of recent upgrades to instrumentation, software, and methods, driven by needs from the user community. Planned upgrades within the next decade are included that will significantly enhance instrument capability and performance.

Torres, James [ORNL] (ORCID:0000000289407610)↗

DOE OSTI2026

pathSQE : an automated workflow for single-crystal inelastic neutron scattering data processing and analysis

Inelastic neutron scattering (INS) experiments utilizing modern time-of-flight spectrometers enable the comprehensive mapping of the energy (E)- and momentum (Q)-resolved dynamical structure factor of single crystals, probing both the lattice and magnetic excitations. Yet, the large size and complexity of four-dimensional INS data are challenging current analysis workflows, often resulting in an underutilization of the measured information. To help address this issue, this paper introduces new software interfaced with the Mantid framework, pathSQE, designed to streamline the processing, analysis and interpretation of 4D single-crystal INS data. By automating key tasks such as 1D/2D slicing, symmetrization, Brillouin zone folding, data visualization, prioritization and filtering, and comparisons with simulations, pathSQE facilitates and accelerates INS data analysis workflows. Here, this paper outlines the features and implementation and provides several illustrations of the use of pathSQE on data collected on single crystals using direct-geometry time-of-flight spectrometers at the Spallation Neutron Source, including Ge, FeSi, MnO and SnS single-crystal measurements on the ARCS, HYSPEC and CNCS neutron spectrometers. Beyond streamlining post-experiment data processing, pathSQE establishes an automated and modular processing pipeline that could support future real-time experiment steering.

36 MATERIALS SCIENCE↗

DOE OSTI2024

AmeriFlux FLUXNET-1F US-xTL NEON Toolik (TOOL)

This is the AmeriFlux Management Project (AMP) created FLUXNET-1F version of the carbon flux data for the site US-xTL NEON Toolik (TOOL). This is the FLUXNET version of the carbon flux data for the site US-xTL NEON Toolik (TOOL) produced by applying the standard ONEFlux (1F) software. Site Description - The Toolik field site is located in a remote wilderness area at the Toolik Field Station which is on land managed by the Bureau of Land Management. The area is underlain by continuous permafrost, which exerts a major influence on hydrology and the distribution, structure, and function of terrestrial and aquatic ecosystems. Because of its location between the Brooks Range and the coastal plain, the vegetation and soils at TOOL are representative of much of the Alaskan foothills tundra. This terrestrial field site is collocated with NEON’s Toolik Lake aquatic site. The closest city, Fairbanks, Alaska is 400 miles away. The Dalton Highway (also known as the Haul Road or Pipeline Road), which traverses the middle of the state from Fairbanks to Prudhoe Bay, provides access to the area.

Network), NEON (National Ecological Observatory↗

DOE OSTI2026

CyTRICS™ Assessment Report: Whole Home Battery Applications

This report examines the software supply chain security posture of mobile applications developed for consumer whole-house battery and energy-management products. While these applications are not currently integrated with critical infrastructure, their growing role in connected energy domain spaces underscores the importance of understanding the external dependencies, permission structures, and runtime behaviors that could introduce systemic risk; particularly, if adoption expands into more critical environments.

25 ENERGY STORAGE↗

DOE OSTI2024

Focused Ion Beam Tomography of Alloy 617 Corroded in Molten Chloride Salt

Materials qualification of reactor structural materials is a critical step in rapid implementation of advanced nuclear reactor technologies, particularly to assess the corrosion performance in these designs. Accelerated qualification of reactor structural materials requires incorporating powerful computational toolsets, such as phase field modelling in the Multiphysics Object-Oriented Simulation Environment (MOOSE) framework, to predict the evolution of structural materials due to corrosion. Accordingly, computational toolsets will require experimental data generated at appropriate length scales to validate accuracy. Focused ion beam (FIB) provides a high degree of control over manipulation of materials for analytical purposes, including capturing data on the evolution in the microstructure and elemental composition of materials at the mesoscale, an appropriate length scale for phase field modelling of intergranular diffusion phenomena using the MOOSE framework. For instance, the FEI Helios G4 UX dual beam plasma FIB microscope at the Irradiated Materials Characterization Laboratory (IMCL) is capable of backscatter diffraction (EBSD) and energy-dispersive x-ray spectroscopy (EDS) documenting the evolution in the microstructure and elemental composition, respectively. The Helios can perform EDS and EBSD three-dimensionally (3D) using tomography, which is then combined using different software packages to visualize 3D volumes correlating elemental composition to microstructural data. The purpose of this investigation was to develop a streamlined characterization and data processing workflow for 3D tomography studies on the FEI Helios G4 plasma FIB. The investigation is segmented into three parts: 1) Optimizing the data collection workflow, 2) identifying appropriate data processing and visualization software (i.e. DREAM.3D, MIPAR, and VGStudioMax), and 3) establishing an infrastructure for public release. The optimization of the data collection workflow is in collaboration with members of the U220 department to setup formal training on the tomography operation of the G4, through ThermoFisher Scientific, and exploring DREAM.3D, MIPAR, and VGStudioMax data processing/visualization software packages. VGStudioMax currently demonstrates the most promise for future use. Optimization of the data collection and processing workflow is still ongoing. A collaboration with INL High Performance Computing (HPC) established an open-source license for expediting the public release of FIB tomography datasets through HPC. FIB tomography data generated by the G4 will provide comprehensive data for validating 3D phase field mesoscale modelling tools within the MOOSE framework for accelerated qualification of reactor structural materials.

Copeland-Johnson, Trishelle↗

DOE OSTI2025

MHD Analysis of Dual-Coolant Lead-Lithium Blanket for Spherical Tokamak Advanced Reactor

The tritium breeding blanket is vital for future fusion power plants, with the Spherical Tokamak Advanced Reactor (STAR) project highlighting the dual-coolant lead-lithium (DCLL) design. The DCLL blanket performs shielding, energy exhaust, and tritium breeding using a lead-lithium alloy , with lithium as the breeder and lead as the neutron multiplier. It also serves as the primary coolant, with helium providing supplemental cooling. Reduced-activation ferritic/martensitic steel is used for the blanket structure. Magnetohydrodynamic (MHD) phenomena influence the liquid metal flow in a magnetic field, affecting heat transfer in the breeder affected by energetic neutrons. Understanding key flow parameters in such conditions is critical for efficient DCLL design. This study uses three-dimensional thermofluid MHD analysis with ANSYS CFX software, modified at Princeton Plasma Physics Laboratory, to simulate high Hartmann flows. The neutronics code MCNP, coupled with plasma equilibrium, provides heat source distribution. In conclusion, we examine electromagnetic interactions in adjacent fluid domains and analyze the magnetic field’s impact on flow distribution in the inboard and outboard blanket layout, using detailed mesh generation for accurate results.

DCLL↗

DOE OSTI2024

Thermodynamics-informed latent space dynamics identification

This software showcases a latent space dynamics identification method, namely tLaSDI, that embeds the first and second principles of thermodynamics. The latent variables are learned through an autoencoder as a nonlinear dimension reduction model. The latent dynamics are constructed by a neural network-based model that precisely preserves certain structures for the thermodynamic laws through the GENERIC formalism. An abstract error estimate is established, which provides a new loss formulation involving the Jacobian computation of autoencoder. The autoencoder and the latent dynamics are simultaneously trained to minimize the new loss. Computational examples demonstrate the effectiveness of tLaSDI, which exhibits robust generalization ability, even in extrapolation. In addition, an intriguing correlation is empirically observed between a quantity from tLaSDI in the latent space and the behaviors of the full-state solution.

Cheung, Siu Wun↗

DOE OSTI2025

Contribution to Open Molecules Dataset (coordcomplexsampling)

The Open Molecules Dataset is a project led by external collaborators, focused on the production of a wide diversity of molecular chemistries. This project will include high-throughput electronic structure calculations on metal coordination complexes, biomolecules, and electrolytes. Solvation effects, conformers, chemical reactivity, and spin/charge sampling will be pursued for elements on the periodic table up to, but not including the actinides. We aim to contribute code related to sampling for transition metal complexes, in particular, and expand software capabilities related to other thrusts desired.

Taylor, Michael G. [Los Alamos National Laboratory↗

DOE OSTI2025

Evolution of the ATLAS event data model for the HL-LHC

The upcoming high-luminosity run of the CERN Large Hadron Collider (HL-LHC) will yield an unprecedented volume of data. In order to process this data, the ATLAS collaboration is evolving its offline software to be able to use heterogeneous resources such as graphical processing units (GPUs) and field-programmable gate arrays (FPGAs). To reduce conversion overheads, the event data model (EDM) should be compatible with the requirements of these resources. While the ATLAS EDM has long allowed representing data as a structure of arrays, further evolution of the EDM can enable more efficient sharing of data between CPU and GPU resources. Some of this work will be summarized here, including extensions to allow controlling how memory for event data is allocated and the implementation of jagged vectors.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials Using MALAMUTE

Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy, aims to develop and qualify additively-manufactured materials for nuclear applications. The key challenges to these efforts are the microstructural variabilities observed on the AM products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-through-put experimental and modeling techniques to accelerate the qualification efforts. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the AM process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture the microstructural variabilities is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning modeling capabilities to develop a digital twin for AM that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation for AM materials. The melting and subsequent solidification that occurs during the AM process is a complex phenomenon that requires multiscale multiphysics analysis. Idaho National Laboratory’s (INL) Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for AM materials in an efficient, reliable, and cost-effective way. This work package focuses on understanding the role of process variabilities on the various microstructural characteristics of the AM materials. Microstructures unique to AM materials, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. In fiscal year (FY) 24, we significantly advanced upon our work in the last fiscal year, both on physics-based and ML models. The alloy solidification model available in MOOSE has been extended to incorporate the thermodynamic properties and free energy relevant to 316SS. The model demonstrates the Cr segregation that occurs during solidifcation. It is demonstrated that rate of solidification and solute segregation is primarily influence by the cooling rate dictating the level of freezing. This work captures the microstructural variabilities at the subgrain level that are often missing in the part-scale models. With an aim to connect the microstructural evolution model to realistic process conditions, a reduced order model is developed for predicting the thermal conditions around meltpool from high-fidelity process simulations. Furthermore, machine learning approach is used to accelerate the temperature prediction during the AM process. In the following years, MALAMUTE will be used to connect different aspects of the models and quantitatively predict the microstructural evolution. The developed ML-based surrogate model will consider the process conditions as the input to predict the microstructural features in a cost-effective way. The generated microstructures can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work help identify the key microstructural features at the subgrain level that are significant in property/performance prediction of the AM products. This work will provide inputs to the large-scale process variability models to reevaluate and validate assumptions/simplifications made in the part-scale models. Furthermore, through active learning this work will help identify the data need from both modeling and experimental sides for development of a robust digital twin for AM.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Demonstrating Advanced Sensors for In-Situ Monitoring Towards Qualification of Nuclear Relevant Components

The U.S. Department of Energy’s Office of Nuclear Energy Advanced Materials and Manufacturing Technologies (AMMT) program is pursuing qualification of laser powder bed fusion (LPBF) components for nuclear applications. A major focus of this effort is the use of in situ process monitoring and machine learning–based tools to establish real-time quality assurance. The primary objective of this report is to identify and evaluate the most relevant in situ sensor systems for LPBF, and to document the deployment of these systems across platforms critical to the AMMT program. This work demonstrates how in situ monitoring can detect process anomalies, track geometry-dependent flaws, and identify limiting combinations of processing parameters—particularly those related to energy density and complex geometries (e.g., overhanging structures). To support this goal, a diverse suite of sensor modalities was evaluated across LPBF platforms, including visible and near-infrared (NIR) imaging, fringe projection profilometry, long-wavelength infrared (LWIR) thermography, and high-speed photodiode/pyrometry systems. These sensor streams were integrated with Peregrine, a machine-agnostic software platform that, among other capabilities, can generate real-time process anomaly classification. This report documents sensor deployments on multiple AMMT flagship platforms, including the Concept Laser M2 and Renishaw AM400/AM250 systems. Calibration builds with complex, flaw-prone geometries such as unsupported overhangs, stepped features, and thin walls, were used to evaluate how well Peregrine and its associated sensors could detect process anomalies and other instabilities under varied energy densities. It will be shown how Peregrine reliably identifies common process anomalies such as recoater streaking, superelevation, etc., and can be used in post-build analysis for anomaly spatial distributions throughout the build height to better understand the impact of geometry and processing parameter choice on the build. This work demonstrates measurable progress toward the vision that components can be born-qualified by establishing a real-time monitoring framework, identifying limiting process conditions, and laying the foundation for sensor fusion–enabled prediction pipelines that are scalable across platforms and applicable to nuclear-relevant components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Design Methods, Tools, and Data for Ceramic Solar Receivers

This report presents the development of tools and methods for evaluating the reliability and performance of ceramic materials in high temperature solar receivers. As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat requirements, current high temperature metallic materials face challenges in maintaining structural integrity. This report explores advanced ceramics as a promising alternative, given their superior high temperature strength and lower thermal expansion, compared to metals. To address the need for effective ceramic receiver design tools, this report integrates statistical failure models of ceramics into the existing srlife tool: an open-source software package designed to estimate the life of high temperature CSP components. These failure models account for the inherent variability and flaw distribution in ceramics, as well as the impact of subcritical crack growth under high temperature cyclic loads. The report also presents experimental data collected for a commercially available ceramic material, SiC, and details the process of estimating reliability model parameters from these data. A comparative design analysis is then performed between ceramic (SiC) and metallic (current nickel-based superalloys A740H and A282) receiver. This comparison demonstrates that SiC receivers can achieve service life exceeding 30 years under high incident heat flux conditions, compared to just a few years for metallic receivers.

14 SOLAR ENERGY↗