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DOE OSTI2025

Engineered Methylobacterium extorquens grows well on methoxylated aromatics due to its formaldehyde metabolism and stress response

ABSTRACT Lignin is a vast yet underutilized source of renewable energy. The microbial valorization of lignin is challenging due to the toxicity of its degradation intermediates, particularly formaldehyde. In this study, we engineeredMethylobacterium extorquensPA1 to metabolize lignin-derived methoxylated aromatics, vanillate (VA) and protocatechuate (PCA), by introducing thevanandpcagene clusters. Compared toPseudomonas putida,M. extorquensPA1 exhibited better formaldehyde detoxification, enabling robust growth on VA without accumulation of formaldehyde. Genetic analyses confirmed that formaldehyde oxidation and stress response systems, rather than C 1 assimilation, were important for VA metabolism. Additionally, VA and PCA were found to disrupt membrane potential, contributing to their inherent toxicity. Our findings establishM. extorquensPA1 as a promising chassis for lignin valorization and provide a framework for engineering formaldehyde-resistant microbial platforms. IMPORTANCE In developing biotechnological solutions for a circular economy, it is critical to valorize all parts of renewable resources, such as lignocellulose from vegetative components of agricultural crops and from bioenergy feedstocks. After chemical breakdown, the aromatics arising from lignin present significant challenges for use due to their toxicity. Here, we address one component of this challenge—the methoxy groups that get released as formaldehyde—and show that existing biotechnological platform organisms with strong formaldehyde metabolism, such asMethylobacterium extorquens, can be transformed into highly capable utilizers of methoxylated aromatics.

Microbiology↗

DOE OSTI2026

Genetic and metabolic drivers of membrane remodeling in Clostridium thermocellum under alcohol stress

Clostridium thermocellum is a leading candidate for consolidated bioprocessing of lignocellulosic biomass into biofuels due to its native cellulolytic capabilities. Beyond ethanol, C. thermocellum is being developed as a platform for producing higher-chain alcohols such as isobutanol and n-butanol. However, its physiological adaptations to alcohol stress remain poorly understood. Here, we investigate how C. thermocellum remodels its membrane lipid composition in response to exogenous ethanol, n-butanol, isobutanol, and butyrate. Exposure to linear alcohols such as n-butanol or to organic acids like butyrate increased the proportion of straight-chain fatty acids in the membrane at the expense of branched-chain species, whereas exposure to the branched alcohol isobutanol produced the opposite effect. Isotope tracer experiments demonstrated that C. thermocellum directly incorporates the carbon backbones of exogenous alcohols and acids into fatty acids, providing a mechanistic basis for these contrasting shifts. We show that the bifunctional aldehyde/alcohol dehydrogenase AdhE is essential for the assimilation of exogenous alcohols into fatty acids, acting through its oxidative activity by first oxidizing alcohols to aldehydes and then converting them to acyl-CoA intermediates. Deletion of the pyruvate:ferredoxin oxidoreductase isozyme pfor4 abolished branched-chain fatty acid synthesis, but supplementation with isobutanol restored production, indicating that Pfor4 substitutes for the canonical branched-chain α-keto acid dehydrogenase complex. These findings reveal two distinct routes for branched-chain fatty acid production in C. thermocellum: a Pfor4-dependent pathway from α-keto acid intermediates derived from amino acid synthesis, and an AdhE-dependent salvage pathway that assimilates exogenous branched-chain alcohols.

Acetivibrio thermocellus↗

DOE OSTI2024

Renal vascular control during normothermia and passive heat stress does not differ between healthy younger men and women

The mechanisms underlying greater heat-induced acute kidney injury risk in men versus women remain unknown. This study examined renal vascular control, including both vasodilatory (oral protein load) and vasoconstrictor (cold presser test) responses, during normothermia and heat stress and compared these responses between men and women. The results indicated that in both conditions neither renal vasodilatory nor vasoconstrictor responses differ between younger men and younger women.

Physiology↗

DOE OSTI2026

Cellular signaling within aged skeletal muscle reveals a dysregulated stress-induced remodeling response following volumetric muscle loss in female mice

Severe muscle trauma disrupts endogenous repair mechanisms, producing chronic functional deficits that are incompletely characterized in aged populations. This study investigated inflammatory, molecular, and physiological responses to volumetric muscle loss in young adult and aged female mice. Serum cytokine profiling revealed elevated baseline inflammation in aged animals and a blunted response to injury, with cytokines such as IL-6 increasing 4.4-fold in young versus 1.8-fold in aged mice at day 3 compared to baseline. By day 28 post-injury, histological analyses showed comparable reductions in muscle size and increases in fibrosis across ages. Despite these similar tissue-level outcomes, age-dependent differences emerged in downstream functional and molecular responses. Muscle functional testing demonstrated persistent force deficits independent of age but altered muscle relaxation kinetics in aged mouse muscles (p < 0.001), suggesting dysregulated excitation-contraction coupling. Additionally, mice displayed age-associated differences in post-injury limb loading. Global proteomic analyses further confirmed age-associated enrichment of complement and antigen-processing pathways alongside metabolic dysfunction (p < 0.05). Phosphoproteomic profiling revealed reduced basal kinase activity in the muscles of aged mice yet exaggerated injury-induced phosphorylation of Mapk1-associated phosphosites, indicating a dysregulated stress response. Collectively, these findings suggest that aged murine muscles function within a heightened inflammatory and perturbed kinase-signaling environment that may hinder the coordination of regenerative programs, underscoring the need for regenerative strategies that address age-specific molecular contexts to improve functional recovery across the lifespan.

Habing, Krista M.↗

DOE OSTI2024

Utah FORGE 5-2428: Coupled Investigation of Fracture Permeability Impact on Reservoir Stress and Seismic Slip - 2024 Annual Workshop Presentation

This is a presentation on the Coupled Investigation of Fracture Permeability Impact on Reservoir Stress and Seismic Slip Behavior by Lawrence Livermore National Laboratory, presented by Kayla Kroll. This presentation addresses testing and modelling related to the dependency of EGS production on sustained permeability and sufficient fluid flow through pre-existing or induced fractures in hot rock. This presentation was featured in the Utah FORGE R&D Annual Workshop on August 13, 2024.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Development and test of a large-aperture Nb3Sn cos-theta dipole coil with stress management

The stress-managed cos-theta (SMCT) coil is a new concept which was proposed and is being developed at Fermilab in the framework of US Magnet Development Program (US-MDP) for high-field and/or large-aperture accelerator magnets based on low-temperature and high-temperature superconductors. A 120-mm aperture two-layer Nb3Sn SMCT dipole coil has been developed at Fermilab to demonstrate and test the SMCT concept including coil design, fabrication technology and performance. The first SMCT demo coil was fabricated and assembled with 60-mm aperture Nb3Sn coil inside a dipole mirror configuration and tested separately and in series with the insert coil. This paper summarizes the design, parameters, and quench performance of the 120-mm aperture SMCT coil in a dipole mirror configuration.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Beyond Capacity Credits: Adaptive Stress Period Planning for Evolving Power Systems

This paper combines and applies concepts from several researchers to outline an alternative framework to plan power systems for resource adequacy needs, which we call Adaptive Stress Period Planning (ASPP). It first provides background information regarding least-cost planning objectives and the challenge of balancing an increasing need for model representation with computational intensity as power systems evolve in complexity. Next, it motivates the opportunity for a new paradigm by outlining challenges of frameworks in use today that rely on aggregate capacity heuristics (i.e., capacity credits and planning reserve margins). Subsequently, it lays out main process details of ASPP, which more directly represents spatial and temporal dynamics of power systems in a capacity expansion model with a process to adaptively select risk periods. The paper concludes with a summary of the approach, its benefits, and opportunities for future work.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Development and Test of a Large Aperture $Nb_3Sn$ Cos-Theta Dipole Coil with Stress Management

An innovative stress-management (SM) concept for cos-theta (CT) coils (SMCT coil concept) has been proposed at Fermilab. A large-aperture two-layer Nb3Sn SMCT dipole coil was designed and manufactured to validate and test the SM concept including coil design, fabrication technology, and performance. The first large-aperture SMCT coil (SMCT1) was fabricated and assembled with a small-aperture Nb3Sn coil inside a dipole mirror magnet. SMCT1 coil tests in a dipole mirror structure was performed in two configurations - SMCTM1a with only powered two-layer SMCT1 coil and SMCTM1b with the SMCT coil connected in series with an inner two-layer dipole coil. The test goals are to prove the SMCT coil concept in two-layer and four-layer mirror configurations; demonstrate that the magnet can reach the targeted quench current at the established preload; study magnet training, training memory after thermal cycle, ramp rate and temperature dependences of the magnet quench current; and test the SMCT1 coil quench protection parameters. This paper summarizes the SMCT1 coil design and parameters, the coil main fabrication steps, its assembly in the dipole mirror structure. The results of the SMCTM1a/b mirror test are presented and discussed.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Characterization of Stress-Corrosion-Cracking in Plutonium-Bearing Storage Containers

Introduction • The Integrated Surveillance Program, under the Department of Energy, is responsible for the periodic surveillance of storage containers containing plutonium-bearing materials. • The container-packages are designed to isolate the materials for 50 to 100 years with minimal surveillance. • During monitoring, corrosion-pitting and stress-corrosion-cracking (SCC) has been identified in some of the inner-cans near the weld regions. • SCC through wall penetration would result in an undesired increased risk of leakage. • An investigation is in progress to identify and characterize corrosion events to determine the prevalence of corrosion features and the likelihood of a throughwall breach. • Here, we discuss the characterization efforts carried out by Scanning Electron Microscopy (SEM), including 3D-tomography by Focused Ion Beam (FIB) methods.

Perez, Emmanuel E.↗

DOE OSTI2024

Enhancing the Harris and Crighton Particle-in-Cell (PIC) Stress Model with Bayesian Learning

This is ongoing work towards developing and integrating a Bayesian Neural Network (BNN) model for Particle-in-Cell (PIC) stress in MFiX legacy code.

Marayikkottu, Akhil V.↗

DOE OSTI2024

Effect of Thermal Aging on Microstructure and Stress Corrosion Cracking Behavior of an Alloy 152 1st Layer Butter Weldment

Nickel-based Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs are expected to operate for 40- 80 years. Likewise, water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is critical for the long-term performance of both existing and advanced nuclear power plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 152 weldments during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni2Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 152 under accelerated thermal aging. The materials studied involved three heats of Alloy 152 used to produce a dissimilar metal weld (DMW) joining an Alloy 690 plate to an Alloy 533 low alloy steel (LAS) plate, thermally aged at three different temperatures (370°C, 400°C and 450°C) for different durations up to 75,000h (equivalent to 60 years of reactor service). The microstructural characterization by means of synchrotron X-ray conducted in small, 0.2 mm - step line scans in the high-deformation regions of the weld root – covering areas spanning from the weld heat affected zone (HAZ) in Alloy 690 to the weld and weld butter on LAS - did not show evidence of LRO in any of the three Alloy 152 heats aged at 370°C and 450°C to an equivalent of 60 years of service. However, the first weld butter layer has high levels of deformation and is highly susceptible to SCC even in its non-aged condition. Nanohardness testing confirmed the extreme hardening with aging (ΔHV ≅ 100) at two locations within this weldment. In absence of LRO, hardening is suspected to be due to thermally-induced Cr carbide precipitation and coarsening. Testing in a primary water environment of the 1st layer of Alloy 152 weld butter aged at 370°C to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloys. Similarly, the SCC CGR response of the aged weld butter does not appear to show a deterioration in performance, however, the difficult-to-test weldment geometry may affect the test results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Closing the Loop Between In Situ Stress Complexity and EGS Fracture Complexity (Quarterly Research Performance Progress Report: Q3Y3)

As part of Task 1, we have started by testing our modeling capabilities by reproducing isothermal DFIT simulations presented in the literature. To start, we have been working towards adjusting numerical parameters to reproduce DFIT tests with different fracture geometries. Then, we have focused modeling the DFIT conducted at well 58-32 (cycle 4 in zone 2). Specifically, we have carefully analyzed the influence of the aperture-contact stress relationship and investigated how two different laws affect model results. We have also introduced thermal effects in the model and rerun the simulations to estimate the effect of cooling on the DFIT response. Due to the small amount of fluid injected during a DFIT, thermal effects seem to be moderate.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Photovoltaic Cable Jackets: A Comparison of Representative Products Using Combined-Accelerated Stress Testing [Slides]

Photovoltaic (PV) cables facilitate the distribution of electricity collected from modules to the energy grid. Durable cabling enables continuous operation of PV installations, whereas cables with a lifetime less than the modules must be replaced - reducing electricity generation and adding to the operating expense. This study primarily focusses on the aging of the key cable types using the combined-accelerated stress testing (C-AST) protocol. Representative cables for utility, building, and control/auxiliary applications were examined. Cable jacket materials examined include: polyolefin, polyethylene, polyamide, poly(vinyl chloride), chlorinated polyethylene, thermoplastic elastomer, and ethylene propylene diene monomer rubber. Specimen characterizations applied include: optical microscopy, mechanical profilometry, instrumented indentation, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), Fourier-transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). A variety of performance and durability characteristics were observed, depending on the base material, polymer formulation, and jacket color. The results from C-AST are analyzed and discussed relative to a recent industry survey on electronic balance of system components in addition to a recent study where similar cables were aged using steady state ultraviolet weathering (International Electrotechnical Commission Technical Specification 62788-7-2). Recommendations are made for the screening, industry qualification, and service life prediction of PV cable jackets.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Stress Testing the Standard Model of Particle Physics at the Large Hadron Collider

Final technical report for the DOE grant "Stress Testing the Standard Model of Particle Physics at the Large Hadron Collider", awarded to Prof. Aram Apyan at Brandeis University. The work focused on the ATLAS experiment at LHC. During the award period the group worked on ATLAS physics analyses, all-silicon Inner Tracker (ITk) detector upgrade, and reconstruction and calibration.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Mitigate Stress Corrosion Cracking (SCC) in High-strength Al Castings (CRADA 508)

Development of high strength, corrosion resistant, aluminum alloys is important to a number of industries, including automotive, aerospace, power, etc. Understanding how processing methods such as casting, chemistry, additives and recycle content affect an alloy’s microstructure and performance in real world environments is crucial to their implementation. One major concern is how the repeated exposure to saline solutions can be detrimental to the structural integrity of aluminum alloy components. This study was undertaken as a collaboration between Eck Industries and PNNL to investigate the stress corrosion cracking (SCC) and corrosion behavior of aluminum alloys. This work examines the SCC response of three different materials set. First is cast A206 Al alloy produced by three different casting techniques (i.e., permanent mold, and sand casting with and without chill) and with or without nano forming additives as potential grain refiners. The second materials set comprises Al alloy tubes extruded by PNNL’s ShAPE process and produced using raw material with three different ratios of twitch and pre-consumer Al 6061 scrap. Finally, the third materials set comprises two Al-Si-Mg-Fe alloys with controlled Si% and Fe% to mimic recycle grade Al alloys. The corrosion behavior of these materials was characterized using SCC testing and scanning electrochemical cell microscopy (SECCM) technique; mechanical behavior was characterized using tensile testing, and microstructure was characterized using optical and electron microscopy techniques. Of the A206 Al alloys, the samples with nano forming additives performed poorly compared to those without. The best SCC performance (i.e. least degradation in mechanical properties) was demonstrated by A206 alloy sand cast with chill while the permanent mold sample showed the worst SCC performance. The SECCM was performed on A206 alloy sand cast with chill to understand the effect of microstructure and determine the location-dependent corrosion properties on grain boundaries (GB) and inside grains (IG) on the sample. The corrosion potential and current measured on GB and IG at various points on the sample established that the GB locations are more cathodic and corrosive than the IG locations. Further work needs to be conducted to investigate the mechanisms behind the observed dependence of SCC on casting technique and nano forming additives. Among the ShAPE extruded tubes, SECCM data suggests the decreasing order of tendency to corrode as follows: 100% twitch > 75% twitch > 50% twitch. Finally, both variants of the Al-Si-Mg-Fe alloys showed a large volume fraction of Fe- and Si-containing intermetallics and additional work is needed to discern differences in their respective corrosion responses. In summary, correlating local electrochemical behavior (e.g. via SECCM) with micro/nanostructure, in conjunction with bulk mechanical behavior, can help identify the right fabrication method and alloy chemistry to minimize SCC issues in Al alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Optimization of a 123 mm Aperture Nb3Sn Dipole Coil with Stress Management

A 123 mm aperture Nb3Sn cos-theta (CT) dipole coil with stress management (SM) was developed at Fermilab to demonstrate and test the SM concept. Additive Manufacturing technology was used to produce the coil mandrel. Several changes were made to the SMCT coil design and technology based on the analysis of post-production and two cold tests of the first SMCT coil. This article describes the differences in coil design, fabrication steps, and final parameters of the second SMCT coil and its components.

Novitski, Igor [Fermilab]↗

DOE OSTI2025

Closing the Loop Between In Situ Stress Complexity and EGS Fracture Complexity: Quarterly Research Performance Progress Report

58 GEOSCIENCES↗

DOE OSTI2025

TARP Identifying Critical Thresholds for Acute Response of Plants and Ecosystems to Water Stress at Walker Branch Watershed, 2002-2005

This dataset contains data from a manipulative field study aimed at identifying critical thresholds for acute response of plants and ecosystems to water stress (TARP) that took place at Walker Branch Watershed in Oak Ridge, Tennessee from 2002-2005 (2002-06-20 to 2005-12-16). The study used understory tents for the removal of 100% of the growing-season throughfall and stem flow, to provide data on the impact of acute drought on mechanisms responsible for growth and mortality of deciduous forest canopy trees representative of common plant functional types (Liriodendron and Quercus). Through three years of manipulation (2003, 2004 and 2005; pretreatment measurements in 2002) various measures of tree response to surface moisture deficits were recorded including root and leaf traits, plant nonstructural carbohydrates status, hourly sapflow, basal area, and periodic observations of foliar photosynthesis and conductance. Additionally, environmental data such as air and soil temperature, soil water content, and soil matric potential were recorded. This dataset contains data 16 files in comma-separate (*.csv) format. Additional metadata are provided: 16 data dictionaries and a file-level metadata file in comma separate (*.csv) format and a user guide in PDF (*.pdf) format.

basal area↗