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DOE OSTI2025

Fully implicit crystal plasticity models representing orientations with modified Rodrigues parameters

Here, this work describes a crystal plasticity formulation combining several mathematical, numerical, and implementation choices to produce a highly efficient model. Specifically, the key choices in the implementation are (1) representing orientations with modified Rodrigues parameters, (2) implementing a fully coupled implicit time integration for the elastic stretch, the crystal orientations, and the model internal variables, (3) implementing the model in the NEML2 constitutive modeling framework, based on PyTorch, to vectorize the calculations and port the computation to GPUs and other hardware accelerators, and (4) an exact implementation of the consistent tangent matrix, even for arbitrary coupling to other field variables beyond the displacements, like temperature, neutron fluence, etc. The first two features of the model are, to our knowledge, novel. The paper considers each of these choices individually as well as the final model as a whole. This includes a full description of modified Rodrigues parameters, their advantages over other representations of orientations, the mathematical formulae and tools required to implement a model with modified Rodrigues parameters, and a detailed description of the geometry of the space of modified Rodrigues parameters (in an appendix). It also includes a description of a fully implicit time integration scheme for the orientations and the advantages in representing orientations with modified Rodrigues parameters in implementing such a model. The work then assess, via numerical examples, the advantages of fully coupled implicit time integration versus more common decoupled and explicit time integration schemes. These studies demonstrate the computational advantages of fully coupled integration versus other time integration algorithms, though the performance of the competing models depends on the complexity of the underlying single crystal model. The study concludes by demonstrating that the choice of time integration method affects the sharpness of the predicted texture, with explicit methods for integrating the orientations overestimating texture sharpness and implicit methods underestimating texture sharpness.

Crystal plasticity↗

DOE OSTI2025

Uniform Field Electrode Generator

SAND2025-03788O Uniform Field Electrode Generator is a user-friendly tool designed to create uniform electric field electrodes, essential for high voltage applications. By generating electrodes with precise dimensions, it ensures a consistent electric field across their surfaces. This software is particularly beneficial for researchers and engineers working on projects like closing switches and studying power flow in advanced systems, such as the Z machine. Its unique approach simplifies the design process, making it accessible for users without technical expertise, while enhancing the efficiency and effectiveness of their electrical applications. 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.

Mason, Tyler [Sandia National Lab. (SNL-CA), Liver↗

DOE OSTI2026

Powered by dGen Webinar [Slides]

NLR's Powered By Webinar Series featuring NLR's dGen Modeling Tool. The Distributed Generation Market Demand (dGenTM) model simulates customer adoption of distributed energy resources for residential, commercial, and industrial entities in the United States or other countries through 2050. The model enables analysis at multiple geographic levels (national, state, and utility, or below) and offers sophistication in representation of decision-making regarding economic and behavioral considerations. Analysts have used dGen to answer questions about load forecasting and integrated resource planning, policy analysis, locational value of distributed energy resources, and more. dGen is open source, and various energy organizations - including independent system operators, regional transmission organizations, and the California Energy Commission - use the model internally.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Calculating topological properties of artificial graphene in B-field

SAND2025-03258O Calculating topological properties of artificial graphene in B-field is a user-friendly tool designed to analyze artificial graphene systems influenced by magnetic fields. It helps researchers understand the unique properties of these materials by calculating the local Chern marker, a key indicator of their behavior. With just one file, this software runs easily on any device with Matlab, making it accessible for scientists and engineers. It provides valuable insights into the electronic characteristics of artificial graphene, which supports advancements in material science and technology, paving the way for innovative applications in electronics and beyond. 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.

Spataru, Dan [Sandia National Lab. (SNL-CA), Liver↗

DOE OSTI2024

7th World Congress on Integrated Computational Materials Engineering (ICME 2023) (Final Technical Report)

Integrated Computational Materials Engineering (ICME) has received international attention due to its potential to shorten product development time, while lowering cost and improving design and manufacturing outcomes. ICME is an approach to designing materials solutions for specific applications that use computer modeling programs to predict the behavior of materials and integrate this information into the overall materials, processing, and manufacturing design cycle. The 7th World Congress on Integrated Computational Materials Engineering (ICME 2023) was held in Orlando, Florida from May 21–25, 2023 with the goal to convene stakeholders from across all areas of modeling and simulation, experimental specialization, and design, as well as from across academia, government, and industry, to address ICME tools and techniques and their integration, as well as to examine their application in engineering. This atmosphere facilitated rich interactions between the experimentalists, modelers, and computational and design, from academia, government, and industry, to discuss ICME tools and techniques and their application in engineering.

36 MATERIALS SCIENCE↗

DOE OSTI2025

A Mass Conservation Relaxed (MCR) LSTM Model for Streamflow Simulation Across CONUS

The recent development of the physics-aware Mass-Conserving Long Short-Term Memory network (MC-LSTM) provides an alternative to other data-driven Deep Learning (DL) models in hydrology. Mass-Conserving Long Short-Term Memory incorporates mass conservation directly into the LSTM architecture. Despite the theoretical advancements, studies have reported a surprisingly limited performance of the MC-LSTM in streamflow simulation. We hypothesize that such a limitation is due to the unrealistic mass conservation scheme in MC-LSTM, which overlooks unobserved incoming water fluxes beyond precipitation. As an attempt to verify this hypothesis, we propose a Mass Conservation Relaxed LSTM (MCR-LSTM), which incorporates a bi-directional mass relaxation (MR) component to account for potential incoming water fluxes beyond precipitation. We train and test the proposed MCR-LSTM model across 531 watersheds in the contiguous United States (CONUS) against three baseline models: the Sacramento Soil Moisture Accounting, LSTM, and MC-LSTM. Our results show that MCR-LSTM outperforms MC-LSTM despite its underperformance compared to LSTM. Specifically, MCR-LSTM's advantage over MC-LSTM is mainly seen in the Plains and Western U.S., where the newly incorporated MR component better simulates water loss and suggests the likely existence of additional incoming water fluxes beyond precipitation, respectively. The novelty and contribution of this study are twofold: firstly, it introduces an alternative physics-aware DL tool (i.e., MCR-LSTM) in hydrology with higher accuracy in specific regions compared to MC-LSTM. Secondly, it provides a diagnosis of regions where strict, precipitation-based mass conservation constraints may be unrealistic in streamflow simulation.

deep learning↗

DOE OSTI2024

Workflows Community Summit 2024: Future Trends and Challenges in Scientific Workflows

The 2024 Workflows Community Summit report presents the outcomes of a three-day international gathering that brought together 109 experts from 18 countries to discuss future trends and challenges in scientific workflows. The summit focused on six key areas: time-sensitive workflows, convergence of AI and HPC workflows, multi-facility workflows, heterogeneous HPC environments, user experience and interfaces, and FAIR computational workflows. Discussions highlighted emerging challenges such as integrating AI with traditional HPC, managing workflows across diverse facilities, addressing heterogeneity in computing environments, and ensuring workflows are findable, accessible, interoperable, and reusable (FAIR). The report outlines recent advances, ongoing challenges, and provides recommendations for each topic area, emphasizing the need for standardization, improved interoperability, and the development of more sophisticated tools and frameworks to support the evolving landscape of scientific workflows in the era of exascale computing and AI integration.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

SPAROW: Stochastic Programming and Related Optimization Workflows

SAND2026-16703O SPAROW: Stochastic Programming and Related Optimization Workflows is a Python library tool that facilitates the development and solution of stochastic programming problems. It provides a user-friendly class structure for defining stochastic programs through scenario-based representations of uncertainties. SPAROW incorporates multiple optimization strategies, including integer programming with all scenarios, progressive hedging, Benders decomposition, and Snoglode, a novel technique developed by Carnegie Mellon University. It also features interfaces to external solvers and functions that are commonly used in analysis workflows, making it applicable to a wide range of scientific and engineering design challenges, particularly in power grid planning. 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.

Hart, William [Sandia National Lab. (SNL-NM), Albu↗

DOE OSTI2024

Application of quantitative risk assessment to address stakeholder questions in geologic carbon storage

Ambitious international greenhouse gas emissions reduction targets demand a rapid transformation to a low-carbon economy. This transformation includes the accelerated adoption of carbon dioxide (CO2) capture and storage (CCS) technology. However, as with any large-scale engineering enterprise, the widespread commercial-scale deployment of geologic carbon storage (GCS) raises important questions about technology and cost-effectiveness, safety, environmental risk, and long-term liability. Effectively assessing and managing risks and liability associated with GCS projects is a key technical need throughout the project life cycle-from site selection and permitting to monitoring design, operational risk management, and post-operational site closure. This presentation highlights recent advancements in tools for quantitative risk assessment, being developed by the National Risk Assessment Partnership (NRAP). NRAP is a multi-year, multinational laboratory research collaboration sponsored by the U.S. Department of Energy's Office of Fossil Energy and Carbon Management. Our focus will be on these tools' applications in addressing critical stakeholder questions related to supporting permitting to ensure secure and environmentally protective storage; designing effective and efficient monitoring plans; evaluating the effectiveness of remedial actions and risk management alternatives; and informing liability assessment and investment decisions. This paper will detail the key functionality of NRAP’s Open-Source Integrated Assessment Model (NRAP-Open-IAM), a computational framework for assessing leakage risk and containment assurance. This model features streamlined workflows for calculating leakage risk profiles, delineating risk-based area of review, and assessing contingency plans and post-injection site care requirements. ORION is an open-source, observation-based ensemble forecasting toolkit to help operators assess the seismic hazard at a carbon storage site. The State of Stress Analysis Tool (SOSAT), designed to assess subsurface stress conditions and evaluate geomechanical risk resulting from CO2 injection in an area of interest will also be presented. We will also introduce a prototype model to evaluate storage project costs and liability associated with risk management. The Technoeconomic and Liability Evaluation for Storage (TALES) model uses results from forecasts of leakage and induced seismicity risk to estimate the lifecycle cost of managing risk. Finally, a preliminary example of how the NRAP Risk-based Adaptive Monitoring Plan (RAMP) tool can be used to design efficient and effective site monitoring plans and estimate the detectability of fluid leakage will be provided. The relevance of these tools for addressing key stakeholder questions amidst uncertainty will be emphasized.

decision support↗

DOE OSTI2025

Radiation portal monitor data file format for comprehensive background radiation monitoring

Radiation portal monitors (RPMs) are widely used at border security checkpoints to detect the presence of radioactive materials in people, vehicles, and cargo. Typically, RPM detection systems consist of two pillars equipped with gamma and neutron detectors. To improve detection efficiency, RPMs employ techniques such as a limited energy window, dynamic alarm thresholds, and lead shielding. However, without continuous monitoring of background radiation, signal interpretation can be compromised, because environmental factors and mechanical failures can cause fluctuations. Here, we introduce a daily file format that logs gamma background and neutron background radiation levels continuously over a 24 h period; this format is different from traditional formats that record data only when the RPM is active or occupied. The approach enables RPM operators and analysts to (1) identify and diagnose malfunctioning components, (2) adjust system settings to account for dynamic environmental factors, and (3) use the recorded data to characterize outer space phenomena. Continuous background reporting is essential for identifying issues such as faulty connections, voltage divider failures, and errors in background updates. Continuous background reporting also enables the detection of external influences, including nearby X-ray scanners, temperature fluctuations, rainfall, cosmic radiation, and lunar phase changes. These data files are designed to be easily evaluated and parsed using common tools, and a quick review by an expert is often sufficient for problem diagnosis. We anticipate that continuous background radiation monitoring and these new strategies will significantly improve the accuracy and reliability of RPM systems, reducing the rate of false alarms and enhancing overall system performance.

Background radiation monitoring↗

DOE OSTI2024

NSTX-U National Research Program: White Paper in Response to Call from FESAC Sub-Committee

Both scientific and technical innovation is needed for the realization of an attractive engineering solution for a timely and cost-effective Pilot Plant, the design and construction of which is the overarching recommendation of the FESAC Long Range Plan, and the 2021 NASEM Pilot Plant reports, which underpin the Bold Decadal Vision. The two most significant plasma physics gaps to close for a Compact Pilot Plant (CPP) are core confinement improvement and heat flux mitigation, neither of which have been closed in an integrated fashion for any planned fusion power production device. High core confinement and stability are essential for producing majority self-driven plasmas in CPPs with reduced size and auxiliary heating power requirements, with an improvement in confinement being the major driver for cost reduction of a CPP. The National Spherical Tokamak Experiment - Upgrade (NSTX-U) is a unique low aspect ratio research facility that will address the fundamental challenge of developing the science and technology basis for a CPP design that integrates high core and edge confinement with the ability to mitigate very high incident heat fluxes. NSTX-U capabilities will enable the high performance, already achieved on NSTX, to extend into physics regimes much closer to those anticipated in Spherical Tokamak (ST)-based CPPs. These confinement and stability properties will be assessed by a full complement of diagnostics and analysis tools, which will also aid in the development of the underlying theory and predictive models needed for further optimization. Both conventional and transformative heat flux mitigation methods, such as liquid lithium plasma-facing components, will be developed and tested in-situ in NSTX-U at incident heat fluxes of ~100 MW/m 2 , and will inform plans and reduce risk for a subsequent major upgrade to the device to fully heated, high-Z wall and full liquid lithium divertor capability, a technology that potentially could then be implemented on any magnetic confinement device at any aspect ratio. NSTX-U research is fully complementary to programs performed on other STs, nationally and internationally. Furthermore, NSTX-U research has a direct connection to the private sector by informing design choices for future power production facilities being developed by these companies. The NSTX-U program will operate as a national User Facility, with collaborating researchers, engineers, and graduate students from 19 outside institutions, and open to participation and experiments led by researchers from both public and private entities. The research program will advance workforce development through training of young scientists, engineers, and technicians, and it will also serve for further diagnostic innovation, especially for high heat flux and high-Z wall environments, and implementation of advanced artificial intelligence (AI) for plasma and heat flux control.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

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 OSTI2025

Conjugate Heat Transfer Modeling of Salt-Filled Fuel Pins for Stable Salt Reactor Safety Analysis

The Stable Salt Reactor (SSR) combines the proven structural design of light water reactor fuel assemblies with the inherent safety and fuel-cycle advantages of molten salt technology. In its fast reactor configuration, the SSR utilizes recycled nuclear waste as fuel, sealed within narrow salt-filled fuel pins and cooled by a surrounding liquid salt coolant. Reliable transfer of heat from the molten fuel salt through the cladding to the external coolant is essential for both reactor safety and performance. This work investigates conjugate heat transfer (CHT) in the SSR’s salt-filled fuel pins using NekRS, a high-fidelity spectral element computational fluid dynamics (CFD) solver. The analyses capture internal natural convection within the molten fuel salt and external forced convection in the coolant, under steady-state and transient operating conditions. Parametric studies evaluate how variations in reactor power and coolant flow rate influence heat transfer distributions and system response. The high-fidelity CFD results are time-averaged and post-processed for direct comparison with moderate-fidelity Reynolds-averaged Navier–Stokes (RANS) models, and for the development of reduced-order models within the SAM system code. These validated models support fast-running safety analyses of normal and off-normal transients, improving predictive capability for key safety margins. By integrating advanced CFD with system-level safety tools, this study strengthens the modeling framework for SSR design, reduces uncertainty in molten salt CHT simulations, and accelerates the engineering and licensing of next-generation nuclear reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

SURVEILLANCE DETECTION FOR TRANSPORTATION OPERATIONS PERSONNEL TO PREVENT HIJACKING, THEFT, SABOTAGE, AND MALICIOUS SECURITY EVENTS DURING TRANSPORTING NUCLEAR MATERIAL

The secure transportation of high-consequence materials, including nuclear and radiological assets, is a critical global priority in the face of escalating terrorism, security threats, and violent protests targeting these operations. Effective surveillance detection—the ability to identify, assess, and respond to potential threats across a continuum of scenarios—is paramount in addressing these challenges. This paper outlines a phased, multi-tiered training program designed to strengthen the surveillance detection capabilities of organizations responsible for nuclear material transport. The proposed training program adopts a progressive approach, gradually increasing in technical complexity to provide participants with comprehensive knowledge and tools for implementing robust security strategies. It targets a wide spectrum of stakeholders, including competent authorities, regulators, inspectors, shippers, carriers, law enforcement, and emergency response personnel, equipping them to plan, evaluate, and safeguard nuclear material transportation effectively. Each phase of the program emphasizes distinct elements of the surveillance detection continuum and transport security, focusing on critical topics such as threat identification, adversary task timelines, protective methodologies, and attack mitigation strategies. The training framework is anchored in technical exchanges and scenario-driven courses that reflect real-world complexities and challenges. By addressing the surveillance detection continuum comprehensively—from early threat assessment to active countermeasures—the program reinforces global efforts to secure nuclear assets. It aligns with international security objectives and fosters a strong security culture within participating organizations, ensuring personnel are prepared to counter potential threats and maintain the safe, secure movement of these materials. Ultimately, this initiative aims to enhance preparedness, security, and response capabilities, supporting the global mission to safeguard high-consequence materials against evolving threats.

Zineddin, Dr. Z. [ORNL] (ORCID:0009000848740725)↗

DOE OSTI2026

4D insights into lithium-ion battery sidewall rupture during thermal runaway

Thermal runaway (TR), characterized by rapid exothermic reactions, presents a serious safety risk in lithium-ion batteries (LiBs). External triggers such as high temperatures, mechanical abuse, or internal short circuits (ISCs) can initiate TR, often resulting in sidewall rupture, which may escalate to catastrophic battery pack failure. In this study, we developed and applied high-speed synchrotron imaging techniques to investigate sidewall rupture mechanisms in LiBs subjected to different triggering scenarios. Using in situ 4D tomographic imaging, we visualized the dynamic evolution of sidewall rupture with high spatial and temporal resolution. The results revealed distinct failure behaviors linked to each trigger, underscoring the complex and condition-specific nature of sidewall breach and battery failure. These insights highlight the critical importance of implementing tailored safety strategies across diverse applications. Our findings demonstrate the powerful potential of synchrotron high-speed tomography as a diagnostic tool for advanced safety testing and cell qualification.

25 ENERGY STORAGE↗

DOE OSTI2025

Acetate as a Platform for Carbon-Negative Production of Renewable Fuels and Chemicals (Final Technical Report)

This project was an industrial-academic collaboration between experts at the University of Wisconsin-Madison, the University of Kentucky, and LanzaTech, a world leader in the use of gas fermentation to sustainably produce fuels and chemicals. The project developed technologies to create an integrated process for converting carbon dioxide and renewable hydrogen into molecules that can be blended with liquid transportation fuels or used in an array of chemical applications. The project was motivated by the Program Objectives of eliminating carbon dioxide release in the production of chemicals by integrating the unique and efficient capabilities of two microorganisms into a single process. The first microbe, an acetogen, produces acetate from carbon dioxide and hydrogen while the second microbe upgrades acetate from acetogen fermentation permeates to higher-value chemical products. The carbon dioxide released in the upgrading process is recycled internally to produce more acetate. As such, the process can be designed to operate with zero carbon dioxide release and net positive carbon dioxide capture. The process has the potential to provide an alternative paradigm to the current bioeconomy – one in which acetate is the primary energy carrier instead of sugars. Our process by-passes photosynthesis and the barriers created by biomass as primary chemical feedstock. As such, the process can be scaled to meet existing sources of carbon dioxide emissions and located anywhere renewable hydrogen can be provided. Our work developed microorganisms with optimized metabolism for producing acetate and other microorganisms with improved conversion of acetate to dodecanol and dodecyl-acetate. We developed synthetic biology tools for a promising non-model bacterium that could enhance metabolic engineering efforts to convert acetate to chemical products. We conducted protein engineering studies to improve the activity of key enzymes involved in our metabolic pathways. We conducted a full technoeconomic analysis that set technical targets for each strain to meet economic goals. We identified key technical barriers in our process and proposed strategies to overcome them.

09 BIOMASS FUELS↗

DOE OSTI2026

A decade of progress in understanding and managing legacy well integrity for geologic carbon storage

This study reviews a decade of research progress in legacy well integrity and risk management for geologic carbon storage (GCS) to commemorate the 20 th anniversary of the Intergovernmental Panel on Climate Change’s 2005 Special Report on Carbon Capture and Storage. In the past ten years, legacy well research has benefited from global efforts to constrain emissions from abandoned oil and gas wells, a continued focus on well materials performance in the presence of CO 2 -rich fluids, and practical experience gained through GCS implementation. Field measurements of abandoned well emissions show that leakage is not universal or catastrophic but forms a continuum of low-to-moderate fluxes that depend on isolation integrity and environmental attenuation. Materials research has constrained the conditions under which Portland cements exhibit self-sealing and non-sealing behaviors, and has identified the impact of geomechanical properties, non-uniform pathway apertures, multi-phase flow, and impurities in the CO 2 stream, on leakage pathways as important new areas for investigation. GCS projects at brownfield sites have inspired the creation of new workflows that integrate various tools and technologies to manage legacy well leakage risks. GCS implementation has also motivated a push towards scenario-based well modeling that directly informs permit applications. These advances inspire new research questions for the coming decade, particularly around the level of legacy well leakage risk that is environmentally acceptable and tolerable to stakeholders when sequestering millions of tonnes of CO 2 annually.

Carbon capture and storage↗

DOE OSTI2024

Tusqh

SAND2025-00675O Tusqh is a software tool that generates cubical meshes in 2D and 3D and computes the homology of these meshes using persistent homology. It includes a grid cell in the output if its volume-fraction is above a selectable threshold, estimated by sampling points within the cell. Tusqh incorporates anti-aliasing algorithms to mitigate grid orientation and scale effects. It is designed for creating finite element meshes for simulations and can be used in various applications such as heat diffusion, mechanical simulations, and computer graphics rendering. The software outputs meshes in an open format compatible with downstream software. 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.

SciDAC↗