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DOE OSTI2025

Determination of Constraint-Independent Crack Tip Opening Angle for Stable Crack Growth in High-Strength Ductile Steels

The crack tip opening angle (CTOA) is one of fracture toughness parameters that has been used for decades in describing large stable crack growth in thin-walled aerospace structures under the low-constraint conditions. Recently, the pipeline industry has developed a growing interest in using the CTOA parameter to serve as the minimum required fracture toughness to arrest dynamic crack propagation in modern gas transmission pipelines made of high-strength ductile steel. To meet this industrial need, the CTOA test standard ASTM E3039 was therefore developed for measuring the constant critical CTOA. ASTM E3039 recommends a drop weight tearing test (DWTT) specimen with a shallow crack for standard CTOA testing, but its CTOA may depend on the low constraint condition of the DWTT specimen at the crack tip. Verifying the constraint independence of the DWTT-measured CTOA thus becomes indispensable for applying CTOA toughness to the running fracture control in the pipeline design. For this purpose, the present paper evaluates critical CTOA values in a set of fracture toughness tests on single-edge notched bend (SENB) specimens with shallow and deep cracks, based on four CTOA estimation models. Among these, the Ln(P)-LLD linear fit model is similar to that recommended by ASTM E3039 for CTOA calculation. Fracture test data for X80 pipeline steel and HY80 structural steel were considered in the CTOA evaluation. The results showed that the four CTOA models were able to determine a constraint independent CTOA value for stable crack growth in the SENB specimens. As a result, a single, reliable, constant CTOA value could be determined regardless of the specimen geometry or the crack-tip constraint conditions. Therefore, the CTOA measured using ASTM E3039 is constraint-independent and transferable to use in cases of actual cracks propagating in gas transmission pipelines.

36 MATERIALS SCIENCE↗

NASA NTRS2021

Mass Inferencing Model Creation And Deployment To Lunar Excavation Robot, RASSOR

NASA’s Regolith Advanced Surface Systems Operations Robot (RASSOR) Excavator is a teleoperated mobile robotic platform with a unique space regolith excavation capability. This research project developed functionality for inferencing regolith mass ingested during RASSOR operation, enhancing RASSOR’s ability to successfully complete ISRU missions. Radio wave propagation time to the Moon and back is ~2.56 seconds. Though teleoperation is possible with this delay, autonomous capability that enables RASSOR to plan and execute excavation missions intelligently and efficiently is preferred. To teleoperate or run autonomously, it is crucial for the quantity of regolith mass ingested by RASSOR to be available as a system state for efficient operation (e.g. knowledge of whether drums are full informs the task of highest priority, whether it be continuing to dig, or returning to a processing plant to offload regolith). A configurable data reduction and analysis pipeline was created to allow for straightforward incorporation of new data, such as that from lunar excavation, to improve model performance in new environments. Four distinct modeling approaches were employed in developing a mass inferencing approach that could work on RASSOR. All four models take in system states and output a mass prediction for each set of the robot’s bucket drums. Initial results from deployment to RASSOR and testing in a simulated lunar environment show that the models have <10% mean error during robot operation. Future work includes refinement of a model that estimates regolith mass in real-time during excavation as well as further testing of the developed models on the hardware.

ROS↗

DOE OSTI2025

Towards constraining cosmological parameters with SPT-3G observations of 25% of the sky

The South Pole Telescope (SPT), using its third-generation camera, SPT-3G, is conducting observations of the cosmic microwave background (CMB) in temperature and polarization across approximately 10 000 deg$^2$ of the sky at 95, 150, and 220 GHz. This comprehensive dataset should yield stringent constraints on cosmological parameters. In this work, we explore its potential to address the Hubble tension by forecasting constraints from temperature, polarization, and CMB lensing on early dark energy (EDE) and the variation in electron mass in spatially flat and curved universes. For this purpose, we investigate first whether analyzing the distinct SPT-3G observation fields independently, as opposed to as a single, unified region, results in a loss of information relevant to cosmological parameter estimation. We develop a realistic temperature and polarization likelihood pipeline capable of analyzing these fields in these two ways, and subsequently forecast constraints on cosmological parameters. Our findings indicate that any loss of constraining power from analyzing the fields separately is primarily concentrated at low multipoles ($\ell$ < 50) and the overall impact on the relative uncertainty on standard $Λ$ cold dark matter parameters is minimal (< 3%). Our forecasts suggest that SPT-3G data should improve by more than a factor of 90 and 190 the figure of merit of the EDE and the varying electron mass models, respectively, when combined with Planck data. The likelihood pipeline developed and used in this work is made publicly available online.

Vitrier, A. [Paris, Inst. Astrophys.]↗

DOE OSTI2024

Data Format and Descriptions for the Alabama Carbon Storage: Data Sharing and Engagement Project

The Alabama Carbon Storage: Data Sharing and Engagement (ACS-DSE) project seeks to develop publicly accessible geologic carbon storage models and data across the southern Gulf Coastal Plain of Alabama. The public online platform developed for this project will include geologic, geophysical, infrastructure, and other relevant datasets and geologic models of the study area. Datasets, model surfaces (e.g. structural contour maps, isolith maps, porosity maps), and infrastructure data (e.g. offshore pipelines, field boundaries) will be downloadable in commonly used file formats. The anticipated primary geologic datasets are well headers, formation tops, average reservoir properties, and core analyses; these will be available as commaseparated values (CSV) text files and MS Excel workbooks. Geophysical logs will be available in Log ASCII Standard (LAS) file format. Modeled surfaces, such as structure contour maps, will be available in ArcGIS formats and text files. Infrastructure data will be available as ArcGIS shapefiles. This document provides information on the data sources and attributes of the datasets.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

Large Language Model Integration for Knowledge Retrieval and Interaction for the DUNE Experiment

The Deep Underground Neutrino Experiment (DUNE) is a next-generation neutrino experiment that will generate an unprecedented volume of heterogeneous information-from documentation and technical notes to experimental data and reconstruction pipelines. Efficient knowledge retrieval and contextual understanding are increasingly critical for collaboration-wide productivity and onboarding. In this work, we present DUNE-GPT, a prototype framework that leverages large language models (LLMs) and retrieval-augmented generation (RAG) to enable natural-language querying of DUNE's internal documentation and technical resources. The system provides an intelligent interface for DUNE collaborators to interact with experiment-specific knowledge while maintaining data privacy and infrastructure compliance within Fermilab computing resources.

Rafique, A. [Argonne (main)]↗

DOE OSTI2024

CONSTRAINT-INDEPENDENT CONSTANT CTOA DETERMINATION FOR DUCTILE STABLE CRACK GROWTH

Crack tip opening angle (CTOA) has been used as a reliable fracture toughness parameter for decades to characterize stable ductile crack growth for thin-walled aerospace structures in the low-constraint conditions. Recently, the CTOA parameter was also applied to the pipeline industry, and a CTOA test standard ASTM E3039 was thus developed for testing a critical constant CTOA. Research showed that the constant CTOA can reasonably describe fracture toughness required to arrest a dynamic crack propagation for a modern gas pipeline. However, the CTOA fracture criterion requires constraint-independent CTOA toughness against stable ductile crack growth. ASTM E3039 recommends a drop weight tearing test (DWTT) specimen for CTOA testing. Since a shallow crack is used, DWTT measured CTOA may depend on constraint level at the crack tip. To understand if it is the case, this paper evaluates the critical CTOA for a set of fracture toughness tests on single edge notched bend (SENB) specimens with shallow and deep cracks based on four CTOA estimation models. In which, the Ln(P)-LLD linear fit model is similar to that used by ASTM E3039 in the CTOA calculation. Fracture test data for X80 pipeline steel and HY80 structural steel are considered in the CTOA evaluation. The results show that the four CTOA models can determine a crack size-independent constant CTOA over stable ductile crack growth for the SENB specimens. As a result, CTOA determined by ASTM E3039 is constraintindependent and transferable to use for an actual crack propagating in a gas pipeline.

Zhu, Xian-Kui↗

DOE OSTI2025

White Paper: Scalable Digital Twin Capabilities for Aging and Surveillance of Engineered Systems

This white paper presents a multi-year initiative to develop practical, secure, and scalable digital twin capabilities for engineered systems in aging and surveillance contexts—an approach pioneered at the National Nuclear Security Administration (NNSA) Lawrence Livermore National Laboratory (LLNL) that maps directly onto the needs and ambitions of the Navy for ship- and fleet-level digital twins. LLNL’s work in building part- and process-level digital twins for advanced manufacturing, with a vision to scale up to entire factory floors and, ultimately, enterprise-wide digital twins, offers an adaptable pathway for the Navy as it seeks to modernize lifecycle management, readiness, and predictive maintenance across ships and fleets. For our application, we integrate physics-based modeling with automated data ingestion, processing, and AI-driven calibration, creating hybrid models that are both interpretable and data responsive. We modernized legacy workflows, established centralized data infrastructure, automated experimental pipelines, and demonstrated end-to-end coupling of accelerated aging data with finite element simulations via optimization and surrogate modeling. The result is a generalizable framework that supports part-level digital twins today and lays the groundwork for future system-level twins suitable for Navy applications.

36 MATERIALS SCIENCE↗

NASA NTRS1997

A Parallel Pipelined Renderer for the Time-Varying Volume Data

This paper presents a strategy for efficiently rendering time-varying volume data sets on a distributed-memory parallel computer. Time-varying volume data take large storage space and visualizing them requires reading large files continuously or periodically throughout the course of the visualization process. Instead of using all the processors to collectively render one volume at a time, a pipelined rendering process is formed by partitioning processors into groups to render multiple volumes concurrently. In this way, the overall rendering time may be greatly reduced because the pipelined rendering tasks are overlapped with the I/O required to load each volume into a group of processors; moreover, parallelization overhead may be reduced as a result of partitioning the processors. We modify an existing parallel volume renderer to exploit various levels of rendering parallelism and to study how the partitioning of processors may lead to optimal rendering performance. Two factors which are important to the overall execution time are re-source utilization efficiency and pipeline startup latency. The optimal partitioning configuration is the one that balances these two factors. Tests on Intel Paragon computers show that in general optimal partitionings do exist for a given rendering task and result in 40-50% saving in overall rendering time.

Chiueh, Tzi-Cker↗

DOE OSTI2024

Accelerate microstructure evolution simulation using graph neural networks with adaptive spatiotemporal resolution

Abstract Surrogate models driven by sizeable datasets and scientific machine-learning methods have emerged as an attractive microstructure simulation tool with the potential to deliver predictive microstructure evolution dynamics with huge savings in computational costs. Taking 2D and 3D grain growth simulations as an example, we present a completely overhauled computational framework based on graph neural networks with not only excellent agreement to both the ground truth phase-field methods and theoretical predictions, but enhanced accuracy and efficiency compared to previous works based on convolutional neural networks. These improvements can be attributed to the graph representation, both improved predictive power and a more flexible data structure amenable to adaptive mesh refinement. As the simulated microstructures coarsen, our method can adaptively adopt remeshed grids and larger timesteps to achieve further speedup. The data-to-model pipeline with training procedures together with the source codes are provided.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Cryptic cycling by electroactive bacterioplankton in Trout Bog Lake

The potential for extracellular electron transfer (EET) is a prevailing genomic feature of humic lake bacterioplankton. However, there has been little evidence for the substantial ecological contribution predicted by genetics. We hypothesized that anoxygenic phototrophic electrotrophs and accompanying heterotrophic electrogens cycle dissolved organic matter (DOM) between oxidized and reduced states. We predicted that such bacterioplankton would exhibit diel-scale oscillations due to the light dependency of photosynthesis. Using Trout Bog Lake in Wisconsin, USA, as our model ecosystem, we profiled the water column with depth-discrete metagenomic, physiochemical, and electrochemical analyses. We observed variation in oxidation reduction potential (ORP) in response to sunlight, initiating at depths populated by anoxygenic phototrophs with EET genes. We developed an automated buoy to measure electric current flow between many pairs of electrodes simultaneously, observing correlation in electron consumption to sunlight. Our results, combined with published metatranscriptomic analysis, indicate the occurrence of electron cycling between phototrophic oxidation (electrotrophic metabolism) by Chlorobium and anaerobic respiration (electrogenic metabolism) by Geothrix, involving DOM. We also repeatedly observed gradual seasonal increases in hypolimnion ORP throughout summer. These diel and seasonal patterns imply that electroactive DOM mediates the ecology of electroactive bacteria in lakes, controlling humic lake methane emissions.IMPORTANCEWe investigated the physical, chemical, and redox characteristics of a bog lake and electrodes hung therein to test the hypothesis that dissolved organic matter is being cycled between oxidized and reduced states by electroactive bacterioplankton powered by phototrophy. To do so, we performed field-based analyses on multiple timescales using both established and novel instrumentation. We paired these analyses with recently developed bioinformatics pipelines for metagenomics data to investigate genes that enable electroactive metabolism and accompanying metabolisms. Our results are consistent with our hypothesis and yet upend some of our other expectations. Our findings have implications for understanding greenhouse gas emissions from lakes, including electroactivity as an integral part of lake metabolism throughout more of the anoxic parts of lakes and for a longer portion of the summer than expected. Our results also give a sense of what electroactivity occurs at given depths and provide a strong basis for future studies.

carbon emissions↗

DOE OSTI2026

ML–Enabled FPGA Framework for Fast Quantum State Discrimination in Mid-Circuit Measurement Regimes

Accurate and low-latency quantum state discrimination is essential for protocols involving mid-circuit measurement (MCM) and conditional feed-forward. In superconducting quantum systems, conventional readout pipelines transfer measurement data to host processors for post-processing, introducing millisecond-scale delays that far exceed qubit coherence times. To overcome this bottleneck, we present an in-situ machine learning (ML) inference engine implemented on an FPGA for real-time quantum state discrimination. Our design performs inference directly on digitized readout signals with 40 ns latency, supports both qubit and qutrit readout, and enables conditional operations without host-side intervention. This capability is critical for MCM and for feedback-driven protocols such as quantum error correction. We validate the system on superconducting transmon hardware, demonstrating robust discrimination fidelity across multiple qubit and qutrit channels. We further demonstrate conditional qutrit logic driven by FPGA-resident classification, highlighting the potential of low-latency ML-on-FPGA control for NISQ applications and scalable fault-tolerant quantum computing.

Vora, Neel [Lawrence Berkeley National Laboratory ↗

DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

This Cooperative Research and Development Agreement (CRADA) between Oak Ridge National Laboratory (ORNL) and ZEISS Industrial Metrology has demonstrated the transformative potential of artificial intelligence (AI)-enabled x-ray computed tomography (XCT) to accelerate the qualification and certification of additively manufactured (AM) parts. At the core of this effort is Simurgh, an AI-powered XCT reconstruction framework jointly advanced by ORNL and ZEISS that integrates computer-aided design (CAD) models, physics-based simulations, and deep learning to overcome the long-standing challenges of metal artifact correction, long scan durations, and limited flaw detectability in dense and geometrically complex components. Simurgh enables high-throughput, high-quality 3D reconstruction from sparse and fast scans, which reduces XCT acquisition times by more than an order of magnitude and simultaneously improves defect detection limits by up to fourfold compared with industry-standard approaches. This capability reduces scan costs by more than 50%, lowers labor overhead, and makes XCT characterization economically viable for routine industrial use. By enabling reliable flaw detection in minutes rather than hours, Simurgh facilitates real-time feedback loops for process parameter optimization, which was highlighted in a recent npj Computational Materials (a Nature journal) issue. In the published study, more than 100 alloy coupons were characterized within a single day. This work represents a tenfold acceleration in the development of novel AM alloys and processes compared with conventional workflows. The ZEISS collaboration has also demonstrated the scalability of Simurgh to diverse application domains, including aerospace, nuclear, automotive, and biomedical components; in these applications, ensuring structural integrity is paramount. By drastically reducing barriers to XCT adoption, this partnership has laid the foundation for digital twins and data-driven certification pipelines and directly addressed bottlenecks in qualifying new materials and designs. Together, ORNL and ZEISS have shown that Simurgh advances the state of the art in nondestructive evaluation and aligns with the broader mission of enabling Industry 4.0 manufacturing ecosystems, in which intelligent, cost-effective, rapid quality assurance is integral to accelerating innovation and ensuring safety in critical applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

36 MATERIALS SCIENCE↗

DOE OSTI2025

Computationally Guided and Experimentally Validated Design of Custom Chelators for Critical Mineral Recovery

Selective, high throughput separation of target critical metals from complex environments such as fly ash leachates and mining process streams presents a significant challenge for economical production. Custom chelators and sorbents are an attractive technology for selective metal extraction, however it can be difficult to predict their performance, and significant experimental efforts are often required to develop chelating technologies. Here, we present a computational strategy focused on modelling chelator-metal binding interactions and benchmark these results versus experimental data. A computational pipeline combining forcefield, semiempirical, and meta-GGA methods with a thermodynamic framework optimized for error cancellation has been developed to predict binding energies of chelator complexes towards critical mineral recovery applications. This approach, originally validated on [2.2.2] cryptates binding mono- and divalent cations, demonstrated robust predictive capabilities with an R2 of 0.850 against experimental aqueous binding energies. The workflow includes metadynamics for exploring high-dimensional potential energy surfaces and a cluster-continuum model for accurate yet computationally efficient solvation modeling. Error cancellation between solvation energies of free and chelator-coordinated ions enables faster convergence, even with finite cluster sizes. Initial studies on the cryptates revealed consistent metal-ligand coordination patterns, with systematic variations influenced by ion size and charge, highlighting key structural features linked to binding selectivity. Further studies of a proprietary chelator have resulted in identification of previously unreported selectivity towards economically significant metals, which in-house experiments have confirmed, demonstrating the feasibility of this approach. By applying this methodology to new chelators targeting critical minerals such as lithium, cobalt, nickel and other strategic metals, we aim to accelerate the discovery of next-generation chelators for efficient recovery, recycling, and separation processes. This computational framework serves as the backbone of a high-throughput design pipeline tailored for sustainable resource utilization and may be applied to a wide range of systems to meet experimental needs.

computational materials↗

NASA NTRS1984

Optical systolic solutions of linear algebraic equations

The philosophy and data encoding possible in systolic array optical processor (SAOP) were reviewed. The multitude of linear algebraic operations achievable on this architecture is examined. These operations include such linear algebraic algorithms as: matrix-decomposition, direct and indirect solutions, implicit and explicit methods for partial differential equations, eigenvalue and eigenvector calculations, and singular value decomposition. This architecture can be utilized to realize general techniques for solving matrix linear and nonlinear algebraic equations, least mean square error solutions, FIR filters, and nested-loop algorithms for control engineering applications. The data flow and pipelining of operations, design of parallel algorithms and flexible architectures, application of these architectures to computationally intensive physical problems, error source modeling of optical processors, and matching of the computational needs of practical engineering problems to the capabilities of optical processors are emphasized.

Neuman, C. P.↗

NASA NTRS1988

Recursive least squares estimation and Kalman filtering by systolic arrays

One of the most promising new directions for high-throughput-rate problems is that based on systolic arrays. In this paper, using the matrix-decomposition approach, a systolic Kalman filter is formulated as a modified square-root information filter consisting of a whitening filter followed by a simple least-squares operation based on the systolic QR algorithm. By proper skewing of the input data, a fully pipelined time and measurement update systolic Kalman filter can be achieved with O(n squared) processing cells, resulting in a system throughput rate of O (n).

Chen, M. J.↗

NASA NTRS1990

Feasibility study, software design, layout and simulation of a two-dimensional fast Fourier transform machine for use in optical array interferometry

The NASA-Cornell Univ.-Worcester Polytechnic Institute Fast Fourier Transform (FFT) chip based on the architecture of the systolic FFT computation as presented by Boriakoff is implemented into an operating device design. The kernel of the system, a systolic inner product floating point processor, was designed to be assembled into a systolic network that would take incoming data streams in pipeline fashion and provide an FFT output at the same rate, word by word. It was thoroughly simulated for proper operation, and it has passed a comprehensive set of tests showing no operational errors. The black box specifications of the chip, which conform to the initial requirements of the design as specified by NASA, are given. The five subcells are described and their high level function description, logic diagrams, and simulation results are presented. Some modification of the Read Only Memory (ROM) design were made, since some errors were found in it. Because a four stage pipeline structure was used, simulating such a structure is more difficult than an ordinary structure. Simulation methods are discussed. Chip signal protocols and chip pinout are explained.

Boriakoff, Valentin↗

NASA NTRS1994

Telecommunications issues of intelligent database management for ground processing systems in the EOS era

Future NASA earth science missions, including the Earth Observing System (EOS), will be generating vast amounts of data that must be processed and stored at various locations around the world. Here we present a stepwise-refinement of the intelligent database management (IDM) of the distributed active archive center (DAAC - one of seven regionally-located EOSDIS archive sites) architecture, to showcase the telecommunications issues involved. We develop this architecture into a general overall design. We show that the current evolution of protocols is sufficient to support IDM at Gbps rates over large distances. We also show that network design can accommodate a flexible data ingestion storage pipeline and a user extraction and visualization engine, without interference between the two.

Touch, Joseph D.↗