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DOE OSTI2021

Preliminary Cryogenic Cold Test Results of the First 9-Cell LSF Shape Cavity

Following successful prototyping and testing of single- & 5-cell LSF shape cavities *, **, the first 9-cell LSF shape cavity LSF9-1 was successfully constructed using an innovative process at JLab with the in-house facilities. The cavity was then shipped to KEK for post-fabrication mechanical adjustment and ILC TDR style treatment and surface processing. Cold testing was carried out at the JLab VTA facility, instrumented with a suite of Kyoto instruments. Favorable values for the bath pressure detuning sensitivity and Lorentz force detuning coefficient were experimentally measured, validating the design improvement in cell stiffeners. Pass-band measurements indicate 4 out of 9 cells reaching gradient capability of > 45 MV/m, including 2 cells reaching 51 MV/m. Cornell OST detectors identified the cell and location responsible for the current hard quench limit. Multipacting-like barriers observed in end cells are investigated both analytically and numerically. The cavity was shipped to FNAL and received a light EP at the joint ANL/FNAL facility for further cold testing at Jlab. Two new 9-cell LSF cavities are being constructed including one made of large-grain niobium material.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Final Technical Report (FTR) - DE-EE0009084: Prefabricated Construction: Guidance, Technical Assistance, and Virtual Inspections

This final technical report summarizes research, case studies, and resources developed from 2020–2025 on prefabricated construction and remote virtual inspections. It documents key findings on benefits, challenges, and best practices, highlights examples from multiple states, and provides guidance to support wider adoption of these innovations in the construction sector.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2020

LBNF CMGC Delivery Method: ICE Process

The Construction Manager/General Contractor (CM/GC) delivery method is intended to benefit the design process, value engineering, risk mitigation, and schedule optimization while promoting construction and design innovation. This delivery method is particularly suited for complex projects that require significant consideration of contractor means and methods. Fermilab’s Far Site Conventional Facilities proceeded with a CM/GC delivery method to account for the unique conditions of excavating over 300,000 cubic yards of rock in tunnels and caverns that will be constructed approximately 5000-ft deep in the repurposed Homestake Mine in Lead, SD. The experiences of the Independent Cost Estimating (ICE) process are presented.

Pelletier, Douglas↗

DOE OSTI2021

Preliminary Cryogenic Cold Test Results of the First 9-Cell LSF Shape Cavity

Geng, Rong-Li↗

DOE OSTI2024

Extended dynamic mode decomposition for model reduction in fluid dynamics simulations

High computational cost and storage/memory requirements of fluid dynamics simulations constrain their usefulness as a predictive tool. Reduced-order models (ROMs) provide a viable solution to this challenge by extracting the key underlying dynamics of a complex system directly from data. We investigate the efficacy and robustness of an extended dynamic mode decomposition (xDMD) algorithm in constructing ROMs of three-dimensional cardiovascular computations. Focusing on the ROMs' accuracy in representation and interpolation, we relate these metrics to the truncation rank of singular value decomposition, which underpins xDMD and other approaches to ROM construction. Our key innovation is to relate the truncation rank to the singular values of the original flow problem. This result establishes a priori guidelines for the xDMD deployment and its likely success as a means of data compression and reconstruction of the system's dynamics from dominant spatiotemporal structures present in the data.

Mechanics↗

DOE OSTI2023

The Center for Performance and Design of Nuclear Waste Forms and Containers (WastePD) Energy Frontier Research Center (Final Report)

The DOE Office of Environmental Management is responsible for high level nuclear waste that must be safely isolated from humans and the environment for extremely long periods. The waste forms and containers are made of glass, ceramics, and metals. Verified safe disposal requires understanding the fundamental mechanisms of waste form degradation and the design of new waste forms with improved performance, which comprise the goals of the Energy Frontier Research Center known as the Center for the Performance and Design of Nuclear Waste Forms and Containers, WastePD. WastePD was constructed to develop innovative approaches and solutions to those goals through the synergistic interactions of individuals who are experts in the degradation behavior, modeling, and design of glasses, ceramics and metal alloys. WastePD is the first center ever created to address this diverse group of materials in a comprehensive and coordinated manner. The science goals are grouped into three common topics: corrosion mechanisms via advanced characterization, environmental impacts, and materials design. Synergistic interactions in these areas were a key component of WastePD. The fundamental understanding of the degradation mechanisms of the waste forms and containers as well as the development of new materials with improved properties will allow DOE to prevent environmental contamination and to explore totally new repository concepts. WastePD was operational from August 2016 through July 2022, but the DOE support was drastically reduced for the last two years. This final technical report covers the full period of performance. However, much of what was accomplished in the first four years is nicely summarized in a review paper published in 2021, which is appended to this report. Therefore, this final report focuses on the technical findings from the last two years of WastePD activities. Considerable progress was made in the areas of a) the environmental and compositional impacts on the corrosion of borosilicate and aluminosilicate glasses, b) the mechanism of glass corrosion and the structure and evolution of the surface alteration layer, c) the effects of environment and composition on the corrosion of pyrochlore, perovskite, hollandite, and other oxide ceramics, d) the corrosion mechanism of multi-principal element metallic alloys, and e) a new framework for understanding the pitting corrosion of metals.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Eco-Friendly High-Performance Carbon Building Material Development from Coal

The development of eco-friendly high-performance building materials based on coal-derived materials is greatly beneficial for promoting environmental sustainability and the coal industry. This project focused on advancing technology to create innovative and scalable construction materials from two domestic sources: (1) coal-derived pyrolyzed char (PC), and (2) solvent-extracted coal deposit, extracts, and residue (CDER). It aimed to simultaneously develop and produce two types of coal-derived building products: (1) char-based concrete bricks (CCB) for wall construction in buildings, and (2) carbon-based structural units (CSU) intended as alternatives to traditional wood, concrete, or steel framing structures. The project team has successfully developed methods for manufacturing CCB samples. Extensive experiments were conducted to assess various manufacturing techniques for these samples. This included measuring their physical properties such as thermal conductivity (ranging from 0.26 to 0.38 W/mK) and bulk density (ranging from 0.85 to 1.15 g/cm 3 ), along with their mechanical properties (e.g., compressive strength ranging from 14 to 16 MPa at 28 days) for samples with a PC composition of 70%. Quality assurance and quality control tests, focusing on density and compressive strength, were also performed on samples selected randomly from pilot-scale production, and cured for a long term (over three months). The average long-term compressive strength of two randomly selected CCB samples was measured as 15.1 MPa, which was higher than the required target strength of 14 MPa. This indicates that the manufactured CCB samples from the preliminary pilot scale production run have good quality control and long-term strength performance.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Digital Miniature Cathode Ray Magnetometer

In this study, we introduce the concept and construction of an innovative Digital Miniature Cathode Ray Magnetometer designed for the precise detection of magnetic fields. This device addresses several limitations inherent to magnetic probes such as D.C. offset, nonlinearity, temperature drift, sensor aging, and the need for frequent recalibration, while capable of operating in a wide range of magnetic fields. The core principle of this device involves the utilization of a charged particle beam as the sensitivity medium. The system leverages the interaction of an electron beam with a scintillator material, which then emits visible light that is captured by an imager. The emitted scintillation light is captured by a CMOS sensor. This sensor not only records the scintillation light but also accurately determines the position of the electron beam, providing invaluable spatial information crucial for magnetic field mapping. The key innovation lies in the combination of electron beam projection, CMOS imager scintillation-based detection, and digital image signal processing. By employing this synergy, the magnetometer achieves remarkable accuracy, sensitivity and dynamic range. The precise position registration enabled by the CMOS sensor further enhances the device’s utility in capturing complex magnetic field patterns, allowing for 2D field mapping. In this work, the optimization of the probe’s performance is tailored for applications related to the characterization of insertion devices in light sources, including undulators.

Turqueti, Marcos↗

DOE OSTI2024

From biowaste to BioPave: Biological pathways for sequestration of anthropogenic CO 2 and enhancing durability of roadway infrastructures

Biomass-derived bio-oils are emerging as sustainable, low-carbon alternatives for construction materials, particularly in innovative pavement applications, 'BioPave'. Here, this study evaluates bio-oils from various sources, including algae and wastewater biomass, revealing variations in carbon, nitrogen, and sulfur contents, along with viscosity. We focused on their application in outdoor construction, assessing their resistance to thermal and solar radiation, and moisture. The study also examines their interaction with siliceous surfaces and their influence on asphalt adhesion in BioPave systems under moisture conditions. Laboratory experiments and computational modeling demonstrated molecular composition significantly influenced bio-oils' responses to thermal and UV exposure. Bio-oils rich in polar groups showed hardening upon thermal treatment, while those with higher concentrations of saturated aliphatics remained more stable. Furthermore, our findings highlight the significance of dosage control in maximizing beneficial effects of bio-oils in intermolecular interactions at bitumen-aggregate interface in BioPave applications. These findings offer insights into the potential of bio-oils in sustainable construction and the need for dosage control to optimize pavement performance.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2022

The Future of Building Science Education with the U.S. Department of Energy Solar Decathlon: Preprint

Experience the future of Building Science Education with the U.S. Department of Energy Solar Decathlon, from community-focused designs to real-life innovative zero energy buildings constructed by students. In this paper, we will introduce the Solar Decathlon programs and a reimagined Building Science Education curriculum that is transforming education to inspire future building design professionals and bring sustainable, equitable design and construction strategies to the real world. The Solar Decathlon is a collegiate-level building design competition that challenges students in 10 Contests, from embodied environmental impact to affordability and resilience. We will cover the structure of the competition and its two Challenges - the Build Challenge and the Design Challenge - as well as additional programs that impact all aspects of the buildings industry. These programs include the Solar Decathlon Building Science Education course, a free online video series that provides students and working professionals with building science fundamentals; the Design Partners Program, which connects innovative student design teams and local building owners seeking low-risk, low-cost opportunities to incorporate sustainable design alternatives into their building portfolio; and Solar Decathlon Pro, a program piloted in 2021 that brings Solar Decathlon resources to design professionals. The Solar Decathlon's effective approach to bringing real-world solutions to building science empowers future professionals to do impactful work.

buildings↗

DOE OSTI2025

Futureproofing through 2035 for the AI and HPC Power Density Trend

HPC and AI are businesses necessitating growth for providing performance improvement with increased power and cooling. As HPC and AI computers and their supporting facilities approach utility scale with a frequency of technology innovation outpacing utility and construction timelines, understanding and designing for this trend has become critical. This paper will provide historical trend data for facilities and compute racks, relate power trend data to cooling technology capabilities, and reason through constraints impacting anticipated future power densities to aid the reader in futureproofing a facility’s power and cooling systems through the mid-2030’s.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Reimagining Heating, Ventilation, and Air Conditioning for New Manufactured Homes

Manufactured homes represent one of the most affordable paths to home ownership for American households, but minimum-efficiency equipment and poor-quality home installation can lead to excess energy use and high operating costs. Slipstream, with partners from the Florida Solar Energy Center (FSEC), Northwest Energy Works, and Washington State University, identified and tested manufactured home HVAC innovations targeted for new construction offering the most promising mix of improved energy performance and likelihood of industry uptake.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Track Seeding and Labelling with Embedded-space Graph Neural Networks

To address the unprecedented scale of HL-LHC data, the Exa.TrkX project is investigating a variety of machine learning approaches to particle track reconstruction. The most promising of these solutions, graph neural networks (GNN), process the event as a graph that connects track measurements (detector hits corresponding to nodes) with candidate line segments between the hits (corresponding to edges). Detector information can be associated with nodes and edges, enabling a GNN to propagate the embedded parameters around the graph and predict node-, edge- and graph-level observables. Previously, message-passing GNNs have shown success in predicting doublet likelihood, and we here report updates on the state-of-the-art architectures for this task. In addition, the Exa.TrkX project has investigated innovations in both graph construction, and embedded representations, in an effort to achieve fully learned end-to-end track finding. Hence, we present a suite of extensions to the original model, with encouraging results for hitgraph classification. In addition, we explore increased performance by constructing graphs from learned representations which contain non-linear metric structure, allowing for efficient clustering and neighborhood queries of data points. We demonstrate how this framework fits in with both traditional clustering pipelines, and GNN approaches. The embedded graphs feed into high-accuracy doublet and triplet classifiers, or can be used as an end-to-end track classifier by clustering in an embedded space. A set of post-processing methods improve performance with knowledge of the detector physics. Finally, we present numerical results on the TrackML particle tracking challenge dataset, where our framework shows favorable results in both seeding and track finding.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Perspectives on Potential Advanced Construction Technologies for Nuclear Energy

Advanced reactor technologies have attracted considerable financial support, catalyzing innovation in the nuclear energy landscape. These next generation reactors are designed with enhanced passive safety systems and the potential for cost reductions. As these advanced reactors approach technological maturity, their commercial success also requires focused examination and essential support. Economic assessments in the nuclear energy sector often emphasize construction costs and the risk of scheduling delays as primary contributors to deployment expenditures. Traditionally, vital elements of nuclear energy deployment including civil/structural engineering, design sophistication and automation have been either undervalued or postponed in the development cycles. Additionally, the nuclear industry’s collective experience in nuclear project execution has diminished over the past several decades due to the infrequency of new plant constructions. Hence, the National Reactor Innovation Center’s (NRIC) Advanced Construction Technology Initiative (ACTI) aims to reduce cost overruns and schedule slippages that have plagued the construction of nuclear power plant projects. With this initiative, NRIC is facilitating the development of advanced nuclear plant construction technologies and approaches through partnerships that would provide game-changing benefits to the construction of advanced nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

ADVANCED CONSTRUCTION TECHNOLOGY INITIATIVE (ACTI)

Advanced reactor technologies have attracted considerable financial support, catalyzing innovation in the nuclear energy landscape. These next generation reactors are designed with enhanced passive safety systems and the potential for cost reductions. As these advanced reactors approach technological maturity, their commercial success also requires focused examination and essential support. Economic assessments in the nuclear energy sector often emphasize construction costs and the risk of scheduling delays as primary contributors to deployment expenditures. Traditionally, vital elements of nuclear energy deployment including civil/structural engineering, design sophistication and automation have been either undervalued or postponed in the development cycles. Additionally, the nuclear industry’s collective experience in nuclear project execution has diminished over the past several decades due to the infrequency of new plant constructions. Hence, The National Reactor Innovation Center’s (NRIC) Advanced Construction Technology Initiative (ACTI) program aims to reduce cost overruns and schedule slippages that have plagued the construction of nuclear power plant projects. With this initiative, NRIC is facilitating the development of advanced nuclear plant construction technologies and approaches through partnerships that would provide game-changing benefits to the construction of advanced nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Phase I Summary of Management Activities - Advanced Construction Technology Initiative Project

As the end of the year is approached, it is essential to review the National Reactor Innovation Center (NRIC) management activities undertaken during the Advanced Construction Technology Initiative (ACTI) project. The ACTI project was launched to support a transformation in nuclear energy construction, management, and deployment costs, enabling nuclear energy to make important contributions to the energy systems of the future. This transformation will increase the confidence of investors, energy system planners, policymakers, and ultimately consumers in the capability of nuclear energy to meet future needs; thus, it represents a critical element of advanced nuclear energy system demonstration. Development and/or demonstration project(s) will consider regulatory requirements for commercial nuclear implementation and will incorporate strategies to develop regulator experience and review of the technology. GE Hitachi (GEH), a leading player in the nuclear industry that offers a range of products and services including nuclear reactor design, fuel supply, and decommissioning solutions, submitted a proposal for the ACTI project. GEH was awarded the contract for the first phase of the project.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Construction Methodology Transformation for the Benefit of Workforce Development

Construction is a key economic engine driving both national and global economies. While manual, onsite construction methods dominate the U.S. construction industry, a major shift towards offsite methods has been underway due to its efficiency, speed, and potential cost savings. The workforce necessary for offsite construction growth does not exist in its current form because of the focus on onsite methodologies and the lack of exposure to offsite building methods at all levels of a student’s learning journey. The growth of the U.S. construction industry and competitiveness in an increasingly global construction market over the coming decades can only be supported by a dramatic increase in the use of offsite methods, which requires ramping up workforce training for certain skillsets. The goal of Construction Methodology Transformation for the Benefit of Workforce Development was to understand the opportunities and barriers in both education and industry and to identify best practices for offering curriculum and training to educators, industry, and students that would support skills needed for careers in offsite construction. Our team proposed combining three offsite construction workforce development needs: content development, exposure and training, and job placement - under a single Platform model that would increase experience and career opportunities for students and help match them with potential industry members. Through our proposed solution we expected to see: developed offsite curriculum being utilized by educators and students; an increase in the identification of construction technology and offsite construction methods; an average increase in knowledge gain of at least 25% after participation in pilots; better equipped candidates who are prepared for jobs in offsite construction; and a beta workforce development platform that helps build more pathways for students looking for careers in offsite construction. The two pilots included almost 250 students and resulted in an average knowledge gain of 37 percent. Our research has identified areas of opportunity, for both education and industry to make collaborative training programs more efficient and successful. The chosen techniques for this program are extremely effective when both the school and factory have solid processes and cultures in place to accept students into training programs. This project serves as an important stepping stone to industrywide collaboration to move workforce development for offsite construction forward across the country. With continued collaboration programs like this can provide much needed early exposure and training in offsite construction and we can begin to fill important positions for the future of construction.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗