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DOE OSTI2026

Improved manufacturability of vacuum thermoforming molds by segmentation

Thin polymer shell components used in consumer goods, the automotive industry, and marine applications are often produced by thermoforming. Depending on the quantity of parts, molding processes can increase throughput significantly when compared to processes such as milling or additive manufacturing. One disadvantage to mold-based manufacturing methods, however, is that molds must be produced to form the required geometry. Mold production is often complex and requires a large capital investment. For large-scale molding processes, mold production is sometimes complicated by the requirement for large working volume machine tools which are capable of machining the cavities to the appropriate tolerances for the selected molding process. Here, this paper focuses on a segmented design for a large draw ratio (>3:1 molded surface area to sheet surface area) thermoforming mold and a cost-benefit analysis of segmentation versus monolithic design. Discussion of the thermoforming tests are included. The primary goals were to improve manufacturability and reduce the overall cost of the mold.

Manufacturability↗

DOE OSTI2023

Magnetic levitation

A magnetic levitation system is described, including a first cylinder-shaped magnet; a second cylinder-shaped magnet coaxially aligned with the first cylinder-shaped magnet; and a first cavity coaxially aligned with the first cylinder-shaped magnet; wherein the surfaces of the like-poles of the first and second cylinder-shaped magnets are parallel to each other and face each other to result in a linear magnetic field between the first and the second magnets. Methods of using a magnetic levitation system for analyzing a diamagnetic or paramagnetic sample are also described.

Ge, Shencheng↗

DOE OSTI2023

Interpretable inverse-designed cavity for on-chip nonlinear photon pair generation

Inverse design is a powerful tool in wave physics for compact, high-performance devices. To date, applications in photonics have mostly been limited to linear systems and it has rarely been investigated or demonstrated in the nonlinear regime. In addition, the “black box” nature of inverse design techniques has hindered the understanding of optimized inverse-designed structures. We propose an inverse design method with interpretable results to enhance the efficiency of on-chip photon generation rate through nonlinear processes by controlling the effective phase-matching conditions. We fabricate and characterize a compact, inverse-designed device using a silicon-on-insulator platform that allows a spontaneous four-wave mixing process to generate photon pairs at a rate of 1.1 MHz with a coincidence to accidental ratio of 162. Our design method accounts for fabrication constraints and can be used for scalable quantum light sources in large-scale communication and computing applications.

42 ENGINEERING↗

DOE OSTI2020

Method and system for compact efficient laser architecture

A laser amplifier module having an enclosure includes an input window, a mirror optically coupled to the input window and disposed in a first plane, and a first amplifier head disposed along an optical amplification path adjacent a first end of the enclosure. The laser amplifier module also includes a second amplifier head disposed along the optical amplification path adjacent a second end of the enclosure and a cavity mirror disposed along the optical amplification path.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Selective acoustic control of photon-mediated qubit-qubit interactions

Quantum technologies such as quantum sensing, quantum imaging, quantum communications, and quantum computing rely on the ability to actively manipulate the quantum state of light and matter. Quantum emitters, such as color centers trapped in solids, are a useful platform for the realization of elementary building blocks (qubits) of quantum information systems. In particular, the modular nature of such solid-state devices opens up the possibility to connect them into quantum networks and create nonclassical states of light shared among many qubits. The function of a quantum network relies on efficient and controllable interactions among individual qubits. In this context, we present a scheme where optically active qubits of differing excitation energies are mutually coupled via a dispersive interaction with a shared mode of an optical cavity. This generally off-resonant interaction is prohibitive of direct exchange of information among the qubits. However, we propose a scheme in which by acoustically modulating the qubit excitation energies it is, in fact, possible to tune to resonance a preselected pair of qubits and thus open a communication channel between them. This method potentially enables fast (approximately nanoseconds) and parallelizable on-demand control of a large number of physical qubits. In this work, we develop an analytical and a numerical theoretical model demonstrating this principle and suggest feasible experimental scenarios to test the theoretical predictions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2024

Enhancing the Q-Factor of a Practical Qubit Niobium Three-Dimensional λ/4-Resonator Through Surface Treatment

Quantum computing stands as a revolutionary frontier in information technology, with the potential to solve complex problems far beyond the capacity of classical computers. At the heart of this disruptive innovation are qubits, forming the fundamental backbone of quantum computing. A leading-edge solution for constructing robust, enduring qubits involves embedding a Josephson junction within a high Q-factor, superconducting three-dimensional cavity. Further, our recent innovation lies in developing a uniquely optimized, quarter-wave resonator-based superconducting cavity, functioning at 6 GHz, specifically tailored for quantum computers. In this work, we elucidate our advancement towards elevating the Q-factor tenfold, an achievement made possible through the enhancement of machining precision, the application of rigorous postprocessing techniques—including mechanical, chemical, and surface treatments—as well as the refinement of our testing methods.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2025

Defect And Damage Characterization Of Additively Manufactured Titanium Alloy Ti-5553 Using Traditional Computed Tomography Volume Segmentation And Machine Learning Algorithms

The mechanical response of a component is affected by defects, such as porosity, arising from the laser powder bed fusion (LPBF) fabrication process. Thus, it is important to develop accurate and efficient inspection methods for identifying porosity. In this work, porosity identified in an X-ray computed tomography (XCT) volume of a Ti-5553 coupon was compared to pores identified in a serial sectioned volume that represented the ground truth. The porosity of the XCT scan was identified using contrast-based, ISO-based, and machine learning (ML) methods for segmentation. Large inherent porosity was easy to identify, but the ISO thresholding still struggled due to the intensity gradient resulting from both the beam hardening in XCT and the uneven lighting of the serial sectioning panels. Further, the results show that ML-based methods were better suited for identifying small pores and reducing the amount of false positives. Additionally, high strain-rate impact testing was done on some of the XCT samples as well as post-mortem XCT inspection, and the same suite of segmentation and quantification tools were used to identify the large spallation cavities. The comparison of porosity pre- and post-mortem provides insight on the influence of the LPBF porosity on the formation of spall cavities.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Tamper indicating seal

A system and method for detecting tampering with a seal is provided. A loop seal tamper indicating device includes a seal wire that may be passed through a secured item or container to form a loop with the free ends of the seal wire passing through a seal housing. A plunger body including an adhesive-filled cavity is inserted into the seal housing, such that a piston expresses the adhesive into the space between the seal housing and the plunger body. The adhesive may contain reflective particles and is cured to fix the particles and the adhesive in place. A reference image may be taken to record the unique identifier and reflective signature of the adhesive. Future validation images may be compared to the reference image to determine whether the reflective signature has changed, thus indicating that the seal has been tampered with.

42 ENGINEERING↗

DOE OSTI2022

Accelerated Lifetime Test of the SRF Dressed Cavity/Tuner System for LCLS II HE Project

The off-frequency detune method is being considered for application in the LCLS-II-HE superconducting linac to produce multi-energy electron beams for supporting multiple undulator lines simultaneously [1]. Design of the tuner has been changed to deliver roughly 3 times larger frequency tuning range. Working requirements for off-frequency operation (OFO) state that cavities be tuned at least twice a month. This specification requires the in-crease of the tuner longevity by 20 times compared with LCLS-II demands. Accelerated longevity tests of the LCLS-II HE dressed cavity with tuner were conducted at FNAL's HTS. Detail analysis of wearing and impacts on performances of the tuner's piezo and stepper motor actuators will be presented. Additionally, results of longevity testing of the dressed cavity bellow, when cooled down to 2 K and compressed by 2.6 mm for roughly 2000 cycles, will be presented.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

The Fermilab SSR1 and HB650 Synoptic and EPICS remote cryogenic control system

The 325MHz Single Spoke Resonator 1 (SSR1) Cryomodule (CM) has a 5.3-meter length, and it has 288-liter liquid helium @ 4.5K mode. The High Beta 650 MHz (HB650) CM contains six elliptical cavity cryomodules, has a 9.9-meter overall length and it has 530-liter liquid helium. The SSR1 and HB650 CM had been tested at Fermilab Cryomodule Test Facility (CMTF). Their cryogenic control system includes the Siemens Process Control System S7-400, Automation Direct DL205 PLC, and remote synoptic HMI/EPICS Phoebus GUI. This paper presents a method which has been successfully used by Fermilab PIP2 IT cryogenic remote on-line, real-time control systems.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

The influence of physical and algorithmic factors on simulated far-field waveforms and source–time functions of underground explosions using unsupervised machine learning

SUMMARY Characterizing explosion sources and differentiating between earthquake and underground explosions using distributed seismic networks becomes non-trivial when explosions are detonated in cavities or heterogeneous ground material. Moreover, there is little understanding of how changes in subsurface physical properties affect the far-field waveforms we record and use to infer information about the source. Simulations of underground explosions and the resultant ground motions can be a powerful tool to systematically explore how different subsurface properties affect far-field waveform features, but there are added variables that arise from how we choose to model the explosions that can confound interpretation. To assess how both subsurface properties and algorithmic choices affect the seismic wavefield and the estimated source functions, we ran a series of 2-D axisymmetric non-linear numerical explosion experiments and wave propagation simulations that explore a wide array of parameters. We then inverted the synthetic far-field waveform data using a linear inversion scheme to estimate source–time functions (STFs) for each simulation case. We applied principal component analysis (PCA), an unsupervised machine learning method, to both the far-field waveforms and STFs to identify the most important factors that control variance in the waveform data and differences between cases. For the far-field waveforms, the largest variance occurs in the shallower radial receiver channels in the 0–50 Hz frequency band. For the STFs, both peak amplitude and rise times across different frequencies contribute to the variance. We find that the ground equation of state (i.e. lithology and rheology) and the explosion emplacement conditions (i.e. tamped versus cavity) have the greatest effect on the variance of the far-field waveforms and STFs, with the ground yield strength and fracture pressure being secondary factors. Differences in the PCA results between the far-field waveforms and STFs could possibly be due to near-field non-linearities of the source that are not accounted for in the estimation of STFs and could be associated with yield strength, fracture pressure, cavity radius and cavity shape parameters. Other algorithmic parameters are found to be less important and cause less variance in both the far-field waveforms and STFs, meaning algorithmic choices in how we model explosions are less important, which is encouraging for the further use of explosion simulations to study how physical Earth properties affect seismic waveform features and estimated STFs.

58 GEOSCIENCES↗

DOE OSTI2023

Investigation of desorption of hydrogen gas from polymer matrix using thermal desorption analysis and finite element modeling

Polymer materials are used widely as sealing materials and liners in hydrogen storage and transportation infrastructure. During operating conditions, polymers are exposed to high pressure hydrogen gas periodically. When in contact, the hydrogen gas diffuses through the polymer material with ease due to its smaller sized molecules compared to the polymer molecules. In the event of rapid decompression of outside hydrogen gas, the hydrogen molecules within the polymer diffuse out. This process is known as the desorption of polymer and can cause blisters or cracking causing permanent damage to the polymer. Here, we used a combined experimental and modeling approach to investigate the desorption of the hydrogen gas in the polymer. Thermal desorption analysis (TDA) experiments were performed on the polymer sample exposed to the high-pressure hydrogen gas to measure the diffusion coefficient and equilibrium hydrogen concentration. Experiments also provided the quantity of hydrogen within the polymer during the desorption process which followed Fick’s law. However, for higher pressurization values, some anomaly was observed in the quantity of hydrogen remaining in the polymer sample. A continuum mechanics based coupled diffusion–deformation-damage model was deployed to simulate the gas desorption process in the material using the finite element method to understand its effect on the material. It was found that the anomaly in TDA results were due to the blister formation on the polymer surface which resulted in longer hydrogen retention. Simulations also showed that blister formation can be affected by multiple parameters such as the addition of filler particles, and pre-existing cavity size.

36 MATERIALS SCIENCE↗

DOE OSTI2021

A phononic interface between a superconducting quantum processor and quantum networked spin memories

We introduce a method for high-fidelity quantum state transduction between a superconducting microwave qubit and the ground state spin system of a solid-state artificial atom, mediated via an acoustic bus connected by piezoelectric transducers. Applied to present-day experimental parameters for superconducting circuit qubits and diamond silicon-vacancy centers in an optimized phononic cavity, we estimate quantum state transduction with fidelity exceeding 99% at a MHz-scale bandwidth. By combining the complementary strengths of superconducting circuit quantum computing and artificial atoms, the hybrid architecture provides high-fidelity qubit gates with long-lived quantum memory, high-fidelity measurement, large qubit number, reconfigurable qubit connectivity, and high-fidelity state and gate teleportation through optical quantum networks.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Development and validation of a humidified CAPS-PMSSA with an improved methodology to calculate the truncation correction factor

Absorbing aerosols play an important role in the Earth’s radiation budget, and current uncertainties associated with their radiative impacts remain substantial. An element of this uncertainty derives from insufficient understanding of the extent to which water, as a coating on absorbing particles, enhances the absorption. Here, we describe and characterize the performance of a cavity-attenuated phase shift single scatter albedo spectrometer (CAPS-PMSSA) system that has been modified to enable concurrent aerosol extinction and scattering measurements, from which aerosol absorption is derived, at relative humidities up to ~90%. The modified instrument is referred to as the humidified CAPS (HCAPS). Additionally, we develop and validate an update to a method to calculate the truncation correction factor, used to correct the scattering measurements, that can account for the effects of particle growth and compositional changes resulting from water uptake. The method can be applied to experiments that use either size-selected or polydisperse aerosol samples of either known or unknown composition. Overall, we show that measurements made with the HCAPS, when processed using the updated truncation correction method, enable accurate measurement of the influence of water uptake on light absorption.

Dal Porto, Rachael [University of California, Davi↗

DOE OSTI2025

Laser-Modulation-Driven X-Ray Pulse Shaping in Regenerative Amplifier Free-Electron Lasers

In this Letter, we present a robust method for generating custom-shaped, coherent hard x-ray pulses in regenerative amplifier free-electron lasers (RAFELs) using laser-induced energy modulation of the electron beam. A temporally shaped optical modulation imprints an optical-wavelength energy pattern on the beam, which interacts with the recirculated seed in the x-ray cavity to generate spectral sidebands. These sidebands lie outside the Bragg reflection bandwidth and are extracted as out-coupled radiation, while the seed is retained for continued amplification, enabling a novel mechanism for both output coupling and pulse shaping. Furthermore, this approach allows deterministic control over the spectral and temporal properties of the emitted x-rays, including multicolor generation, twin-pulse structures, pulse duration tuning, and complex temporal waveforms. Importantly, it does not require modification of the RAFEL cavity or optics and is fully compatible with high-repetition-rate operation, offering a practical pathway to deliver coherent, shaped, and on-demand x-ray pulses for advanced time-resolved and nonlinear x-ray science.

Free-electron lasers↗

DOE OSTI2025

Modeling Sepsis: Establishment and Validation of a 72-Hour Swine Model of Penetrating Abdominal Trauma

Background/Objectives: Fecal peritonitis following penetrating abdominal trauma is a serious condition that often results in sepsis and organ failure. The aim of our study was to develop a novel conscious porcine model of sepsis and organ dysfunction caused by multiple penetrating injuries to the small and large intestines. Methods: Twelve female Yorkshire pigs (average weight 50.6 ± 6.5 kg) were divided into two groups: Penetrating Abdominal Trauma (PAT) (n = 8) and Control (n = 4). All surgical procedures were performed under anesthesia with adequate analgesia. In the PAT group, the small and large intestines were punctured, and feces mixed with saline were introduced into the abdominal cavity to induce peritonitis. The Control group received sham surgery with only saline solution. The animals were observed in a conscious state over a period of 72 h, vital parameters were recorded, and blood samples were taken regularly. We adapted a pig-specific SOFA score and developed pig-specific SIRS criteria and NEWS2 score to assess organ function. The model was validated by independent investigators. Results: The survival rate in the PAT group was 75%, with an average survival time of 58.5 h, while all animals in the Control group survived to euthanasia. Monitoring showed pathophysiological changes, such as tachycardia, leucopenia, and thrombocytopenia, indicative of sepsis and organ dysfunction. Blinded investigators independently confirmed the model’s validity. Conclusions: A new swine model of penetrating abdominal trauma and sepsis has been successfully developed that demonstrates significant physiological and immunologic changes comparable to human sepsis. This new model provides a realistic platform for future research into sepsis, its diagnostics, and the evaluation of therapeutic strategies.

General & Internal Medicine↗

DOE OSTI2024

A tunable dielectric resonator for axion searches at 11 GHz

In the context of axion search with haloscopes, tunable cavity resonators with high quality factor and high effective volume at frequencies above about 8 GHz are central for probing the axion-photon coupling with the required sensitivity to reach the QCD axion models. Higher order modes in dielectrically-loaded cavities allow for higher effective volumes and larger quality factors compared to basic cylindrical cavities, but a proper cavity frequency tuning mechanism to probe broad axion mass ranges is yet not available. In this work, we report about the design and construction of a tunable prototype of a single-shell dielectric resonator with its axion-sensitive pseudo-TM$_{030}$ high-order mode at about 11 GHz frequency. A clamshell tuning method previously tested for empty cylindrical resonators has been perfected for this geometry through simulations and in situ tests conducted at cryogenic temperature. Tuning is accomplished in a range of about 2 $\%$ the central frequency, without significantly impacting the quality factor of about 175000. The experimental results presented in this work demonstrate the tunability of this type of resonator, definitely confirming its applicability to high frequency axion searches.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

High‐Temperature Single‐Photon Emission From Covalently Functionalized van der Waals Heterostructures

Two-dimensional (2D) transition metal dichalcogenides (TMDs) such as tungsten diselenide (WSe 2 ) are attractive nanomaterials for quantum information applications due to single-photon emission (SPE) from intrinsic atomic defects. Defect and strain engineering techniques have been developed to produce high purity, deterministically placed SPE in WSe 2 . However, a major challenge in the application of these techniques is the low temperature required to observe defect-bound TMD exciton emission, typically limiting SPE to T < 30 K. SPE at higher temperatures either loses purity or requires integration into complex devices such as optical cavities. Here, 2D heterostructure engineering and molecular functionalization are combined to achieve high purity (>90%) SPE in strained WSe 2 persisting to over T = 90 K. Covalent diazonium functionalization of graphite in layered WSe 2 /graphite heterostructures maintains high purity up to T = 90 K and single-photon source integrity up to T = 115 K. This method preserves the best qualities of SPE from WSe 2 while increasing working temperature to more than three times the typical range. This work demonstrates the versatility of surface functionalization and heterostructure design to synergistically improve the properties of quantum emission and offers new insights into the phenomenon of SPE from 2D materials.

2D materials↗