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DOE OSTI2026

A critical review on additive manufacturing of refractory alloys from a data analytics perspective- beyond nickel-based superalloys

Refractory alloys (RAs) are promising materials due to their exceptional physicochemical properties, but most research remains at the laboratory scale. For broader adoption, advancements in manufacturing are essential. Because their high stability makes conventional methods like machining and casting difficult, additive manufacturing (AM) is emerging as an effective approach for fabricating refractory alloy components. However, AM's repeated non-equilibrium thermal cycles introduce undesired features (e.g. defects, anisotropic microstructures, and residual stresses), which are magnified due to RAs’ unique properties. This paper comprehensively reviews the state-of-the-art methods of AM for refractory alloys. It explores data analytics techniques to establish design rules based on multi-fidelity experimental and computational methods. Furthermore, it investigates integrated, collaborative efforts to harmonise standalone databases, information, knowledge, and predictive models at multi-physics, multi-stage, and multi-scale. Unlike the existing literature that focuses primarily on material systems or process fundamentals, this work provides an integrated perspective on AM of refractory alloys from a data analytics standpoint, highlighting the roles of integrated computational materials engineering (ICME), verification, validation, and uncertainty quantification (VV&UQ), and digital twin-driven qualification in overcoming data scarcity and accelerating rapid qualification.

Additive manufacturing↗

DOE OSTI2024

Multi-scale impacts of climate change on hydropower for long-term water-energy planning in the contiguous United States

Climate change impacts on watersheds can potentially exacerbate water scarcity issues where water serves multiple purposes including hydropower. The long-term management of water and energy resources is still mostly approached in a siloed manner at different basins or watersheds, failing to consider the potential impacts that may concurrently affect many regions at once. There is a need for a large-scale hydropower modeling framework that can examine climate impacts across adjoining river basins and balancing authorities (BAs) and provide a periodic assessment at regional to national scales. Expanding from our prior assessment only for the United States (US) federal hydropower plants, we enhance and extend two regional hydropower models to cover over 85% of the total hydropower nameplate capacity and present the first contiguous US-wide assessment of future hydropower production under Coupled Model Intercomparison Project phase 6’s high-end Shared Socioeconomic Pathway 5-8.5 emission scenario using an uncertainty-aware multi-model ensemble approach. We present regional hydropower projections, using both BA regions and US Hydrologic Subregions (HUC4s), to consistently inform the energy and water communities for two future periods—the near-term (2020–2039) and the mid-term (2040–2059) relative to a historical baseline period (1980–2019). We find that the median projected changes in annual hydropower generation are typically positive—approximately 5% in the near-term, and 10% in the mid-term. However, since the risk of regional droughts is also projected to increase, future planning cannot overly rely on the ensemble median, as the potential of severe hydropower reductions could be overlooked. The assessment offers an ensemble of future hydropower generation projections, providing regional utilities and power system operators with consistent data to develop drought scenarios, design long duration storage and evaluate energy infrastructure reliability under intensified inter-annual and seasonal variability.

13 HYDRO ENERGY↗

DOE OSTI2025

Fine-scale vegetation composition and structure shape spatiotemporal variation in surface albedo across a low Arctic tundra landscape

The unprecedented rate of warming in the Arctic is driving changes in the structure and composition of tundra vegetation. Increases in deciduous tall shrub cover, height, and density are of particular concern, as these changes alter local surface albedo in ways that could amplify effects on the regional surface energy budget (SEB). Despite this importance, significant uncertainties remain in understanding the interplay between fine-scale vegetation patterns and emergent albedo dynamics across space and time. Here, we address these uncertainties by (1) quantifying spatiotemporal variation in surface shortwave albedo and (2) determining the relative influence of fine-scale vegetation composition, structure, and environmental conditions on albedo across a representative low-Arctic tundra landscape on Alaska’s Seward Peninsula. To do this, we synthesized multi-scale, multi-platform remote sensing observations, including a novel Landsat-derived albedo time series, a fine-scale map of Arctic plant functional type (PFT) fractional cover, and airborne LiDAR estimates of canopy height and topography. We show that there are substantial reductions in winter albedo for pixels dominated by tall, woody PFTs (28.13%) relative to pixels dominated by non-woody vegetation, but almost no change in summer albedo (3% increase). Further, we identified a unimodal trend in the relationship between canopy height and the timing of the springtime transition from high (snowy) to low (leafy) albedo (peak at 5.5 m), possibly because of competing ‘snow-fence’ and ‘protrusion’ snow-shrub interactions. To explore the primary drivers of albedo, we constructed a random forest model and found that canopy height and the fractional cover of woody PFTs were as- or more important predictors of winter albedo than topographic features. These findings provide strong evidence for the impacts of local vegetation characteristics on regional surface albedo, highlighting the need for better quantification of snow-shrub interactions to accurately predict the Arctic’s SEB under future environmental change.

Arctic↗

DOE OSTI2022

Perspective—Lithium Metal Nucleation and Growth on Conductive Substrates: A Multi-Scale Understanding from Atomistic, Nano-, Meso-, to Micro-Scales

Reversible lithium (Li) deposition and stripping on conductive substrates like copper is vital for long-life high-energy rechargeable Li batteries. The reversibility is believed hindered by solid electrolyte interphase (SEI) formation and Li dendritic growth. Via in situ, operando cryo-microscopy and molecular dynamics simulation, we discovered amorphous Li before a disorder-order phase transition to bcc phase. The kinetics plays a significant role in Li nucleation and morphology evolution. This perspective on Li nucleation and growth from atomistic to nano- (<20 nm), meso- (20–100 nm), and micro-scales (>100 nm) provides a practical guidance on regulating dense Li deposits reversibly for long life performance.

25 ENERGY STORAGE↗

DOE OSTI2022

Quantum-Accurate Multiscale Modeling of Shock Hugoniots, Ramp Compression Paths, Structural and Magnetic Phase Transitions, and Transport Properties in Highly Compressed Metals

Fully characterizing high energy density (HED) phenomena using pulsed power facilities (Z machine) and coherent light sources is possible only with complementary numerical modeling for design, diagnostic development, and data interpretation. The exercise of creating numerical tests, that match experimental conditions, builds critical insight that is crucial for the development of a strong fundamental understanding of the physics behind HED phenomena and for the design of next generation pulsed power facilities. The persistence of electron correlation in HED materials arising from Coulomb interactions and the Pauli exclusion principle is one of the greatest challenges for accurate numerical modeling and has hitherto impeded our ability to model HED phenomena across multiple length and time scales at sufficient accuracy. An exemplar is a ferromagnetic material like iron, while familiar and widely used, we lack a simulation capability to characterize the interplay of structure and magnetic effects that govern material strength, kinetics of phase transitions and other transport properties. Herein we construct and demonstrate the Molecular-Spin Dynamics (MSD) simulation capability for iron from ambient to earth core conditions, all software advances are open source and presently available for broad usage. These methods are multi-scale in nature, direct comparisons between high fidelity density functional theory (DFT) and linear-scaling MSD simulations is done throughout this work, with advancements made to MSD allowing for electronic structure changes being reflected in classical dynamics. Main takeaways for the project include insight into the role of magnetic spins on mechanical properties and thermal conductivity, development of accurate interatomic potentials paired with spin Hamiltonians, and characterization of the high pressure melt boundary that is of critical importance to planetary modeling efforts.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2023

Durable Module Materials (DuraMAT) Consortium (Final Technical Report)

The DuraMAT Consortium brings together DOE national lab and university research capabilities with the photovoltaic (PV) and supply-chain industries to accelerate a sustainable, just, and equitable transition to zero carbon electricity generation by 2035 through our five core objectives: development of a central data resource for PV modules, multi-scale and multi-physics modeling, disruptive acceleration science, forensic tools for fielded modules, and materials solutions for more durable, reliable, and resilient modules.

14 SOLAR ENERGY↗

DOE OSTI2023

Data-driven time-scale separation of ODE right-hand sides using dynamic mode decomposition and time delay embedding

Multi-physics simulation often involves multiple different scales. The ARKODE ODE solver package in the SUNDIALS library addresses multi-scale problems with a multi-rate time-integrator that can work with a right-hand side that has fast scale and slow scale components. In this report, we use dynamic mode decomposition and time delay embedding to extract the fast and slow components of the right-hand sides of a simple ODE from data. We then use the extracted components to solve the ODE with ARKODE. Finally, to move towards a real-world use case, we attempt to extract fast and slow scale dynamics from synthetic seismic modeling data.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Curating Carbon Storage Data for Reuse: Enabling Research and Modeling from Earth’s Surface to Subsurface

The volume of public geologic carbon storage (GCS) data resources has continued to increase in recent years as the result of an increase in funding from government, industry, and academia towards national, basin, regional and field scale studies to ensure carbon capture and storage becomes a commercially viable operation. Despite the increasing volume of data, GCS data applied towards analyses such as geologic, cost, and risk modeling continues to be multi-sourced and often disparate in nature, published across government agencies, websites, data repositories and buried in derivative reports and documents. Much of the time preparing for an analysis and derivative product development is spent collecting, aggregating, transforming and preparing input data. There have been significant efforts within the DOE National Energy Technology Laboratory’s Carbon Storage Program to optimize multi-source, multi-scale subsurface geologic data curation and aggregation to support data discovery, interoperability, and reuse. Methods include the use of artificial intelligence, machine learning, and data science techniques. This talk will discuss the workflows, best practices, and processes developed to support the aggregation and curation of data through the whole system – surface to subsurface data - that support multi-scale, multi-purpose analysis for carbon storage research.

Morkner, Paige↗

DOE OSTI2025

Integrated Molten Salt Reactor Modeling Capabilities in NEAMS Thermal Hydraulics Tools

The DOE Nuclear Energy Advanced Modeling and Simulation (NEAMS) program supports a full range of computational thermal fluids analysis capabilities and code developments for a broad range of advanced reactor concepts. The research and development approach under the thermal fluids technical area synergistically combines three length and time scales in a hierarchical multi-scale approach. To enable multi-scale thermal fluids capability using these codes, a key joint effort has been underway to develop an integrated system- and engineering-scale thermal fluids analysis capability, through integration of SAM and Pronghorn codes, both based on the MOOSE framework.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Interactions between molecular-scale biogeochemical processes and hyporheic exchange for understanding coupled Fe-S-C cycling in iron-rich riparian wetlands (Final Technical Report)

Riparian wetlands are dynamic interfaces that exert strong control over water quality, contaminant mobility, and greenhouse gas emissions. These systems are characterized by hyporheic exchange between oxic surface water and anoxic groundwater, which generates steep redox gradients and promotes spatially and temporally variable microbial activity. Despite growing recognition of tightly coupled iron (Fe), sulfur (S), and carbon (C) cycling in these environments, the mechanisms governing these interactions—particularly under low-sulfate freshwater conditions—remain poorly constrained. This project developed a mechanistic understanding of how hydrologic variability and microbial processes interact to control Fe–S–C cycling in iron-rich riparian wetlands. Using a multi-scale and multi-method approach integrating field observations, geochemical and spectroscopic analyses, metagenomics, and reactive transport modeling, we demonstrate that “cryptic” sulfur cycling—rapid sulfur transformations involving intermediate-valence species—plays a dominant and previously underrecognized role in freshwater wetlands. These processes persist despite low sulfate concentrations and significantly influence iron reduction, carbon mineralization, and methane dynamics. The results show that cryptic sulfur cycling enhances dissolved Fe 2+ production, regulates methane concentrations, and is strongly controlled by climate-driven hydrologic fluxes. By linking hydroclimate, subsurface flow, and biogeochemical reactions, this work provides a predictive framework for understanding how wetland systems respond to environmental change, with direct implications for water quality and carbon cycling.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

A Percolating Path to Green Iron

About 1.9 gigatonnes of steel is produced every year emitting 7% (2.7 gigatonnes) of global CO 2 in the process. More than 50% of the CO 2 emissions come from a single step of steelmaking, known as ironmaking. Hydrogen based direct reduction (HyDR) of iron oxide to iron has emerged as an emissions free ironmaking alternative. However multi-scale phenomena ranging from nanometers to meters inside HyDR reactors exhibit detrimental microstructure evolution which resists gaseous transport of H 2 /H 2 O, slows reaction rates and disrupts continuous reactor operation. To resolve the conundrum between atomic and reactor scales, we devise a percolation-theory model to reconcile nanoscale porosity with macroscopic properties relevant to reactor design models. Using synchrotron nano X-ray computed-tomography, we quantify the evolution of pores in iron oxide pellets, and demonstrate how nano-scale pore networks influence micro and macro-scale flow properties such as permeability, diffusivity and tortuosity. Our new modeling framework bridges the gap between scales and offers the criteria to accelerate HyDR by at least 5x via feedstock-reactor synergies based on percolation.

Paul, Subhechchha↗

DOE OSTI2022

Multi-scale quantification of anthropogenic, fire, and drought-associated forest disturbances across the continental U.S., 2000–2014

Our understanding of broad-scale forest disturbances under climatic extremes remains incomplete. Drought, as a typical extreme event, is a key driver of forest mortality but there have been no reports on continental-scale quantification of its impact on forest mortality or how it compares to other natural or anthropogenic drivers. Thus, our ability to understand and predict broad-scale carbon cycling in response to changing climate and extreme events is limited. In this study, we applied an attribution approach based on different sources of data to quantify the area and potential carbon loss/transfer in continental U.S. (CONUS) from four types of disturbance: (1) anthropogenic (especially timber harvest); (2) fire; (3) drought-associated; and (4) other from 2000 to 2014. Our results showed that anthropogenic disturbances, fire, drought-associated disturbances, and other disturbances accounted for 54.3, 10.7, 12.7, and 22.3% of total canopy area loss, respectively. Anthropogenic disturbance was the most important driver contributing to 58.1% potential carbon loss/transfer in CONUS for 2000–2014. The potential carbon loss/transfer from natural disturbances (fire, drought, and other) for the same study period accounted for approximately 41.9% of the total loss/transfer from all agents, suggesting that natural disturbances also played a very important role in forest carbon turnover. Potential carbon loss/transfer associated with drought accounted for approximately 11.6% of the total loss/transfer in CONUS, which was of similar magnitude to potential carbon loss/transfer from fire (~11.0%). The other natural disturbance accounted for 19.3% of potential carbon loss/transfer. Our results demonstrated the importance of the impacts of various disturbances on forest carbon stocks at the continental scale, and the drought-associated carbon loss/transfer data developed here could be used for evaluating the performance of predictive models of tree mortality under droughts.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Topography and functional traits shape the distribution of key shrub plant functional types in low-Arctic tundra

The expansion of shrubs in the Arctic tundra fundamentally modifies land-atmosphere interactions. However, it remains unclear how shrub distribution and expansion differ across key species due to challenges with discriminating tundra plant species at regional scales. Here, we combined multi-scale, multi-platform remote sensing and in situ trait measurements to elucidate the distribution patterns and primary controls of two representative deciduous-tall-shrub (DTS) genera, Alnus and Salix, in low-Arctic tundra. We show that topographic features were a key control on DTSs, creating heterogeneous, but predictable distributions of Alnus and Salix fractional cover (fCover). Alnus was more tolerant of elevation and slope and was found on hilly uplands (slope >10°) within a specific elevational band (200–400 m above sea level [MSL]). In contrast, Salix occurred at lower elevations (50–300 m MSL) on gentler slopes (3-10°) and required adequate soil moisture associated with its profligate water use. We also show that niche differentiation between Alnus and Salix changed with patch size, where larger patches were more specialized in resource requirements than individual plants of Alnus and Salix. To understand what constrains the growth of DTSs at locations with low fCover, we developed environmental limiting factor models, which showed that topography limits the upper bound of Alnus and Salix fCover in 69.2% and 48.7% of the landscape, respectively. These findings highlight a critical need to better understand and represent topography-controlled processes and functional traits in regulating shrub distribution, as well as a need for more detailed species classification to predict shrubification in the Arctic.

alder↗

DOE OSTI2025

Progress Towards Developing Neutron Tolerant Magnetostrictive and Piezoelectric Transducers

Current generation light water reactors (LWRs), sodium cooled fast reactors (SFRs), small modular reactors (SMRs), and next generation nuclear plants (NGNPs) produce harsh environments in and near the reactor core that can severely tax material performance and limit component operational life. To address this issue, several Department of Energy Office of Nuclear Energy (DOE-NE) research programs are evaluating the long duration irradiation performance of fuel and structural materials used in existing and new reactors. In order to maximize the amount of information obtained from Material Testing Reactor (MTR) irradiations, DOE is also funding development of enhanced instrumentation that will be able to obtain in-situ, real-time data on key material characteristics and properties, with unprecedented accuracy and resolution. Such data are required to validate new multi-scale, multi-physics modeling tools under development as part of a science-based, engineering driven approach to reactor development. It is not feasible to obtain high resolution/microscale data with the current state of instrumentation technology. However, ultrasound-based sensors offer the ability to obtain such data if it is demonstrated that these sensors and their associated transducers are resistant to high neutron flux, high gamma radiation, and high temperature. To address this need, the Advanced Test Reactor National Scientific User Facility (ATR-NSUF) is funding an irradiation, led by PSU, at the Massachusetts Institute of Technology Research Reactor to test the survivability of ultrasound transducers. As part of this effort, PSU and collaborators have designed, fabricated, and provided piezoelectric and magnetostrictive transducers that are optimized to perform in harsh, high flux, environments. Four piezoelectric transducers were fabricated with either aluminum nitride, zinc oxide, or bismuth titanate as the active element that were coupled to either Kovar or aluminum waveguides and two magnetostrictive transducers were fabricated with Remendur or Galfenol as the active elements. Pulse-echo ultrasonic measurements of these transducers are made in-situ. This paper will present an overview of the test design including selection criteria for candidate materials and optimization of test assembly parameters, data obtained from both out-of-pile and in-pile testing at elevated temperatures, and an assessment based on initial data of the expected performance of ultrasonic devices in irradiation conditions

Reinhardt1, Brian↗

DOE OSTI2024

A network approach for multiscale catchment classification using traits

Abstract. The classification of river catchments into groups with similar biophysical characteristics is useful to understand and predict their hydrological behavior. The increasing availability of remote sensing and other large-scale geospatial datasets has enabled the use of advanced data-driven approaches to classify catchments using traits such as topography, geology, climate, land cover, land use, and human influence. Unsupervised clustering algorithms based on the Euclidean distance are commonly used for trait-based classification but are not suitable for highly dimensional data. In this study we present a new network-based method for multi-scale catchment classification, which can be applied to large datasets and used to determine the traits associated with different catchment groups. In this framework, two networks are analyzed in parallel: the first being where the nodes are traits and the second being where the nodes are catchments. In both cases, edges represent pairwise similarity, and a network cluster detection algorithm is used for the classification. The trait network is used to investigate redundancy in the trait data and to condense this information into a small number of interpretable categories. The catchments network is used to classify the catchments into clusters and to identify representative catchments for the different groups using the degree centrality metric. We apply this method to classify 9067 river catchments across the contiguous United States at both regional and continental scales using 274 non-categorical traits. At the continental scale, we identify 25 interpretable trait categories and 34 catchment clusters of sizes greater than 50. We find that catchments with similar trait categories are typically located in the same region, with different spatial patterns emerging among clusters dominated by natural and anthropogenic traits. We also find that the catchment clusters exhibit distinct hydrological behavior based on an analysis of streamflow indices. This network approach provides several advantages over traditional means of classification, including better separation of clusters, the use of alternate similarity metrics that are more suitable for highly dimensional data, and reducing redundancy in the trait information. The paired catchment–trait networks enable analysis of hydrological behavior using the dominant trait categories for each catchment cluster. The approach can be used at multiple spatial scales since the network topologies adjust automatically to reflect the trait patterns at the scale of investigation. Finally, the representative catchments identified as hub nodes in the network can be used to guide transferable observational and modeling strategies. The method is broadly applicable beyond hydrology for classification of other complex systems that utilize different types of trait datasets.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

IDAES-PSE Software Tools for Optimizing Energy Systems and Market Interactions

Modern power grids coordinate electricity production and consumption via multi-scale wholesale energy markets. Historically, levelized cost metrics were the de facto standard for techno-eco-nomic analyses of energy systems and comparison of technology options. However, these metrics neglect the complexity of energy infrastructure including the time-varying value of electricity. An emerging alternative is multi-period optimization, which considers the locational marginal price of electricity as input data (parameters). In this work, we present a general interface for multi-period optimization with time-varying energy prices to facilitate rapid analysis and comparison of potential energy systems models. The PriceTakerModel class is written in the IDAES-PSE platform and allows users to generate a multi-period, price-taker model instance, as well as automatically generate common operational constraints for their model, such as start-up and shutdown. We show this interface successfully generates multi-period price-taker models, facilitates model discrimination, and aids in analyzing various technologies for deployment in unique energy markets.

Laky, Daniel↗

DOE OSTI2023

HIGH-LOW FIDELITY THERMAL HYDRAULIC COUPLING USING AI/MACHINE LEARNING ALGORITHMS

The primary goal of the US Department of Energy (DOE) office of Nuclear Energy Integrated Energy Systems (IES) program is to develop the tools and framework for coupling multi-scale and multi-physical thermal and electrical energy usage and storage systems. High- and low-fidelity (high–low) coupling is a key feature of multi-scale, multi-component systems and has been an important focus of research in the nuclear energy community for the past two decades. An essential feature of demonstrating the capability to couple high-fidelity and low-fidelity systems for real-time applications are surrogate/reduced order models (ROM). For the purposes of this study, surrogate models are essentially Blackbox models, typically developed using supervised Machine learning (ML) algorithms. The surrogate models can be used to mimic the response of high-fidelity models to represent large historical datasets and coupled with more general low-fidelity system models distributed as Functional Mock-up Interface (FMI) or Functional Mock-up Units (FMU) modules. The example is demonstrated with Spallation Neutron Source (SNS) First Target Station flow loop data. The flow loop is a liquid mercury loop with a pump, piping, heat exchange, and internal heat generation in the target window. This work elucidates some of the potential benefits and future needs of developing tools for high–low system coupling of energy systems.

Williams, Wesley↗

DOE OSTI2022

Morphological-informed Thermal Property Prediction in the Engineering Domain

Using first-principle, atomic scale methods to predict thermal carrier (electron and phonon) behavior at nanoscale yields highly resolved thermal properties. Density functional theory simulations can model myriad effects on the transport of phonons and electrons (e.g., phonon and electron coupling, electron correlation, defect presence, carrier scattering), and yield thermal properties for small geometric domains such as thermal and electrical conductivity, or heat capacity. While these thermal properties are accurate in atomistic and nanoscopic systems, they must be scaled up to the microstructural domain to be a useful predictor for experimental basis, as the microscale is where myriad changes and physical phenomenon occur within a material (e.g., grain boundaries, precipitate aggregations, interfaces, defect clusters). My talk will discuss the necessity of thermal property predictions for nuclear fuels applications and more. Additionally I will discuss the necessity in developing multi-physics, multi-scale methods for future applications in predictions for not only nuclear fuels, but other materials applications.

36 MATERIALS SCIENCE↗