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DOE OSTI2025

Valued peaks: Sustainable water allocation for small hydropower plants in an era of explicit ecological needs

Optimizing hydropower operations to balance economic profitability and support functioning ecosystem services is integral to river management policy. In this article, we propose a dynamic, constrained optimization framework for small hydropower plants (SHPs) to evaluate trade-offs between economic profitability and socio-ecological requirements. Specifically, we examine the balance between short-term losses in hydropower generation and the potential for compensatory benefits in the form of revenue from recreational ecosystem services, irrespective of the direct beneficiary. Our framework integrates a fish habitat model, a hydropower optimization model, and a recreational ecosystem service estimate to evaluate different environmental flow scenarios. The optimization process gives three outflow release scenarios, informed by previous streamflow realisations (dam inflow), and designed environmental flow constraints. The framework is applied and tested for the river Kuusinkijoki in North-eastern Finland, which is a habitat for migratory brown trout and grayling populations. We show that the revenue loss due to the environmental flow constraints arises through a reduction in revenue per generated energy unit and through a reduction in turbine efficiency. Additionally, the simulation results reveal that all the designed environmental flow constraints cannot be met simultaneously. Under the environmental flow scenario with both minimum flow and flow ramping rate constraints, the annual hydropower revenue decreases by 16.5 %. An annual increase of 8 % in recreational fishing visits offsets the revenue loss. In conclusion, the developed framework provides knowledge of the costs and benefits of hydropower environmental flow constraints and guides the prioritizing process of environmental measures.

13 HYDRO ENERGY↗

NASA NTRS2006

Human Factors Engineering as a System in the Vision for Exploration

In order to accomplish NASA's Vision for Exploration, while assuring crew safety and productivity, human performance issues must be well integrated into system design from mission conception. To that end, a two-year Technology Development Project (TDP) was funded by NASA Headquarters to develop a systematic method for including the human as a system in NASA's Vision for Exploration. The specific goals of this project are to review current Human Systems Integration (HSI) standards (i.e., industry, military, NASA) and tailor them to selected NASA Exploration activities. Once the methods are proven in the selected domains, a plan will be developed to expand the effort to a wider scope of Exploration activities. The methods will be documented for inclusion in NASA-specific documents (such as the Human Systems Integration Standards, NASA-STD-3000) to be used in future space systems. The current project builds on a previous TDP dealing with Human Factors Engineering processes. That project identified the key phases of the current NASA design lifecycle, and outlined the recommended HFE activities that should be incorporated at each phase. The project also resulted in a prototype of a webbased HFE process tool that could be used to support an ideal HFE development process at NASA. This will help to augment the limited human factors resources available by providing a web-based tool that explains the importance of human factors, teaches a recommended process, and then provides the instructions, templates and examples to carry out the process steps. The HFE activities identified by the previous TDP are being tested in situ for the current effort through support to a specific NASA Exploration activity. Currently, HFE personnel are working with systems engineering personnel to identify HSI impacts for lunar exploration by facilitating the generation of system-level Concepts of Operations (ConOps). For example, medical operations scenarios have been generated for lunar habitation in order to identify HSI requirements for the lunar communications architecture. Throughout these ConOps exercises, HFE personnel are testing various tools and methodologies that have been identified in the literature. A key part of the effort is the identification of optimal processes, methods, and tools for these early development phase activities, such as ConOps, requirements development, and early conceptual design. An overview of the activities completed thus far, as well as the tools and methods investigated will be presented.

Mihriban Whitmore↗

DOE OSTI2026

Low-energy ion beam sputtering of polycrystalline diamond

Ion beam milling is a highly versatile and precise technique for the microfabrication of diamond films, enabling controlled material removal at both micrometer and sub-micrometer scales while accommodating complex geometries and surface features. Comprehensive sputtering yield data are essential for process optimization. In this work, we systematically measure the sputter yield of polycrystalline diamond bombarded with $\textrm{N}_2^+$, Ne + , Ar + , Kr + , and Xe + ions over an energy range of 300–900 eV and beam incidence angles of 0°−80°, providing data critical for precision machining applications. Results show that the sputter yield increases with both ion energy and the incidence angle and decreases with increasing ion mass. For $\textrm{N}_2^+$ ions, the sputter yield is largely insensitive to ion energy and exceeds values expected for pure physical sputtering. The concurrent formation of volatile C 2 N 2 molecules during $\textrm{N}_2^+$ ion bombardment suggests that the process is dominated by chemical sputtering. The absence of a peak in the dependence of the sputter yield on the beam incidence angle expected at oblique incidence angles is attributed to the effects of surface roughness.

Materials science↗

NASA NTRS2010

Multi-Stage System for Automatic Target Recognition

A multi-stage automated target recognition (ATR) system has been designed to perform computer vision tasks with adequate proficiency in mimicking human vision. The system is able to detect, identify, and track targets of interest. Potential regions of interest (ROIs) are first identified by the detection stage using an Optimum Trade-off Maximum Average Correlation Height (OT-MACH) filter combined with a wavelet transform. False positives are then eliminated by the verification stage using feature extraction methods in conjunction with neural networks. Feature extraction transforms the ROIs using filtering and binning algorithms to create feature vectors. A feedforward back-propagation neural network (NN) is then trained to classify each feature vector and to remove false positives. The system parameter optimizations process has been developed to adapt to various targets and datasets. The objective was to design an efficient computer vision system that can learn to detect multiple targets in large images with unknown backgrounds. Because the target size is small relative to the image size in this problem, there are many regions of the image that could potentially contain the target. A cursory analysis of every region can be computationally efficient, but may yield too many false positives. On the other hand, a detailed analysis of every region can yield better results, but may be computationally inefficient. The multi-stage ATR system was designed to achieve an optimal balance between accuracy and computational efficiency by incorporating both models. The detection stage first identifies potential ROIs where the target may be present by performing a fast Fourier domain OT-MACH filter-based correlation. Because threshold for this stage is chosen with the goal of detecting all true positives, a number of false positives are also detected as ROIs. The verification stage then transforms the regions of interest into feature space, and eliminates false positives using an artificial neural network classifier. The multi-stage system allows tuning the detection sensitivity and the identification specificity individually in each stage. It is easier to achieve optimized ATR operation based on its specific goal. The test results show that the system was successful in substantially reducing the false positive rate when tested on a sonar and video image datasets.

Chao, Tien-Hsin↗

DOE OSTI2024

Pyrolysis of high-density polyethylene: Degradation behaviors, kinetics, and product characteristics

Pyrolysis is a promising technology for converting plastic waste into valuable raw materials while offering a potential solution to the global plastic pollution crisis. In this study, the thermal pyrolysis of high-density polyethylene (HDPE) is investigated in a drop tube reactor under nearly isothermal conditions. The impact of reaction temperature and gas/volatile residence time on carbon conversion and product distribution is examined across a range of 500–900°C and 3.6–32.2s, respectively. Non-condensable gas products detected by online mass spectrometry are H 2 , CH 4 , C 2 H 4 , C 2 H 6 , C 3 H 6 , and C 3 H 8 . At elevated temperatures and prolonged residence time, H 2 yield reaches as high as 8.6 wt% of the initial HDPE mass due to intensified cracking reactions of C 2 –C 3 hydrocarbons and long-chain aliphatic compounds. Consequently, pyrolysis tars consist mainly of polycyclic aromatic hydrocarbons (PAHs) with 5–7 rings, accompanied by visible coke deposition within the reactor. HDPE decomposition to volatiles is an endothermic process and it is complete at a temperature between 492°C and 525°C, depending on the heating rate employed, from non-isothermal thermogravimetric analysis and differential scanning calorimetry (TGA-DSC) measurements. The thermal degradation of HDPE pellets follows the two-dimensional nucleation growth model for conversion levels up to 0.8 with an apparent activation energy of 259–270 kJ/mol and a pre-exponential factor of 4.83 × 10 17 –1.37 × 10 19 min -1 , determined from various isoconversional methods such as Flynn-Wall-Ozawa (FWO), Kissinger-Akahira-Sunose (KAS), and Starink, along with Criado's master plots. Further, these findings provide valuable insights into optimizing process parameters and refining reactor design for pyrolysis, which can be integrated with gasification and reforming processes to enhance hydrogen production on a larger scale.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2014

Potential for Integrating Entry Guidance into the Multi-Disciplinary Entry Vehicle Optimization Environment

The state-of-the-art in vehicle design decouples flight feasible trajectory generation from the optimization process of an entry spacecraft shape. The disadvantage to this decoupled process is seen when a particular aeroshell does not meet in-flight requirements when integrated into Guidance, Navigation, and Control simulations. It is postulated that the integration of a guidance algorithm into the design process will provide a real-time, rapid trajectory generation technique to enhance the robustness of vehicle design solutions. The potential benefit of this integration is a reduction in design cycles (possible cost savings) and increased accuracy in the aerothermal environment (possible mass savings). This work examines two aspects: 1) the performance of a reference tracking guidance algorithm for five different geometries with the same reference trajectory and 2) the potential of mass savings from improved aerothermal predictions. An Apollo Derived Guidance (ADG) algorithm is used in this study. The baseline geometry and five test case geometries were flown using the same baseline trajectory. The guided trajectory results are compared to separate trajectories determined in a vehicle optimization study conducted for NASA's Mars Entry, Descent, and Landing System Analysis. This study revealed several aspects regarding the potential gains and required developments for integrating a guidance algorithm into the vehicle optimization environment. First, the generation of flight feasible trajectories is only as good as the robustness of the guidance algorithm. The set of dispersed geometries modelled aerodynamic dispersions that ranged from +/-1% to +/-17% and a single extreme case was modelled where the aerodynamics were approximately 80% less than the baseline geometry. The ADG, as expected, was able to guide the vehicle into the aeroshell separation box at the target location for dispersions up to 17%, but failed for the 80% dispersion cases. Finally, the results revealed that including flight feasible trajectories for a set of dispersed geometries has the potential to save mass up to 430 kg.

spacecraft guidance↗

NASA NTRS2003

Specimen Designs for Testing Advanced Aeropropulsion Materials Under In-Plane Biaxial Loading

A design study was undertaken to develop specimen designs for testing advanced aeropropulsion materials under in-plane biaxial loading. The focus of initial work was on developing a specimen design suitable for deformation and strength tests to be conducted under monotonic loading. The type of loading initially assumed in this study was the special case of equibiaxial, tensile loading. A specimen design was successfully developed after a lengthy design and optimization process with overall dimensions of 12 by 12 by 0.625 in., and a gage area of 3.875 by 3.875 by 0.080 in. Subsequently, the scope of the work was extended to include the development of a second design tailored for tests involving cyclic loading. A specimen design suitably tailored to meet these requirements was successfully developed with overall dimensions of 12 by 12 by 0.500 in. and a gage area of 2.375 by 2.375 by 0.050 in. Finally, an investigation was made to determine whether the specimen designs developed in this study for equibiaxial, tensile loading could be used without modification to investigate general forms of biaxial loading. For best results, it was concluded that specimen designs need to be optimized and tailored to meet the specific loading requirements of individual research programs.

Ellis, John R.↗

NASA NTRS2019

Conceptual Design of a Counter-Rotating Fan System for Distributed Boundary Layer Ingesting Propulsion

The present paper details the design of the counter rotating fans for a Turboelectric Distributed Propulsion (TeDP) system. Sixteen propulsors installed in mail-slot-shape nacelles are embedded on an aerodynamically optimized hybrid wing-body configuration. The hybrid-wing/body (HWB) configuration which was previously designed to satisfy the conditions of trim, longitudinally static stability and specific cargo space is employed as the baseline configuration in pursuing an optimal distributed propulsion system. A set of distributed propulsors is conceptually designed and the collective performance is evaluated against the target thrust mandated by the mission requirements. The concept of the distributed propulsion allows the fan pressure ratio to be around 1.27~1.32 for the target thrust. In addition, further splitting of the fan pressure ratio by using the counter-rotating fans for each slot realizes the target pressure ratio with low tip speed. In the distributed propulsion system, the nature of the flow conditions and/or the thickness of the ingested boundary layer may differ and result in different propulsive reaction of each individual propulsor. The optimization is, thus, approached from both the propulsion system and individual propulsor perspectives. An optimal distribution of the thrust and power output is determined by how the system utilizes each passage's propulsive characteristics and its interaction with the airframe. These system level analysis and optimization are conducted using an actuator disk model to account for the propulsion-airframe integration numerically. With respect to the propulsor level, aerodynamic shape optimizations of the fan blades are performed in a sequential multi-objective optimization process for various design objectives, such as mass flow rate condition, fan pressure ratio, efficiency and the exit flow angle of the fan stage by using a genetic algorithm, NSGA-II. The radial chord distribution, and meanline distribution of the rotors are designed on the circumferentially averaged axi-symmetric inlet profiles and tested on the six inlet profiles from six divided sectors to reckon flow distortion. The performances of the counter rotating fans are, thus, evaluated accordingly for obtaining distortion tolerant fan. The performance of the distributed propulsion system is evaluated by two CFD tools, i.e., a multi-stage turbo-machinery CFD code and one propulsion-airframe integration flow solver coupled with a body-force model. The optimized boundary layer ingestion propulsion system of 16 distributed slots not only reaches the system target thrust, but also delivers a close to 20% fuel saving benefit against its counterpart 12 distributed clean inlet propulsion system.

Boundary-Layer-Ingestion Propulsion↗

NASA NTRS2019

Implementing Polar Projections with OGC Services for the Enhancement of AIRS NRT Visualization in LANCE

The Atmospheric Infrared Sounder (AIRS) NRT product is one important element in the Land, Atmosphere Near real-time Capability for EOS (LANCE). The LANCE processing of AIRS NRT products and the image generation are performed at the NASA Goddard Earth Sciences Data and Information Services Center (GES DISC). The Open Geospatial Consortium (OGC) services are being utilized to access AIRS NRT images. The ongoing AIRS NRT imagery enhancement work includes adding a new set of the images in polar projections. Polar projections are commonly used for mapping Antarctica and Arctic regions. We have implemented more precise south polar (EPSG:3031) projection and north polar (EPSG:3413) projection making our OGC service instances more useful and interoperable. Thus, AIRS NRT data can be easily accessed and integrated with other applications. It greatly increases the impact of our data on researches in polar regions.In this presentation, we will introduce the optimized processing workflow for OGC services from data access with spatial-temporal index to data visualization with different SLD, and demonstrate how to use open source software to provide more precise map images in polar projections.

Zhao, Peisheng↗

NASA NTRS2009

Processing and Probability Analysis of Pulsed Terahertz NDE of Corrosion under Shuttle Tile Data

This paper examines data processing and probability analysis of pulsed terahertz NDE scans of corrosion defects under a Shuttle tile. Pulsed terahertz data collected from an aluminum plate with fabricated corrosion defects and covered with a Shuttle tile is presented. The corrosion defects imaged were fabricated by electrochemically etching areas of various diameter and depth in the plate. In this work, the aluminum plate echo signal is located in the terahertz time-of-flight data and a threshold is applied to produce a binary image of sample features. Feature location and area are examined and identified as corrosion through comparison with the known defect layout. The results are tabulated with hit, miss, or false call information for a probability of detection analysis that is used to identify an optimal processing threshold.

Anastasi, Robert F.↗

NASA NTRS1999

Ames Optimized TCA Configuration

Configuration design at Ames was carried out with the SYN87-SB (single block) Euler code using a 193 x 49 x 65 C-H grid. The Euler solver is coupled to the constrained (NPSOL) and the unconstrained (QNMDIF) optimization packages. Since the single block grid is able to model only wing-body configurations, the nacelle/diverter effects were included in the optimization process by SYN87's option to superimpose the nacelle/diverter interference pressures on the wing. These interference pressures were calculated using the AIRPLANE code. AIRPLANE is an Euler solver that uses a unstructured tetrahedral mesh and is capable of computations about arbitrary complete configurations. In addition, the buoyancy effects of the nacelle/diverters were also included in the design process by imposing the pressure field obtained during the design process onto the triangulated surfaces of the nacelle/diverter mesh generated by AIRPLANE. The interference pressures and nacelle buoyancy effects are added to the final forces after each flow field calculation. Full details of the (recently enhanced) ghost nacelle capability are given in a related talk. The pseudo nacelle corrections were greatly improved during this design cycle. During the Ref H and Cycle 1 design activities, the nacelles were only translated and pitched. In the cycle 2 design effort the nacelles can translate vertically, and pitch to accommodate the changes in the lower surface geometry. The diverter heights (between their leading and trailing edges) were modified during design as the shape of the lower wing changed, with the drag of the diverter changing accordingly. Both adjoint and finite difference gradients were used during optimization. The adjoint-based gradients were found to give good direction in the design space for configurations near the starting point, but as the design approached a minimum, the finite difference gradients were found to be more accurate. Use of finite difference gradients was limited by the CPU time limit available on the Cray machines. A typical optimization run using finite difference gradients can use only 30 to 40 design variables and one optimization iteration within the 8 hour queue limit for the chosen grid size and convergence level. The efficiency afforded by the adjoint method allowed for 50-120 design variables and 5-10 optimization iterations in the 8 hour queue. Geometric perturbations to the wing and fuselage were made using the Hicks/Henne (HH) shape functions. The HH functions were distributed uniformly along the chords of the wing defining sections and lofted linearly. During single-surface design, constraints on thickness and volume at selected wing stations were imposed. Both fuselage camber and cross-sectional area distributions were permitted to change during design. The major disadvantage to the use of these functions is the inherent surface waviness produced by repeated use of such functions. Many smoothing operations were required following optimization runs to produce a configuration with reasonable smoothness. Wagner functions were also used on the wing sections but were never used on the fuselage. The Wagner functions are a family of increasingly oscillatory functions that have also been used extensively in airfoil design. The leading and trailing edge regions of the wing were designed by use of polynomial and monomial functions respectively. Twist was attempted but was abandoned because of little performance improvement available from changing the baseline twist.

Cliff, Susan E.↗

NASA NTRSDate not supplied

Mission Design Strategies for Rendezvous and Servicing of Sun-Earth Libration Point Missions

With the launch of the James Webb Space Telescope (JWST) and future launches of the Roman Space Telescope (RST) and larger telescopes such as the proposed Habitable Worlds Observatory (HWO), the questions of where and how to rendezvous to enable servicing of these telescope missions arise. To aid in determining the allowable locations to rendezvous for servicing from a trajectory design approach, our previous research and analysis has shown feasible transfer trajectories between the Sun-Earth Libration L2 region (Quasi-Halo orbit) and the Earth Moon vicinity (Distant Retrograde Orbit (DRO), Quasi-Halo Orbit, Halo Orbit, and Near Rectilinear Halo Orbit (NRHO)), along with the related transfer constraints and the corresponding total fuel mass costs. We now focus on operational-like optimal scenarios for these transfers to complete a rendezvous to permit servicing at various Libration orbit locations. In this paper, we address how operational navigation and maneuver execution uncertainties impact the rendezvous timing and fuel mass (via ΔV). While optimization techniques are applied to ensure minimal ΔVs, we also analyze various transfer trajectory durations and rendezvous arrival geometries. The analysis presented includes dynamical system approaches and applies optimization through several tools including the Adaptive Trajectory Design (ATD) module as an initial guess, numerical computation using the General Mission Analysis Tool (GMAT) and Systems Tool Kit (STK) with higher fidelity perturbation modeling, and recently developed optimization tools that incorporate dynamical systems directly into the optimization process. Transfer trajectory options examined include a direct transfer from Earth versus departures from the previously examined Earth-Moon regime orbits, e.g. NRHOs and DROs. A return from Sun-Earth to lunar vicinity for a complete servicing after a rendezvous in Sun-Earth orbit is also considered. The resultant ΔV’s for each scenario is provided with discussions on various transfer trades, rendezvous considerations, and orbital limitations from the dynamical systems. A Poincare-like mapping of trajectory and rendezvous conditions categorize feasible and optimum transfer approaches, dependent on Sun-Earth orbit mission parameters. The focus of this research addresses questions for upcoming trades regarding servicing options for current and future Sun-Earth L1 and L2 missions. By doing a comprehensive analysis approach (dynamical systems + high fidelity optimization with true operational constraints), this paper will serve as a guide for mission architecture and operational trade considerations.

Maneuver Design↗

NASA NTRSDate not supplied

Computational investigation on the combined effect of pore attributes on strain concentrators in metal additively manufactured materials

Metal additive manufacturing provides a pathway for creating highly optimized components. However, porosity continues to be a prevalent issue for fatigue performance despite best efforts in optimizing process parameters and postprocessing techniques. This work uses finite element analysis to conduct a parametric study to link various pore attributes (i.e., aspect ratio, orientation, and location) to strain concentration factors (SCF) under elastic/plastic deformation during uniaxial loading. Keyhole and lack-of-fusion pores are idealized by prolate and oblate ellipsoids, respectively. Each simulation of the parametric study assumes a single isolated pore in a Ti-6Al-4V material, modeled with J2-plasticity. A reduced-order model is developed to relate pore attributes to SCF, and then used to quantify the variability in SCF for a given experimentally characterized probability distribution of pore attributes. This reduced-order model can be used in a production environment to provide a first-order evaluation to rapidly screen sub-optimally performing components.

Additive Manufacturing↗

NASA NTRSDate not supplied

Comprehensive Digital Twin of a Macro-fluidic Electrochemical Reactor to Optimize the Electrochemical-based Recovery of O2 from Metabolic CO2

Future long-duration missions will require a sustainable and efficient system capable of yielding a minimum of 75% O 2 recovery from metabolic CO 2 to achieve self-sufficiency for long space missions beyond Earth's low orbit. A Macro-fluidic Electrochemical Reactor (MFECR) development effort to electrochemically recover O 2 from CO 2 is underway at NASA Marshall Space Flight Center (MSFC) to increase current O 2 recovery efficiency and reduce air revitalization (AR) system complexity at the International Space Station (ISS) habitat and future long missions. The authors have developed and deployed a digital twin of an actual single cell of the MFECR via a comprehensive 3D multiphysics model that thoroughly replicates the exact configuration and fluid/material domains of the MFECR. This model's electrochemical physics consists of multicomponent-multiphase electrochemical-driven reactions leading to CO 2 conversion to C 2 H 4 and CO along with the formation of H 2 on the cathode in parallel with the generation of O 2 and H 2 O on the anode. This electrochemical model is coupled with all the physics phenomena involved in the process, including but not limited to fluid and non-ideal mass transfer of reactant and product species in free and porous media, convective/conduction/radiative heat transfer, and conduction of DC electrical current with Joule heating generation. The digital twin has proved to be an essential tool for performing different qualitative studies, including the effect of reducing the height (increasing the respect ratio) of the serpentine walls, leading to a further redesign of the EDU (the newly redesigned MFECR EDU has been fabricated and is expected to be used in future tests), the evaluation of setting different MFECRs connected in series, and the assessment of feeding air directly to the MFECR skipping the preceding metabolic CO 2 separation from air. The MFECR's test stand is fully automated and equipped with several inline measurements (flow, pressure, temperature, pH, component concentration) systems on all six MFECR's IO streams, allowing reliable experimental validation of the model, parametric determination of all electrochemical reactions, and process optimization.

Jesus A Dominguez↗

DOE OSTI2025

Employing MACS/ViBRANT as a Surrogate MARVEL Reactor for Startup Reactivity Tuning and Supervisory Control Processes

Advanced nuclear reactors are a key part of the future of nuclear energy both in the United States and globally. They offer unique benefits for various energy-demanding applications, including use in remote locations, compact size, modular manufacturing, remote monitoring, low and/or variable power rating operation, and reliance on novel technologies to enhance operational safety. To achieve economic feasibility, advanced reactors must significantly reduce their workforces in comparison with the current fleet. Achieving this reduction will occur through reducing staff workloads using technology to achieve autonomous or semi-autonomous operations, demonstrated by comprehensive testing and validation activities. These operations will require both software and hardware platforms during the design and testing phases. While simulations are useful during the design phase, their performance can significantly deviate during actual deployment on hardware. This report presents the outcomes of a collaborative technical initiative between the U.S. Department of Energy (DOE) Microreactor Program (MRP) and Advanced Sensors and Instrumentation (ASI) Program. The collaboration utilized the Microreactor Automated Control System (MACS) hardware platform to bridge the gap between theoretical reactor design and actual startup and control operations. Two key use cases were investigated: facilitating the startup testing period and demonstrating supervisory control. The first use case details the key Microreactor Applications Research Validation and Evaluation (MARVEL) reactor startup physics testing activities conducted using the MACS platform. These activities included drum worth measurements, shutdown margin assessment, temperature feedback analysis, and scram time evaluation, as well as unique testing that would apply to the MARVEL reactor to demonstrate the testing methodologies in a low-risk environment. The MACS platform, serving as a surrogate representation of the MARVEL reactor, proved instrumental in performing these tests. The exercise revealed aspects that led to optimized processes, refined hardware design, and enhanced base software capabilities. By maturing methods and technologies in this manner, the initiative promises to reduce wasted time in the actual on-site reactor deployment effort, thereby saving significant time and resources. The second use case focuses on the development and implementation of supervisory control methods aimed at managing core tilt, which can result from asymmetrical operations or manufacturing imperfections in fuel rods or reactivity control devices. A key objective was to assess and compare the use of artificial intelligence (AI) for supervisory control. The effort aimed to define the role of supervisory control to enhance performance without risking control instability. This effort explored three distinct approaches: rules-based (RB) methods, optimization techniques, and reinforcement learning (RL) algorithms. Each approach was evaluated for its ease of implementation, its usability, and its effectiveness in responding to asymmetries in neutron flux. Comparative analysis of these approaches provided valuable insights into their applicability and effectiveness, offering a robust framework for advanced reactor operations. Together, these two use cases highlight the potential of hardware test beds to help streamline the design, operation, and control of advanced nuclear reactors. This collaborative effort underscores the importance of continued innovation and experimentation in achieving the next generation of safe, reliable, and economically viable nuclear energy solutions.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Rapid Evaluation of Amine-Functionalized Solvents for Biomass Deconstruction Using High-Throughput Screening and One-Pot Enzymatic Saccharification

Efficient and sustainable pretreatment of lignocellulosic biomass is critical for biofuel and biochemical production, yet its optimization is often hindered by slow, labor-intensive experimental methods. Here, we report the first demonstration of a custom-built, miniaturized, high-throughput screening platform integrated with one-pot enzymatic saccharification, enabling parallel evaluation of solvent type, feedstock, and temperature with minimal material use and high reproducibility. As a proof-of-concept, the HTX platform was used to screen five amine-functionalized solvents, including isopropanolamine, butylamine, N-methylbutylamine, ethanolamine, and ethanolamine acetate across three bioenergy crops (sorghum, poplar, and switchgrass) and pretreatment temperatures ranging from 80 to 140 °C. Vacuum drying successfully removed more than 99% of the solvents from the pretreated biomass, eliminating the need for water washing prior to saccharification. Isopropanolamine and N-methylbutylamine yielded the highest glucose (70–80%) and xylose (58–67%) release, with trends reflecting feedstock recalcitrance. The produced hydrolysates supported robust growth of an engineered strain of the yeast Rhodosporidium toruloides, confirming biocompatibility. This high-throughput platform provides a scalable, feedstock-agnostic framework for rapid pretreatment screening, accelerating solvent–feedstock pairing and process optimization. Its ability to integrate pretreatment, solvent removal, saccharification, and microbial conversion in a miniaturized format offers significant advantages for cost-competitive biorefinery development.

Biomass↗

DOE OSTI2025

ASSESSING THE EFFECTIVENESS OF ULTRASONIC IMPACT TREATMENT ON RESIDUAL STRESS PROFILES IN DISSIMILAR WELDED JOINTS

Residual stresses (RS) induced during welding processes are a critical concern in materials engineering, as they can significantly impair the mechanical performance of components by reducing fatigue strength and tensile load capacity. This challenge is especially pronounced in dissimilar metal welds (DMWs), where variations in thermal expansion properties between the joined alloys exacerbate the formation of tensile RS. Conventional post-weld heat treatments, though effective for homogeneous materials, often require substantial energy, specialized equipment, and extensive processing time, making them less practical for DMW applications. Thus, there is a clear need for innovative, energy-efficient techniques to mitigate these detrimental stresses. This study investigates ultrasonic impact treatment (UIT) as a possible alternative for mitigating tensile RS in both similar and dissimilar metal welds. To evaluate UIT’s effectiveness, neutron diffraction (ND) was employed as a nondestructive technique to quantify RS in three orthogonal directions—longitudinal, transverse, and normal. The results showed that UIT significantly reduced peak tensile RS, particularly in the longitudinal direction, by up to 180 MPa in similar welds and up to 150 MPa in dissimilar welds. Given the limited literature on UIT application in DMWs, this work contributes valuable data on stress redistribution mechanisms and highlights UIT’s potential as a practical stress-relief method. The findings lay the groundwork for further investigations aimed at optimizing process parameters and understanding long-term performance in welded joints.

EisaZadeh, Hamid [Western Carolina University, Cul↗

DOE OSTI2026

Algebraic Multigrid with Filtering: An Efficient Preconditioner for Interior Point Methods in Large-Scale Contact Mechanics Optimization

Large-scale contact mechanics simulations are crucial in many engineering fields such as structural design and manufacturing. In the frictionless case, contact can be modeled by minimizing an energy functional; however, these problems are often nonlinear, nonconvex, and increasingly difficult to solve as mesh resolution increases. In this work, we employ a Newton-based interior-point (IP) filter line-search method, an effective approach for large-scale constrained optimization. While this method converges rapidly, each iteration requires solving a large saddle-point linear system that becomes ill-conditioned as the optimization process converges, largely due to IP treatment of the contact constraints. Such ill-conditioning can hinder solver scalability and increase iteration counts with mesh refinement. Here, to address this, we introduce a novel preconditioner, algebraic multigrid with filtering (AMGF), tailored to the Schur complement of the saddle-point system. Building on the classical AMG solver, commonly used for elasticity, we augment it with a specialized subspace correction that filters near null space components introduced by contact interface constraints. Through theoretical analysis and numerical experiments on a range of linear and nonlinear contact problems, we demonstrate that the proposed solver achieves mesh independent convergence and maintains robustness against the ill-conditioning that notoriously plagues IP methods. These results indicate that AMGF makes contact mechanics simulations more tractable and broadens the applicability of Newton-based IP methods in challenging engineering scenarios. More broadly, AMGF is well suited for problems, optimization or otherwise, where solver performance is limited by a low-dimensional subspace, such as those arising from localized constraints, interface conditions, or model heterogeneities. This makes the method widely applicable beyond contact mechanics and constrained optimization.

Mathematics and Computing↗