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DOE OSTI2025

Exploring Professor Motivations and Implementations of a Real-World Problem-Solving Project

Engineering education literature offers a variety of theoretical and conceptual frameworks for project-based learning. This study explores the implementation of real-world problem-solving projects in engineering education. The research team analyzed the motivations and methods behind professors' adoption of such projects through exploratory qualitative interviews with seven professor participants who integrated a nation-wide student competition into their courses. We analyzed the resulting data using a constructivist grounded theory approach to identify key themes of professor practices. Findings reveal that the real-world aspect of the projects and alignment with values and research interests were primary motivators for implementation. While implementation methods varied significantly based on context (i.e., university setting, course type), we found that these projects could be effectively integrated into various classroom settings. The findings support the recommendation for non-academic institutions to develop and manage competitions that can be integrated into classrooms and which offer a point of engagement that is available to professors from a wide range of disciplines.

42 ENGINEERING↗

DOE OSTI2025

Exploring Professor Motivations and Implementations of a Real-World Problem-Solving Project: A Case Study in Preparing Students for the Emerging Building Science Industry: Preprint

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

A Neural Optimizer With Decision-Focused Learning for Optimal Energy Storage Operation

Here, this article introduces a neural optimizer-based framework for optimizing battery energy storage system (BESS) control for grid services, including demand charge and energy cost reduction. By leveraging decision-focused learning (DFL), the proposed framework ensures seamless integration and adaptation, significantly enhancing control performance. A patch time-series transformer is employed for peak load forecasting, incorporating aleatoric uncertainty quantification to account for forecasting uncertainties within the decision-making process. The framework utilizes a solver-in-the-loop approach to generate optimal BESS actions, which are then used to train the neural optimizer-based agent. By co-optimizing both BESS operational modes and output power within the NN, the system achieves improved performance and robustness. After initial training, the forecasting and control models are jointly fine-tuned to account for forecasting errors, further improving decision precision and efficiency through DFL. Case studies are performed to validate the performance of the framework using multiple real-world datasets, demonstrating superior performance in monthly peak load forecasting compared to state-of-the-art models. In addition, the results are compared against existing decision-making approaches. The results demonstrate a reduction in monthly peak forecasting error by approximately 15% across various performance measures and achieve an optimization gap for BESS operation that is about three times smaller compared to existing methods.

Kim, Hyeonjin [Pacific Northwest National Laborato↗

DOE OSTI2024

Geometry-complete diffusion for 3D molecule generation and optimization

Abstract Generative deep learning methods have recently been proposed for generating 3D molecules using equivariant graph neural networks (GNNs) within a denoising diffusion framework. However, such methods are unable to learn important geometric properties of 3D molecules, as they adopt molecule-agnostic and non-geometric GNNs as their 3D graph denoising networks, which notably hinders their ability to generate valid large 3D molecules. In this work, we address these gaps by introducing the Geometry-Complete Diffusion Model (GCDM) for 3D molecule generation, which outperforms existing 3D molecular diffusion models by significant margins across conditional and unconditional settings for the QM9 dataset and the larger GEOM-Drugs dataset, respectively. Importantly, we demonstrate that GCDM’s generative denoising process enables the model to generate a significant proportion of valid and energetically-stable large molecules at the scale of GEOM-Drugs, whereas previous methods fail to do so with the features they learn. Additionally, we show that extensions of GCDM can not only effectively design 3D molecules for specific protein pockets but can be repurposed to consistently optimize the geometry and chemical composition of existing 3D molecules for molecular stability and property specificity, demonstrating new versatility of molecular diffusion models. Code and data are freely available on GitHub .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Quantitative Analysis and Prediction of Thermal Runaway Metrics of High-Nickel Oxide Cathodes by Machine Learning Models

The pursuit of higher energy density in lithium-ion batteries has made high-nickel (Ni) layered oxides leading cathode candidates for next-generation electric vehicles. However, their poor thermal stability, particularly at Ni contents ≥ 90%, increases the risk of cathode-initiated thermal runaway. Furthermore, we present a data-driven framework combining linear and nonlinear machine learning models to predict key thermal runaway descriptors from a high-throughput differential scanning calorimetry database. With cathode composition and state of charge (SOC) as input features, the ensemble model accurately predicts peak temperature, heat release, and peak heat flow. SHAP analysis identifies Ni content and SOC as the dominant factors controlling thermal runaway temperature, while SOC primarily governs heat release and peak heat flow. Al, Mg, and Mn improve thermal stability by strengthening metal–oxygen bonding and delaying structural transformation, whereas B mainly reduces heat release through surface passivation. Validation with a new cathode composition confirms accurate prediction of SOC-dependent thermal runaway behavior and critical SOC.

25 ENERGY STORAGE↗

DOE OSTI2026

Physics-informed machine learning exploration of Na storage mechanisms in disordered carbon

Sodium-ion batteries are a cost-effective, sustainable alternative to lithium-ion systems for large-scale energy storage. However, optimizing sodium storage in carbon-based anodes with microstructural complexity and atomic disorder remains a major challenge. The intrinsic inhomogeneity of these materials produces diverse local environments, making it difficult for conventional methods to predict and control ion dynamics. Hard carbon (HC) anodes, composed of ranges of ordered-to-disordered graphitic and amorphous nanodomains, offer tunable ion storage and rate capacity, yet rationale design remains a challenge due to poorly understood correlation between local atomic feature and ion transport mechanism. Here, to address this challenge, we introduce a data-driven framework that integrates validated machine-learned interatomic potentials, large-scale molecular dynamics simulations, and machine learning to elucidate sodium transport mechanisms as a function of carbon and sodium loading densities. By computing per-ion structural descriptors and applying unsupervised learning, we identify distinct diffusion modes governed by microscopic features. Supervised analysis and correlation mapping then establish quantitative links between these transport regimes and processing variables such as bulk carbon density and sodium content. This physics-informed approach establishes quantitative structure–transport relationships and offers actionable design principles for engineering high-performance HC anodes.

Data-driven framework↗

DOE OSTI2026

Ensemble Federated Machine Learning‐Based Cybersecurity Situational Awareness in Microgrid Network

Cyber-physical microgrids are vulnerable to stealthy cybersecurity threats that disguise their actions through the exploitation of system knowledge. Such actions can severely impacts microgrids deployed in defense bases, slowing the response time of military forces during national emergencies. Several machine-learning algorithms have been proposed to detect intrusions in the grid networks; however, these traditional machine-learning algorithms lack data privacy and are subject to several adversarial machine-learning threats. This paper proposes a novel federated machine learning (FML)-based three-model framework to detect and identify stealthy data-integrity attacks while ensuring data privacy in microgrid networks. The proposed architecture uses a variational mode decomposition technique to extract derived features from incoming measurement and control datasets. The extraction of these derived features allows FML models to learn minute variations in data patterns that allow them to perform significantly better than the models trained with generic datasets consisting of raw features. Our experimental results show the efficient performance of the proposed methodology against different types of data integrity attacks while considering primary and secondary controllers in microgrids. Further, the applied FML-integrated random forest ensemble algorithm outperforms the existing generic FML algorithms during noisy and noise-free datasets with prediction latencies of only 91–134 µs per sample within the 0.1 s sampling interval and requires communication bandwidth of around ∼8.25 KB/s at the control center and ∼2.7 KB/s per edge client for communication.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Optimization of the FRIB beam dump: a hybrid genetic algorithm and reinforcement learning approach

The operational envelope of high-power-density systems, such as particle accelerators and advanced nuclear energy systems, is critically constrained by the need to manage extreme thermal loads. To address this, we present a novel hybrid optimization framework combining a genetic algorithm (GA) with a soft actor-critic (SAC) deep reinforcement learning agent. This framework was applied to a practical high-heat-flux problem: redesigning the beam dump at the Facility for Rare Isotope Beams (FRIB) for a power upgrade from 20 kW to 50 kW. The resulting design, validated by three-dimensional conjugate heat transfer simulations, suppresses hazardous hot spots and yields a markedly more uniform temperature distribution. This provides a robust operating margin, increasing the average power-handling capability by 72% relative to the current design, demonstrating the framework’s potential to solve complex thermal management challenges in both accelerator technology and advanced nuclear systems.

Accelerator↗

DOE OSTI2025

Resolving the Coverage Dependence of Surface Reaction Kinetics with Machine Learning and Automated Quantum Chemistry Workflows

Microkinetic models for catalytic systems require estimation of many thermodynamic and kinetic parameters that can be calculated for isolated species and transition states using ab initio methods. However, the presence of nearby coadsorbates on the surface can dramatically alter these thermodynamic and kinetic parameters causing them to be dependent on species coverage fractions. As there are combinatorially many coadsorbed configurations on the surface, computing the coverage dependence of these parameters is far less straightforward. We present a framework for generating and applying machine learning models to predict coverage-dependent parameters for microkinetic models. Our toolkit enables automatic calculation and evaluation of coadsorbed configurations allowing us to sample 2,000 coadsorbed adsorbates and transition states (TSs) for a diverse set of 9 reactions on Cu(111), a challenging surface, with four possible coadsorbates. This dataset was then used to train subgraph isomorphic decision trees (SIDTs) to predict the stability and association energy of configurations. We were able to achieve mean absolute errors (MAEs) of 0.106 eV on adsorbates, 0.172 eV on TSs, and due to natural error cancellation in SIDTs for relative properties, 0.130 eV on reaction energies and 0.180 eV on activation barriers. In conclusion, we describe how to use these models to predict coverage-dependent corrections for adsorbates and TSs and demonstrate on H*, HO*, and O* comparing the generated SIDT model with an iteratively refined version.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Denoising diffusion probabilistic models for generative alloy design

Inverse material design is an extremely challenging optimization task made difficult by, in part, the highly nonlinear relationship linking performance with composition. Quantitative approaches have improved significantly owing to advances in high throughput experimentation and computational thermodynamics. However, existing physics-based tools are mostly forward models; input a chemistry and obtain a prediction. More recently the materials community has leveraged advances in the machine learning community to establish novel inverse design frameworks. Very recently denoising diffusion probabilistic models have been shown to be extremely powerful generators producing synthetic data of various modalities e.g. images, text, audio, tables, etc.. In this work a novel framework for alloy design and optimization is proposed leveraging these class of models. Five key generative tasks are demonstrated (1) unconditional generation (2) composition conditioned generation (3) property conditioned generation (4) multi-feedstock conditioned generation and (5) generative optimization. These methods were tested on three case studies: high entropy alloy design, superalloy binder jet additive manufacturing, and in-situ dual-feedstock wire-arc additive manufacturing. Results indicate that the established models are extremely flexible, expressive, and robust. The architecture’s flexibility and training procedure empower the model to learn complex intra-compositional and composition-property relationships. Furthermore, the probabilistic nature of these models makes them well suited for addressing solution non-uniqueness and tackling uncertainty quantification tasks. While the fidelity and quantity of the underlying training data is paramount, we envision that future alloy design frameworks will make extensive use of these kinds of machine learning models as “search” tools bolstering the utility of experimental and computational approaches.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Depot Charging Schedule Optimization for Medium- and Heavy-Duty Battery-Electric Trucks

Charge management, which lowers charging costs for fleets and prevents straining the electrical grid, is critical to the successful deployment of medium- and heavy-duty battery-electric trucks (MHD BETs). This study introduces an energy demand and cost management framework that optimizes depot charging for MHD BETs by combining an energy consumption machine learning model and a linear program optimization model. The framework considers key factors impacting real-world MHD BET operations, including vehicle and charger configurations, duty cycles, use cases, geographic and climate conditions, operation schedules, and utilities’ time-of-use (TOU) rates and demand charges. The framework was applied to a hypothetical fleet of 100 MHD BETs in California under three different utilities for 365 days, with results compared to unmanaged charging. The optimized charging solution avoided more than 90% of on-peak charging, reduced fleet charging peak load by 64–75%, and lowered fleet energy variable costs by 54–64%. This study concluded that the proposed charge management framework significantly reduces energy costs and peak loads for MHD BET fleets while making recommendations for fleet electrification infrastructure planning and the design of utility TOU rates and demand charges.

Song, Shuhan↗

DOE OSTI2026

A human-in-the-loop explanation framework for morphologically transparent AI predictions from whole-slide images

Deep learning models enable the prediction of clinical endpoints from whole-slide images (WSIs), but many such models function as “black boxes”, lacking transparency about whether and which histomorphological patterns drive their predictions, hindering interpretability and clinical adoption. Here we propose a human-in-the-loop explanation framework, MorphoXAI, which provides both local and global interpretability for deep learning models by incorporating human-expert interpretations. At the global level, it reveals the histomorphological patterns on which the model consistently relies to distinguish between classes of WSIs, as well as the patterns associated with confusion between classes. At the local level, it indicates which of these patterns are used in the prediction of an individual WSI and which regions within the slide correspond to such patterns. We validated our method across multiple deep learning–based WSI analysis tasks spanning different tissue types. The results show that our framework generates explanations that accurately reflect the histomorphology underlying the model’s predictions at both global and local levels. For interpretability and clinical utility in diagnostic contexts, human evaluation results showed that our explanations were easy to interpret, rich in diagnostic features, and directly helpful for diagnostic decision-making, thereby enhancing pathologist-AI collaboration. Our work highlights that unifying global and local explanations and grounding them in expert-interpreted morphology enhances the interpretability and verifiability of deep learning models, thereby facilitating the transparent deployment of such models in clinical practice.

Lou, Peiliang↗

DOE OSTI2025

Regime-based aerosol–cloud interactions from CALIPSO-MODIS and the Energy Exascale Earth System Model version 2 (E3SMv2) over the Eastern North Atlantic

This study investigates aerosol-cloud interactions in marine boundary layer (MBL) clouds using an advanced deep-learning-driven synoptic-regime-based framework, combining satellite data (CALIPSO vertically resolved aerosol extinction and MODIS cloud properties) with 1° nudged Energy Exascale Earth System Model version 2 (E3SMv2) simulation over the Eastern North Atlantic (ENA; ∼10°×10°, 2006–2014). The E3SMv2 captures observed seasonal variations in cloud droplet number concentrations (N d ) and liquid water path (LWP), though it systematically underestimates N d . We then partition ENA meteorology into four synoptic regimes (Pre-Trough, Post-Trough, Ridge, Trough) via a deep-learning clustering of ERA5 reanalysis fields, enabling regime-dependent aerosol-cloud interactions analyses. Both satellite and E3SMv2 exhibit an inverted-V LWP-N d relationship. In Post-Trough and Ridge regimes, the satellite shows stronger negative LWP-N d sensitivities than in Pre-Trough regime. The Trough regime displays a muted satellite LWP response. In comparison, the model predicts more exaggerated LWP responses across regimes, with LWP increasing too quickly at low N d and decreasing more sharply at high N d , especially in Pre-Trough and Trough regimes. These exaggerated model LWP sensitivities may stem from uncertainties in representing drizzle processes, entrainment, and turbulent mixing. As for N d susceptibility to aerosols, N d increases with MBL aerosol extinction in both datasets, but the simulated aerosol-cloud interactions appear oversensitive to meteorological conditions. Overall, E3SMv2 better captures aerosol effects under regimes that favor stratiform clouds (Post-Trough, Ridge), but performance deteriorates for regimes with deeper, dynamically complex clouds (Trough), highlighting the need for improved representations of those cloud processes in climate models.

Environmental sciences↗

DOE OSTI2026

Machine learning based prediction of airflow maldistribution in air-to-refrigerant heat exchangers

Flow maldistribution is a common challenge in heat exchanger (HX) design and particularly important for air-to-refrigerant geometries where capacity losses can approach 65%. This has a major impact on central air conditioning systems, as compact duct design motivates the use of A-type HXs which are known to be affected by airflow maldistribution. Because velocity profiles are difficult to predict, components are often oversized leading to increased material cost, system footprint, and refrigerant charge. Several studies detail airflow maldistribution for individual HXs and packages, but findings cannot always be extrapolated to new designs. In this work, a machine learning (ML) based flow profile prediction framework is developed and applied to two common package configurations: (i) A-type and (ii) U-type HXs, across a broad range of HX geometries and flow rates. Porous media CFD simulations are validated against independent data for both package types as well as comprehensive in house measurements for a finless geometry with shape optimized non-round tubes, which validates the framework for new heat transfer surfaces. The ML models are trained on the porous media CFD simulations, predicting volumetric flow rate (VFR) within 1.1% and 1.9% with maximum relative L 2 norm errors of 0.48 and 0.65, respectively, while also delivering 10 5 speed up factor compared to full porous media CFD. HX level simulations show an up to 9% reduction in heat transfer from flow maldistribution, with greater losses occurring at smaller half apex angles. This framework enables rapid and highly accurate prediction of airflow maldistribution induced capacity degradation.

42 ENGINEERING↗

DOE OSTI2025

A structured framework for predicting sustainable aviation fuel properties using liquid-phase FTIR and machine learning

Sustainable aviation fuels have the potential to improve efficiency, reduce emissions, and enhance energy security. To help identify viable sustainable aviation fuels and accelerate research, machine learning models have been developed to predict relevant physicochemical properties. However, many models have limited applicability, leverage data from complex analytical techniques with confined spectral ranges, or use feature decomposition methods that offer limited interpretability. Using liquid-phase Fourier Transform Infrared (FTIR) spectra, this study presents a structured method for creating accurate and interpretable property prediction models for neat molecules, aviation fuels, and blends. Liquid FTIR spectra can be collected quickly and consistently, offering high reliability, sensitivity, and component specificity using less than 2 ml of sample. The method first decomposes FTIR spectra into fundamental building blocks using non-negative matrix factorization (NMF) to enable scientific analysis of FTIR spectra attributes and fuel properties. The NMF features are then used to create five ensemble models for predicting final boiling point, flash point, freezing point, density at 15°C, and kinematic viscosity at -20°C. All models were trained using experimental property data from neat molecules, aviation fuels, and blends. The models accurately predict key properties across a broad range of neat molecules and representative fuels and blends, while enabling interpretation of relationships between compositional elements, such as functional groups or chemical classes, and their resulting properties. This demonstrates strong potential to support sustainable aviation fuel research and development. The models and data are available on an interactive web tool.

Fourier transform infrared spectroscopy↗

DOE OSTI2025

A Novel LDPP-MADDPG Approach for Distributed Power Allocation in mmWave Cellular Networks

This paper considers the problem of distributed beam scheduling and power allocation problem in millimeter- Wave (mmWave) cellular networks, in which multiple Base Stations (BSs) operate as individual operators over a shared spectrum. We propose a novel learning-aided approach that integrates the Lyapunov Drift-Plus-Penalty (LDPP) framework and Multi-agent Deep Deterministic Policy Gradient (MADDPG) reinforcement learning algorithms. This offers a powerful approach to learning stable and constraint-aware policies, reaping the joint benefit of both LDPP and MADDPG, in complex multiagent environments. The major challenge for this approach is to integrate these two approaches in a meaningful and effective manner. The key idea to solve this problem is to introduce a novel feature of local observation that incorporates potential negative value of the reward function due to the stochastic constraints introduced by the LDPP framework. Empirical results demonstrate that our proposed scheme outperforms the baseline methods under various conditions.

99 - GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

A Hybrid Anomaly Detection Approach for Obfuscated Malware

With the rapid evolution of malicious software, cyber threats have become increasingly sophisticated, employing advanced obfuscation techniques to evade traditional detection methods. This study presents a hybrid anomaly detection approach applied to obfuscated malware. Even though there is a large body of research in this field, existing malware detection techniques have some drawbacks, such as requiring large amounts of data, trustworthiness (imprecise results) of algorithms, and advanced obfuscation. To overcome these challenges, there is a need to employ solid and efficient techniques for malware detection. This paper proposes a hybrid approach, combining an autoencoder with traditional machine-learning methods to create an efficient malware detection framework. We used the malware memory dataset (MalMemAnalysis-2022) to evaluate this framework. The results indicate that our proposed approach can detect obfuscated malware when a deep autoencoder used for feature learning is combined with logistic regression, and it is extremely fast with an Accuracy, Detection Rate (DR), Matthew Correlation Coefficient(MCC), and Statistical Parity Difference

malware detection, Hybrid Anomly Detection, Obfusc↗

DOE OSTI2025

Cross-functional transferability in foundation machine learning interatomic potentials

The rapid development of foundation potentials (FPs) in machine learning interatomic potentials demonstrates the possibility for generalizable learning of the universal potential energy surface. The accuracy of FPs can be further improved by bridging the model from lower-fidelity datasets to high-fidelity ones. In this work, we analyze the challenge of this transfer learning (TL) problem within the CHGNet framework. We show that significant energy scale shifts and poor correlations between GGA and r 2 SCAN hinder cross-functional transferability. By benchmarking different TL approaches on the MP-r 2 SCAN dataset, we demonstrate the importance of elemental energy referencing in the TL of FPs. By comparing the scaling law with and without the pre-training on a low-fidelity dataset, we show that significant data efficiency can still be achieved through TL, even with a target dataset of sub-million structures. We highlight the importance of proper TL and multi-fidelity learning in creating next-generation FPs on high-fidelity data.

Huang, Xu [University of California, Berkeley, CA ↗