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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2024

Safety in Artificial Intelligence: Challenges and Opportunities for the U.S. National Labs and Beyond

This report discusses the importance of the critical and underexplored topic of artificial intelligence (AI) safety, as highlighted during the “Strategy Alignment on AI Safety” workshop convened at Lawrence Livermore National Laboratory (LLNL) in April 2024. Through a summary of keynote talks, panel discussions, and breakout sessions, world-leading AI safety experts from academic, industry, national labs, and government agencies clearly agree on the need for and importance of large-scale investments for research and capabilities in AI safety. With the field innovating at unprecedented rates, there is increasing urgency to develop novel evaluation methodologies that allow full considerations of risks/threats of AI technologies in different domains. Quantitative metrics and effective methodologies that can evaluate and audit the “safeness” of how a given AI technology is trained, deployed, or regulated are, at best, nascent for certain scenarios or, more commonly, nonexistent. This maturation gap presents the possibility of serious threats to national security, and further inaction may have serious consequences. Additionally, the gap between the public’s and research community’s perceptions of AI risks/rewards is significant. While numerous voices from the AI community have expressed concern that the risks could be so high that future AI systems could inflict extinction-level damage to humanity if deployed incorrectly, the public largely is aware only of risk in low-impact scenarios. This discrepancy highlights the crucial need for researchers to articulate to governmental bodies what, why, and when various AI risks matter as part of motivating funding requests. Thus, the call to action for this community is to pursue AI safety as a “Big Science” project on a scale comparable to the Manhattan Project. High risks and high payoffs are on the table, but safe AI is a fast-moving target, and large-scale investments are needed to guide development of this technology in a responsible way. We highlight the need for a multilayered solution combining the development of new methods and algorithmic approaches to mitigate threats with an active participation of the government(s) in setting high industry standards and regulations based on state-of-the-art technology. The U.S. Department of Energy (DOE) national laboratories have served as leading institutions for scientific innovation in the U.S. for more than 70 years. Drawing on their expertise in the AI community and their history of safeguarding critical and sensitive information, and as we look to the future, national labs are the best choice for evaluating and safeguarding AI technologies.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Unsupervised Image-Based Classification of Corrosion Severity in Automobile Engine Connecting Rods

Corrosion in engine connecting rods is a critical issue in the automotive industry, potentially leading to catastrophic engine failure, monetary losses, and safety hazards. The labor shortage in the industry further emphasizes the need for fast, accurate, and automated corrosion detection methods to ensure appropriate surface treatments can be applied to restore component integrity. We present an unsupervised image-based framework for classifying corrosion severity in automobile engine connecting rods using short-wave infrared (SWIR) and telecentric grayscale imaging. We employ the structural similarity index measure (SSIM) as a dissimilarity metric and the k-medians clustering algorithm for classification. Our algorithm achieves an overall accuracy of 80.64% for SWIR images, with 100% accuracy in classifying highly corroded samples. For grayscale images, the method attains an overall accuracy of 77.42%, with 90.91% accuracy for highly corroded samples. The method’s ability to work with different imaging modalities and its high accuracy in identifying severe corrosion cases make it a promising tool for automated corrosion assessment in the automotive industry, potentially improving efficiency and safety in engine component maintenance.

42 ENGINEERING↗
DOE OSTI2026

Enhancing Operational Safety via Agentic Dialogue Hazard Identification Analysis

Operational safety in high-stakes domains such as industrial process control, autonomous, and safety-critical systems demand reliable hazard identification. While large language models (LLMs) have shown promise in automating safety analysis tasks, single-turn, monolithic inference is brittle: it lacks the self-correction, deliberation, and contextual refinement that safety engineers apply iteratively. In this paper, we introduce HAZDIAL, a framework that investigates whether structured agentic dialogue (multi-agent, multi-turn interactions) improves the quality of NLP-based hazard identification over single-pass baselines. We systematically compare two dialogue modalities: adversarial debate and constructive discussion, and propose an genetic algorithm-based agentic interaction optimization. We evaluate all configurations against a curated golden dataset using standard classification metrics (accuracy, precision, recall, F1) and a novel dialogue metrics. This work advances the intersection of dialogue systems, multi-agent reasoning, and AI safety, providing empirical evidence for dialogue-driven hazard analysis.

Das, Sanjay [ORNL] (ORCID:0009000542591915)↗
DOE OSTI2020

FY20 SAM Code Developments and Validations for Transient Safety Analysis of Advanced non-LWRs

The System Analysis Module (SAM) is under development at Argonne National Laboratory as a modern system-level modeling and simulation tool for advanced non-light water reactor safety analyses. It utilizes the object-oriented application framework MOOSE to leverage the modern software environment and advanced numerical methods. The capabilities of SAM are being extended to enable the transient modeling, analysis, and design of various advanced nuclear reactor systems. This report summarizes major progress in SAM code development, capability enhancements, demonstration, and validation to support transient safety analysis of advanced non-LWRs. Rapid developments continued in fiscal year 2020 (FY20) to support various needs of the advanced reactor community, especially the NRC and industry on the licensing safety analysis of advanced reactor designs. Significant code changes were made to provide various capability enhancements, bug fixes, and user friendliness improvements. Major code updates are summarized in Section 1, while four important enhancements are detailed in Sections 2-5, including a multi-dimension flow model; reactivity feedback and decay heat models; control and trip system modeling, and additional fluid and solid thermophysical property models. Code validation activities in FY20 include using test data from the Fast Flux Test Facility (FFTF), the High Temperature Test Facility (HTTF), and several separate effects test facilities for pebble-bed modeling.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Development and Demonstration of a Risk-Informed Approach to the Regulatory Required Fuel Reload Safety Analysis

The United States (U.S.) nuclear industry is facing a strong challenge to maintain regulatory-required levels of safety while ensuring economic competitiveness to stay in business. Safety remains a key parameter for all aspects related to the operation of light water reactor (LWR) nuclear power plants (NPPs) and can be achieved more economically by using a risk-informed ecosystem such as that being developed by the Risk-Informed Systems Analysis (RISA) Pathway under the U.S. Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program. The LWRS Program is promoting a wide range of research and development (R&D) activities with the goal to maximize both the safety and economically efficient performance of NPPs through improved scientific understanding, especially given that many plants are considering second license renewal. The RISA Pathway has two main goals: (1) the deployment of methodologies and technologies that enable better representation of safety margins and the factors that contribute to cost and safety; and (2) the development of advanced applications that enable cost-effective plant operation. The plant reload optimization framework development project aims to build an artificial intelligence, i.e., Genetic Algorithm (GA), based reactor core designing tool taking into account reactor safety and fuel performance analyses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Status of SAS4A/SASSYS-1 Software Development and Application (FY2024)

SAS4A/SASSYS-1 is a simulation tool used to perform deterministic analysis of anticipated events as well as design basis and beyond design basis accidents for advanced liquid-metal-cooled nuclear reactors. With its origin as SAS1A in the late 1960s, the SAS series of codes has been under continuous use and development for over fifty years. It has been identified as a critical element of safety analysis capabilities for the U.S. Department of Energy and is utilized within industry to perform the transient safety analyses required to support the licensing of Liquid Metal-cooled Fast Reactors (LMFRs). This report summarizes the code development and update activities carried out during FY2024. In FY2024, programmatic activities focused on key improvements to software useability, such as enhanced user interfaces for reactivity feedback modeling, improvements in stability/useability of the Code Manual, and improvements to the acceptance testing infrastructure, including automation of acceptance testing and generation of the Acceptance Testing Report. To support end user applications, an open training was held, a semi-public forum was maintained, and a practical benchmarking and validation matrix was developed which allowed limitations of existing testing capabilities to be assessed. The existing fuel models were also enhanced with improved modeling capabilities and testing for the oxide and annular fuel models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Status of Multiple Channel Fuel Performance Capabilities Within the SAS4A/SASSYS-1 Safety Analysis Software

SAS4A/SASSYS-1 (SAS) is a fast-running simulation tool used to perform deterministic analysis of anticipated events as well as design basis and beyond design basis accidents for advanced liquid-metal-cooled nuclear reactors. It is a critical element of safety analysis capabilities for the U.S. Department of Energy and is utilized within industry to perform the transient safety analyses required to support the licensing of Liquid Metal-cooled Fast Reactors (LMFRs). Although SAS is exceptionally fast for most transient scenarios, fuel performance calculations, along with the associated pre-transient characterization of the fuel pin, may be required for transient scenarios where fuel pin failure is hypothesized. Both the pre-transient characterization and the transient fuel performance calculation are necessary to properly quantify margins to potential fuel failure and assess the time spent potentially exceeding such margins during events. While safety analysis calculations with fuel performance models provide a more detailed characterization of the reactor during a transient, the pre-transient characterization can be time-consuming and computationally expensive. Often, large numbers of fuel pins have been exposed to similar pre-transient irradiation conditions. Similarly, the same pre-transient fuel characterization may be applicable to numerous transient conditions. This provides an opportunity to optimize the SAS computational framework such that pre-transient fuel characterization can be shared across multiple channels (fuel pins) and across multiple simulations, thus dramatically reducing overall computational costs. This report summarizes progress toward enhancing the SAS computational framework to support shared, multiple channel fuel performance characterizations intended to significantly reduce computational costs. Preliminary testing has shown that the computational time saved by using the pre-transient sharing capability is approximately equal to the time it takes to perform the pre-transient characterization.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Integrated techno-economic framework for nuclear hydrogen production: assessing the role of high temperature steam electrolysis and safety considerations

This manuscript presents a comprehensive techno-economic assessment of nuclear integrated hydrogen production through high-temperature steam electrolysis (HTSE) in the U.S. Gulf Coast region. Given the significant role of hydrogen as an energy carrier and chemical feedstock, the research evaluates the feasibility of co-locating HTSE facilities with existing nuclear power plants (NPPs) to enhance hydrogen production efficiency and cost-effectiveness. Here, the study highlights the advantages of HTSE over traditional low-temperature electrolysis, particularly in leveraging thermal and electrical energy from NPPs. A novel framework for hydrogen deployment is introduced, integrating hydrogen market analysis, techno-economic evaluation (TEA), and safety assessments. The findings underscore the economic viability of hydrogen production in light of current market conditions, including fluctuating natural gas prices and the impact of production tax credits under the Inflation Reduction Act. A case study in the Gulf Coast region demonstrates the potential for strategic hydrogen production to meet growing industrial demand while ensuring safety and regulatory compliance. Overall, this research contributes to the advancement of nuclear integrated hydrogen production as a sustainable energy solution.

08 - HYDROGEN↗
DOE OSTI2020

Report on the Use and Function of the Integrated Operations Capability Analysis Platform (ICAP) and the LWRS Innovation Portal (IP)

The commercial nuclear power industry has achieved excellent safety and reliability performance but is struggling to survive in an electricity market that is increasingly dominated by subsidized renewables and cheap natural gas. These challenges have forced utilities to explore previously uncharted avenues to drastically reduce the operations and maintenance costs of their plants which are the primary drivers of the total cost to produce electricity. The petrochemical industry faced similar challenges some years ago as the costs of extraction and processing were rising while their reservoirs were being depleted along with a drop-in commodity prices that resulted in unsustainable operations. In this challenging climate, they developed a business model called Integrated Operations (IO) that sought to utilize technology to enable news ways of working through the integration of people, technology, process and governance changes. The Light Water Reactor Sustainability (LWRS) program, working with IFE have developed an operating model via transferable learnings from the North Sea O&G industry. This framework is termed “Integrated Operations for Nuclear” (ION). ION is a transformation model that integrates the benefits and features of four principal factors: People, Technology, Process and Governance. The purpose of this report is to describe how to generate an ION business process analysis and utilize this information to reduce O&M costs. In order to make this job easier, DOE LWRS has created a suite of tools that will allow a person who is involved in a transformation effort at their company to build a solid documented business case for embarking on a major transformation effort. These tools, the Integrated Operations Capability Analysis Model (ICAP) and the LWRS Innovation Portal (IP) are described herein with instructions on their use. Instructions on how the interface with the EPRI Business Case Analysis Method (BCAM) are also provided.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Business Case Analysis for Digital Safety-Related Instrumentation & Control System Modernizations

The commercial nuclear sector faces unprecedented financial challenges driven by low natural gas prices and subsidized renewables in a marketplace that does not reward carbon-free baseload capacity. These circumstances, along with increasingly antiquated labor-centric operating models and analog technology, have forced the premature closure of multiple nuclear facilities and placed a much larger population of nuclear power stations at risk. Nuclear plant economic survival in current and forecasted market conditions requires an efficient and technology-centric operating model that harvests the native efficiencies of advanced technology. This is analogous to transformations in nearly every other industry. In light of previous industry experience in modernizing safety Instrumentation and Controls (I&C) systems, nuclear utilities are reluctant to pursue these upgrades due to uncertainty in licensing and cost.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

A SIMPLE TOOL TO EVALUATE COLOR FOR LEGIBILITY AND DISTINGUISHABILITY WHEN DESIGNING DIGITAL DISPLAYS

Color is important in helping users effectively process information like text and symbols when performing tasks on digital displays. Interface designers in safety- and mission-critical industries often utilize human factors design guidelines and standards to make important design decisions like the use of color for legibility and distinguishability. However, such guidance sometimes requires additional interpretation and calculation to readily apply to the design question at hand. This work describes a simple tool that can be used to evaluate the adequacy of color choices from a palette for being legible or distinguishable. The tool eliminates having to manually convert colors to a readable format while providing a specific set of colors that are acceptable from select human factors standards. This paper provides an exemplary case study applied to a digital modification at a nuclear power plant to highlight how the tool may be used in safety and mission-critical industries.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2023

A Blockchain-Enabled Sustainable Safety Management Framework for Connected Vehicles

The notion of an intelligent transportation system (ITS) aims to boost the performance of transportation networks, which has gained more and more traction in both academic and commercial circles. ITS is a constantly evolving vision that combines cutting-edge transportation approaches with new information, communication, computers, and other technology. ITS should discover consequence routes to enhance the sustainability, safety, and trustworthiness of the entire transportation system utilizing emerging technologies. In this paper, a sustainable safety management framework for connected vehicles is proposed by integrating blockchain. It introduces smart transportation equipment called an AI-enabled vehicle smart device (AVSD) for vehicular communications. AVSD can reduce energy consumption by decreasing the computational costs in vehicular communications. Smart contracts are used to identify vehicles automatically and establish secure communication among vehicles and emergency service stations (ESSs) like hospitals, police stations, and fire stations. The experiment results show that the proposed framework provides a communication environment for sustainable safety and security using the introduced smart transportation device. In conclusion, the proposed blockchain-enabled sustainable safety management framework has the potential to improve safety and sustainability in the transportation industry by creating a secure, decentralized, and transparent platform for managing safety data and promoting safe and sustainable driving behaviors.

42 ENGINEERING↗
DOE OSTI2026

Identifying microstructures susceptible to pulverization in commercially irradiated high burnup UO2 under LOCA conditions

High burnup fuel fragmentation (HBFF) has been a concern in the nuclear industry for many years. When UO2 reaches and exceeds pellet average burnups around 55 GWd/tU, microstructural changes in the fuel pellet begin to occur that render the pellet susceptible to fine fragmentation under loss-of-coolant accident (LOCA) conditions. During a LOCA event, the cladding balloons and bursts, potentially releasing part of these fine fuel fragments into the reactor pressure vessel. This process is known as fuel fragmentation, relocation, and dispersal (FFRD). Presently, the US nuclear industry is developing a safety basis for FFRD with the goal of increasing burnups and pressurized water reactor cycle lengths. Increased cycle lengths would push the burnup limits of the fuel rods past the known threshold for HBFF susceptibility. In this work, the microstructural impact on HBFF was investigated by comparing the microstructures of as-irradiated rod segments to their post-LOCA tested counterparts. This investigation found that varied operational histories result in different microstructural evolutions across the pellet radius, which impacts the fragmentation behavior and radial location of the fragmentation. It is noted that regions with a high bubble density and a high density of grain boundaries fragment under LOCA-relevant conditions. In addition to the fragmentation that has been previously reported at the periphery of the fuel, fragmentation was also noted in the dark zone toward the fuel center. Analysis of the power histories of the fuel samples suggests that the dark zone forms in the central regions of the pellet between temperatures of approximately 740 and 960 °C.

McKinney, Casey [ORNL] (ORCID:0000000335383614)↗
DOE OSTI2025

Direct measurement of fluorocarbon radicals in the thermal destruction of perfluorohexanoic acid using photoionization mass spectrometry

Thermal destruction is a critical cornerstone of addressing the rampant contamination of natural resources with per- and polyfluoroalkyl substances (PFAS). However, grave concerns associated with stack emissions from incineration exist because mechanistic studies have thus far relied on ex situ analyses of end products and theoretical calculations. Here, we used synchrotron-based vacuum ultraviolet photoionization mass spectrometry to study the pyrolysis of a representative PFAS-perfluorohexanoic acid-and provide direct evidence of fluorocarbon radicals and intermediates. A key reaction pathway from perfluorocarboxylic acids to ketenes via acyl fluorides is proposed. We furthermore propose CF2/CF3 radical-centered pyrolysis mechanisms and explain their roles in the formation of other products that may form in full-scale incinerators. These results have not only unveiled the role of radicals and intermediates in thermal PFAS decomposition and recombination mechanisms but also provide unique insight into improving the safety and viability of industrial PFAS incineration.

Xu, Ming-Gao↗
DOE OSTI2022

Stealthy Cyber Anomaly Detection On Large Noisy Multi-material 3D Printer Datasets Using Probabilistic Models

As Additive Layer Manufacturing (ALM) becomes pervasive in industry, its applications in safety critical component manufacturing are being explored and adopted. However, ALM's reliance on embedded computing renders it vulnerable to tampering through cyber-attacks. Sensor instrumentation of ALM devices allows for rigorous process and security monitoring, but also results in a massive volume of noisy data for each run. As such, in-situ, near-real-time anomaly detection is very challenging. The ideal algorithm for this context is simple, computationally efficient, minimizes false positives, and is accurate enough to resolve small deviations. In this paper, we present a probabilistic-model-based approach to address this challenge. To test our approach, we analyze current measurements from a polymer composite 3D printer during emulated tampering attacks. Our results show that our approach can consistently and efficiently locate small changes in the presence of substantial operational noise.

Yoginath, Srikanth↗
DOE OSTI2024

Multivariate Time Series Intermittent Fault Detectionin Controller Area Network CAN

Fault detection in Controller Area Network (CAN) systems is crucial for ensuring the reliability and safety of automotive and industrial applications. This study investigates and compares the effectiveness of time series classification models for supervised fault detection in CAN data. This repository contains the code and data for our benchmarking experiment aimed at detecting intermittent faults in automotive Controller Area Network (CAN) data. The goal of this project is to compare various machine learning (ML) and deep learning (DL) models using different Time Series Cross-Validation (TSCV) techniques to evaluate their effectiveness in a streaming environment for fault detection.

Hespeler, Steven [Oak Ridge National Laboratory (O↗
DOE OSTI2021

USE OF COGNITIVE WORK ANALYSIS IN DEVELOPING A NUCLEAR POWER PLANT NEW STATE VISION

The United States nuclear industry is in need of identifying and implementing a new strategy that will lower operating and maintenance costs while maintaining safety for existing plants. The industry must also have a clear and strategic vision of their transformative new state that focuses on ways in which technologies can be integrated to maximize the benefits of technology and people. While there are ongoing efforts in this area, this work discusses how the use of cognitive work analysis may further support these current efforts. This paper provides an overview of cognitive work analysis, as well as the state of current new state development efforts. The use of cognitive work analysis, as a tool to enhance existing practices, is presented in ensuring that the development of a new state vision is systematic and complete.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Evaluation of flame propagation of retrofit energy efficient wall assemblies

Leveraging safety science experience and industry relationships, UL Solutions and the International Association of Fire Fighters (IAFF) initiated a joint project in 2022 under an agreement with the US Department of Energy to evaluate the flame propagation of retrofit energy efficient wall assemblies. A draft of the protocol from the ASTM work was used to test and comparatively study various retrofit energy efficient designs to gain a better understanding of their fire behavior. The goals of this study were as follows: Develop an understanding of fire propagation across new, cost effective, and energy efficient exterior retrofit wall assemblies. Refine the flame propagation draft test method for exterior wall assemblies based on ASTM E2707. Identify conditions that create fire propagation hazards in exterior wall assemblies and educate the fire service on the findings.

42 ENGINEERING↗