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DOE OSTI2025

Supramolecular bending and twisting in the hierarchical self-assembly of monodisperse mesogenic oligomers

Understanding how different forms of supramolecular curvature arise during assembly is crucial to designing and tuning the microstructure of hierarchically self-assembled materials. Here, we show that in crystalline phases of mesogenic oligomers, the oligomer length is a critical parameter that determines the type of curvature (Gaussian or cylindrical) exhibited by the self-assembled structures. We use iterative exponential growth to synthesize monodisperse mesogenic oligomers ranging from dimer to octamer. By analyzing their phase behavior and microstructure, we elucidate how length-dependent thermodynamic and kinetic effects tune their hierarchical degree of ordering. The oligomers’ length-dependent crystalline order drives the formation of scrolled sheets in shorter oligomers and twisted ribbons in longer oligomers. These studies highlight how oligomer length interplays with mesogen geometry and crystalline packing to drive self-assembly, introducing oligomer length as a powerful design parameter toward tailored applications of mesogenic systems.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Process Intensification for Nanocomposite Aluminum Extrusions: CRADA 411 (Final Report)

The project evaluated the feasibility of using Shear Assisted Processing and Extrusion (ShAPE) for the fabrication of extrusions with a diameter of 0.5” and higher from an Al-alloy powder feedstock that contains nanoscale second phases for achieving enhanced elevated temperature strength. PNNL has previously extruded 0.2” diameter rods with high strength aluminum alloy powder Al-12.4TM. This project aimed to scale the process up to a diameter of 1.0” at a length of >24” while retaining the excellent mechanical properties achieved for the 0.2” diameter rods. As part of the project, extrusion dies were fabricated with various design features. As an example, scroll features on the tool die face was introduced to enhance powder mixing, and reduce extrusion load. Varying extrusion ratios were used to obtain better microstructural homogeneity. Use of tool design features together with the optimization of process parameters helped in the fabrication of extrusions that were up to 48” long with a diameter of 0.5” using Al-12.4 TM powder feedstock in a two-step process involving cold compaction followed by extrusion. Extrusions with a diameter of 1.0” could also be fabricated, but limitations on the extent of consolidation were experienced as a result of the torque and ram force capacity of the current ShAPE machine.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Building Technologies Office 03.02.02.38 Milestone Report—Compressor Technology Development for Refrigerants with <150 Global Warming Potential

The major purpose of this project is to enable the development of compressors specifically designed for compatibility with low–global warming potential (GWP) refrigerants (with GWP values below 150). These compressors are intended for applications in residential and light commercial air-conditioning and heat pump systems. This report contains an exhaustive review of the existing literature with the intention of discerning the most efficacious methodologies currently in use for compressor modeling. This fundamental stage was designed to foster a comprehensive understanding of the intricate dynamics and mechanics of compressors. As a result, a model (PDSim) was selected to simulate scroll, rotary and linear compressor technologies.

42 ENGINEERING↗

DOE OSTI2025

High Insulating Vacuum Pump Cart Analysis

To maintain superconductive and cryogenic temperature, it is necessary to utilize high vacuum to eliminate convective heat transfer. To reach the desirable pressure of 10^-6 Torr at a reasonable time, the vacuum pumps and vessel geometry are evaluated for compatibility. Based on the analysis, a list of dry scroll pumps and turbomolecular pumps are recommended.

Chicas, Kelly [Illinois U., Urbana]↗

DOE OSTI2026

Digital Twin User Guide for Chelan County Public Utility District

This user manual offers a comprehensive guide for developing a Digital twin (DT) of a Kaplan turbine at Chelan County Public Utility District (Chelan PUD) using neural networks. As variable renewable generation expands, hydropower units must operate with optimal efficiency and stability. For Kaplan machines, this flexibility is achieved through coordinated control of guide vane (wicket gates) opening and runner blade pitch, which amplifies the plant’s inherent nonlinear behavior and challenges traditional physics-only modeling. The efficiency of the Kaplan turbine varies with different combinations of the guide vans (wicket gate) opening and the blade angle. Each guide van opening and blade angle has a corresponding highest efficiency point, forming a cam relationship that represents the optimal combination.The discharge of a hydraulic turbine is controlled by the opening angle of the guide vans. Therefore, for each value of head, there is a certain guide van opening and blade angle that corresponds to the highest efficiency. For a given head, different combinations of the guide van opening and blade angle have different efficiencies. Therefore, coordinate cam curves are used to describe the relationship between the wicket gate opening and blade angle with different water head. To address these challenges, the manual details a data-driven modeling and learning workflow centered on structured neural networks. The approach is designed to forecast critical operational variables—discharge flow, net head, penstock (or scroll-case) pressure, and generator electrical outputs—by leveraging real-time inputs such as the generator power control setpoint, exciter field current and field voltage, together with hydromechanical commands (e.g., gate position and, when available, runner blade-pitch angle). The neural models are trained and validated on operational data from a Kaplan unit operated by Chelan PUD, demonstrating that the structured NN architecture can learn the coupled gate–blade–electrical dynamics. The result is a robust DT that improves situational awareness and supports data-informed decision-making for Chelan PUD’s Kaplan turbine operations.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

SPRUCE Vegetation Phenology in Experimental Plots from Phenocam Imagery, 2015-2022

This data set consists of PhenoCam data from the SPRUCE experiment from the beginning of whole ecosystem warming (Hanson et al. 2017) in August 2015 through March 31 of 2023, with start- and end-of-season phenological transition dates derived through the end of autumn 2022. Digital cameras, or phenocams, installed in each SPRUCE enclosure track seasonal variation in vegetation “greenness”, a proxy for vegetation phenology and associated physiological activity. Three separate regions of interest (ROIs) were defined for each camera field of view, corresponding to different vegetation types and demarcating (1) Picea trees (vegetation type EN, for evergreen needleleaf); (2) Larix trees (vegetation type DN, for deciduous needleleaf); and (3) the mixed shrub layer (vegetation type SH). This data set consists of three sets of data files: 3-day summary product files: One file for each camera and each ROI (i.e. vegetation type), characterizing vegetation color at a 3-day time step Contains 35 files in *.csv format inside a compressed (*.zip) file. Transition date file: Estimates “greenness rising” (spring) and “greenness falling” (autumn) transition dates derived from the smoothed daily green chromatic coordinate (GCC) values, for each camera and each ROI (i.e. vegetation type) Contains one file in *.csv format Snow flag files: Indicate days with snow on trees or snow on ground for each experimental enclosure Contains two files in *.csv format, one for snow on trees and one for snow on ground This data set consists of two sets of companion files: Accompanying HTML files show the 90th quantiles of the mean GCC plotted together with transition dates for each vegetation type and plot. Contains three files in HTML format, one for each vegetation type One additional file in HTML format with the transition dates plotted for each vegetation type, by year R files for processing Phenocam files and flags. Contains five files in R file (*.R) format in one compressed (*.zip) file User Note: All imagery is posted in near-real time to the PhenoCam Project web page (http://phenocam.sr.unh.edu/), where it is publicly available. Scroll to “spruce” in the Gallery or link directly to the 29 SPRUCE cameras at https://tinyurl.com/y7z5mau7. The data reported here are based on the complete camera record from SPRUCE and supersedes the previously released phenocam datasets (see Related Data Sets). The estimated transition dates for previously released datasets may differ slightly (in most cases, by ±3 days or less), because following standard PhenoCam processing protocols (Richardson et al. 2018, Scientific Data), smoothing and interpolation, outlier removal, and transition date estimation are always conducted using the full data record.

SPRUCE Experiment, Marcell Experimental Forest, Sp↗

DOE OSTI2024

SPRUCE Vegetation Phenology in Experimental Plots from Phenocam Imagery, 2015-2023

This data set consists of PhenoCam data from the SPRUCE experiment from the beginning of whole ecosystem warming (Hanson et al. 2017) in August 2015 through March 31 of 2024, with start- and end-of-season phenological transition dates derived through the end of autumn 2023. Digital cameras, or phenocams, installed in each SPRUCE enclosure track seasonal variation in vegetation “greenness”, a proxy for vegetation phenology and associated physiological activity. Three separate regions of interest (ROIs) were defined for each camera field of view, corresponding to different vegetation types and demarcating (1) Picea trees (vegetation type EN, for evergreen needleleaf); (2) Larix trees (vegetation type DN, for deciduous needleleaf); and (3) the mixed shrub layer (vegetation type SH). This data set consists of three sets of data files: (1) 3-day summary product files: One file for each camera and each ROI (i.e. vegetation type), characterizing vegetation color at a 3-day time step • Contains 36 files in *.csv format inside a compressed (*.zip) file. (2) Transition date file: Estimates “greenness rising” (spring) and “greenness falling” (autumn) transition dates derived from the smoothed daily green chromatic coordinate (GCC) values, for each camera and each ROI (i.e. vegetation type) • Contains one file in *.csv format (3) Snow flag files: Indicate days with snow on trees or snow on ground for each experimental enclosure • Contains two files in *.csv format, one for snow on trees and one for snow on ground This data set consists of two sets of companion files: (1) Accompanying HTML files show the 90th quantiles of the mean GCC plotted together with transition dates for each vegetation type and plot. • Contains three files in HTML format, one for each vegetation type • One additional file in HTML format with the transition dates plotted for each vegetation type, by year (2) R files for processing Phenocam files and flags. • Contains five files in R file (*.R) format in one compressed (*.zip) file User Note: All imagery is posted in near-real time to the PhenoCam Project web page (http://phenocam.sr.unh.edu/), where it is publicly available. Scroll to “spruce” in the Gallery or link directly to the 29 SPRUCE cameras at https://tinyurl.com/sprucecams. The data reported here are based on the complete camera record from SPRUCE and supersedes the previously released data inclusive of the 2015-2022 data (see Related Data Sets). The estimated transition dates for previously released datasets may differ slightly (in most cases, by ±3 days or less), because following standard PhenoCam processing protocols (Richardson et al. 2018, Scientific Data), smoothing and interpolation, outlier removal, and transition date estimation are always conducted using the full data record.

Spruce and Peatland Responses Under Changing Envir↗

DOE OSTI2025

SPRUCE Vegetation Phenology in Experimental Plots from PhenoCam Imagery, 2015-2024

This data set consists of PhenoCam data from the SPRUCE experiment from the beginning of whole ecosystem warming (Hanson et al. 2017) in August 2015 through March 31 of 2025 (2015-08-24 to 2025-03-31), with start- and end-of-season phenological transition dates derived through the end of autumn 2024. Digital cameras, or phenocams, installed in each SPRUCE enclosure track seasonal variation in vegetation “greenness”, a proxy for vegetation phenology and associated physiological activity. Three separate regions of interest (ROIs) were defined for each camera field of view, corresponding to different vegetation types and demarcating (1) Picea trees (vegetation type EN, for evergreen needleleaf); (2) Larix trees (vegetation type DN, for deciduous needleleaf); and (3) the mixed shrub layer (vegetation type SH). This data set consists of three sets of data files: (1) 3-day summary product files: One file for each camera and each ROI (i.e. vegetation type), characterizing vegetation color at a 3-day time step. • Contains 36 files in *.csv format inside a compressed (*.zip) file. (2) Transition date file: Estimates “greenness rising” (spring) and “greenness falling” (autumn) transition dates derived from the smoothed daily green chromatic coordinate (GCC) values, for each camera and each ROI (i.e., vegetation type). • Contains one file in *.csv format. (3) Snow flag files: Indicate days with snow on trees or snow on ground for each experimental enclosure. • Contains two files in *.csv format, one for snow on trees and one for snow on ground. This data set consists of two sets of companion files: (1) Accompanying HTML files show the 90th quantiles of the mean GCC plotted together with transition dates for each vegetation type and plot. • Contains three files in HTML format, one for each vegetation type. • One additional file in HTML format with the transition dates plotted for each vegetation type, by year. (2) R files for processing PhenoCam files and flags. • Contains five files in R file(*.R) format and the components of the phenocamr package (Version 1.1.4) used for calculating transition dates for 2015-2024. These are contained in a compressed (*.zip) file. User Note: All imagery is posted in near-real time to the PhenoCam Project web page (https://phenocam.nau.edu), where it is publicly available. Scroll to “spruce” in the Gallery or link directly to the 29 SPRUCE cameras at https://tinyurl.com/sprucecams. This data set is based on the complete camera record from SPRUCE and supersedes all previously released PhenoCam datasets (see Related Data Sets). The estimated transition dates for previously released datasets may differ slightly (in most cases, by ±3 days or less), because following standard PhenoCam processing protocols (Richardson et al. 2018, Scientific Data), smoothing and interpolation, outlier removal, and transition date estimation are always conducted using the full data record.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Method for Forming Hollow Profile Non-Circular Extrusions Using Shear Assisted Processing and Extrusion (ShAPE)

A process for forming extruded products using a device having a scroll face configured to apply a rotational shearing force and an axial extrusion force to the same preselected location on material wherein a combination of the rotational shearing force and the axial extrusion force upon the same location cause a portion of the material to plasticize, flow and recombine in desired configurations. This process provides for a significant number of advantages and industrial applications, including but not limited to extruding tubes used for vehicle components with 50 to 100 percent greater ductility and energy absorption over conventional extrusion technologies, while dramatically reducing manufacturing costs.

Joshi, Vineet V.↗

DOE OSTI2022

Devices and methods for performing shear-assisted extrusion, extrusion feedstocks, extrusion processes, and methods for preparing metal sheets

Devices and methods for performing shear-assisted extrusion processes for forming extrusions of a desired composition from a feedstock material are provided. The processes can use a device having a scroll face having an inner diameter portion bounded by an outer diameter portion, and a member extending from the inner diameter portion beyond a surface of the outer diameter portion.Extrusion feedstocks and extrusion processes are provided for forming extrusions of a desired composition from a feedstock. The processes can include providing a feedstock having at least two different materials and engaging the materials with one another within a feedstock container.Methods for preparing metal sheets are provided that can include preparing a metal tube via shear assisted processing and extrusion; opening the metal tube to form a sheet having a first thickness; and rolling the sheet to a second thickness that is less than the first thickness.

Whalen, Scott A.↗

DOE OSTI2022

Method for forming hollow profile non-circular extrusions using shear assisted processing and extrusion (ShAPE)

Joshi, Vineet V.↗

DOE OSTI2023

Extrusion processes for forming extrusions of a desired composition from a feedstock

Whalen, Scott A.↗

DOE OSTI2024

Experimental Investigation on Heating Performance of a Cold Climate Thermoelectric-Assisted Heat Pump

To accelerate the electrification of air source heat pumps (ASHPs) in cold climates across the United States, various initiatives have been launched to enhance the effectiveness of ASHPs. One avenue of research involves incorporating thermoelectric (TE) technology into vapor compression refrigeration cycles. This study aims to assess the heating performance of a cold climate ASHP by employing TE modules as a liquid line subcooler. The tested system is a nominal 4.5-ton split heat pump utilizing R410A, equipped with a scroll compressor and an accumulator. An electronic expansion valve was employed for both cooling and heating modes. Two configurations of TE sub-coolers, one utilizing 2 TE bundles and the other 4 TE bundles, were integrated into the liquid line of the tested system. The heating performance of these configurations was evaluated. The results revealed that activating the TE subcooler led to a notable increase in total heat capacity, reaching 1318 W at -15.0 °C and 1164 W at -19.0 °C. The corresponding TE coefficients of performance (COPs) were 1.76 and 1.63, respectively. The activation of the TE sub-cooler resulted in a slight reduction in the overall system COP, with a decrease ranging from -2.6% to -4.2% for these two temperatures. The system COPs were measured at 2.10 and 1.86 for -15.0 °C and -19.0 °C, respectively. This prototype demonstrated a significant augmentation in heating capacity with a minimal sacrifice in COP.

Hu, Yifeng↗

DOE OSTI2025

Normetex Replacement Development

Outline • Background • Previous development efforts • Air Squared redesign • Non-scroll alternatives • Pump performance • Pump performance comparison • Test system overhaul • Conclusions

Angelette, Lucas M. [Savannah River National Labor↗

DOE OSTI2022

Measurement and memory in the periodically driven complex Ginzburg-Landau equation

In the present work we illustrate that classical but nonlinear systems may possess features reminiscent of quantum ones, such as memory, upon suitable external perturbation. As our prototypical example, we use the two-dimensional complex Ginzburg-Landau equation in its vortex glass regime. Here, we impose an external drive as a perturbation mimicking a quantum measurement protocol, with a given “measurement rate” (the rate of repetition of the drive) and “mixing rate” (characterized by the intensity of the drive). Using a variety of measures, we find that the system may or may not retain its coherence, statistically retrieving its original glass state, depending on the strength and periodicity of the perturbing field. The corresponding parametric regimes and the associated energy cascade mechanisms involving the dynamics of vortex waveforms and domain boundaries are discussed.

97 MATHEMATICS AND COMPUTING↗