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Properties and Controlling Processes of Aerosol and Cloud Condensation Nuclei in Marine Boundary Layer Over Eastern North Atlantic (Final Report)
Remote marine low cloud systems have large spatial and temporal coverages. Because of their relatively low optical thickness and background aerosol concentrations, marine low clouds are particularly susceptible to perturbations in aerosols associated with anthropogenic emissions. Recent studies show that a large fraction of the global aerosol indirect forcing can be attributed to changes in marine low clouds, despite their relatively long distance from most anthropogenic sources. Currently, there remain large uncertainties in the magnitude of the global aerosol indirect radiative forcing. One major contribution to this large uncertainty derives from poor understanding of the aerosols under natural conditions, the perturbation by anthropogenic emissions, and the processes that drive them. In this project, we took advantage of the comprehensive, multi-dimensional characterization of meteorological parameters, trace gases, aerosol, cloud, and drizzle fields during the Aerosol and Cloud Experiments in Eastern North Atlantic (ACE-ENA) and the long-term measurements at the Atmospheric Radiation Measurement (ARM) Eastern North Atlantic (ENA) site on Graciosa Island. By synergistically combining in situ measurements, remote sensing retrievals, and model simulations, we quantified aerosol properties in the ENA, their vertical profiles, and variations with season, synoptic state, and airmass. We investigated key aerosol processes, including entrainment of free troposphere aerosol into marine boundary layer, new particle formation, growth of Aitken mode particles, and the influences of these processes on the cloud condensation nuclei (CCN) population in marine boundary layer. The representation of key aerosol processes in the Energy Exascale Earth System Model (E3SM) was evaluated using the observations. This project has led to 26 publications, which are listed at the end of this report.
Reconstruction of sparse, nanoscale metrology data for efficient process control.
Abstract not provided.
Automated Process Control for Industrial Production of Alkali Antimonide Photocathodes
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Advanced Process Control and Dynamic Optimization of Reversible Solid Oxide Cell Systems for Performance and Long-Term Health
This presentation was delivered at the 2024 Hydrogen Annual Merit Review Meeting. It focuses on three aspects of projects focusing on solid oxide cell systems- advanced control including nonlinear model predictive control and traditional control, dynamic optimization with due consideration of chemical degradation over the cell lifetime, dynamic optimization considering physical degradation.
Developing tools and process controls to manufacture energy-efficient powders for additive manufacturing feedstocks: Computational analysis of metal powder manufacturing via machining
Traditionally, metal powders have been produced through methods such as grinding, atomization, and electrolysis. In contrast to these techniques, Metal Powder Works, Inc. has pioneered a methodology based on metal cutting. This innovative approach utilizes a vibrating cutting tool to machine metal particles, in the form of chips, from a workpiece. This technique allows for control of powder particle size, morphology, and avoids any thermally induced material changes. This collaboration aims to elucidate metal cutting characteristics and assess performance on tough materials like Inconel alloys. Computational models, using FEA and SPH techniques, will be developed initially, focusing on aluminum alloy (Al 7075-T6) for studying mesh sensitivity, cutting forces, and chip morphology.
Developing tools and process controls to manufacture energy-efficient powders for additive manufacturing feedstocks
Traditionally, metal powders have been produced through methods such as grinding, atomization, and electrolysis. In contrast to these techniques, Metal Powder Works, Inc. has pioneered a methodology based on metal cutting. This innovative approach utilizes a vibrating cutting tool to machine metal particles, in the form of chips, from a workpiece. This technique allows for control of powder particle size, morphology, and avoids any thermally induced material changes. This collaboration aims to elucidate metal cutting characteristics and assess performance on tough materials like Inconel alloys. Computational models, using FEA and SPH techniques, will be developed initially, focusing on aluminum alloy (Al 7075- T6) for studying mesh sensitivity, cutting forces, and chip morphology.
Elucidating Processes Controlling Arctic Atmospheric Aerosol Sources, Aging, and Mixing States (Final Report)
Atmospheric aerosols play critical roles in the Earth’s energy budget, directly by scattering or absorbing solar and terrestrial radiation and indirectly by serving as seeds (nuclei) for cloud droplet and ice crystal formation and by depositing on snow and ice surface, thereby changing the surface albedo. These effects are dependent on aerosol particle size and chemical composition and impact the hydrological cycle as well. This project provided single-particle size and chemical composition measurements across the entire annual cycle in the high Arctic and in the Alaskan Arctic during fall – winter, addressing the most significant gaps in Arctic aerosol observational data. These needs were based on recent rapid sea ice loss across the entire Arctic, as well as the major annual delays in sea ice freeze-up during fall in the Chukchi Sea and increased wintertime sea ice fracturing in the Beaufort Sea, both off the North Slope of Alaska. Two DOE Atmospheric Radiation Measurement (ARM) field campaigns were conducted for atmospheric aerosol sampling. The Aerosols during the Polar Utqiagvik Night (APUN – ‘snow on ground’ in Iñupiaq) ARM field campaign at Utqagivik, Alaska was conducted from Oct. 28 – Dec. 22, 2018. Aerosol sizing instrumentation and a single-particle mass spectrometer were successfully deployed for size-resolved number concentration measurements and measurements of individual particle size and chemical composition, respectively. These results show the influence of locally-produced sea spray aerosol, with high cloud-forming potential, due to delayed sea ice freeze-up in the fall. During the 2019‐2020 international Multidisciplinary drifting Observatory for the Study of Arctic Climate (MOSAiC) expedition, daily atmospheric aerosol particles were collected aboard the German icebreaker Polarstern in the Central Arctic from Nov. 2019 – Oct. 2020. Sea salt aerosol and marine organics were observed year-round during MOSAiC with varying morphologies and sources. These findings are important because most Arctic models do not include a sea spray aerosol source, despite this source increasing with declining sea ice extent. In addition to collecting new samples and data, this project also conducted further analysis of previously collected single-particle chemical composition measurements within the North Slope of Alaska oil fields and at Utqiaġvik, AK, during Aug. – Sep. 2015 and 2016 field campaigns. This work resulted in the discovery of chemical reactions of oil field combustion emissions occurring within fog droplets across the North Slope of Alaska and forming secondary aerosol, showing the impact of Arctic oil field emissions beyond black carbon aerosol and greenhouse gases. In addition, the distribution of chemical species across the aerosol population within the oil fields was quantified, using these data and a previously development framework. We also presented the first ambient evidence of the collision of two atmospheric particles resulting in formation of an organic-coated ammonium sulfate particle of marine origin, which has implications for cloud formation with declining sea ice extent. Overall, this project has elucidated connections between seawater biogeochemistry, resource extraction activities, atmospheric composition, clouds, and the energy budget of the Arctic region. The results of this project are expected to improve weather and sea ice forecasting for security and development in the Arctic and beyond.
Process Control to Develop a Continuous Flow Al Covetic Reactor Design
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Advanced Manufactured Sensors: Feedstock Development, Fabrication and Process Control
Advanced Manufactured Sensors Project Summary
Process optimization and statistical process control of small features in metal additive manufacturing: It?s the little things that count.
Abstract not provided.
Demonstration of a digital twin of a laser ablated aluminum alloy 6061 disk for fault detection and process control.
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Southern Ocean Aerosols Field Campaign Report
Atmospheric processes over the Southern Ocean have a profound influence on regional and global climate. This is a part of the world where global climate models perform particularly poorly, with models persistently overpredicting the amount of sunlight reaching the Earth's surface (Regayre et al. 2020). A major challenge when trying to improve the representation of atmospheric processes in this part of the globe is the scarcity of observations capable of constraining our understanding. During 2024/25 a U.S. Department of Energy Atmospheric Radiation Measurement (ARM) User Facility field campaign (CAPE-k) deployed a suite of instrumentation at the kennaook/Cape Grim atmospheric monitoring station in Tasmania, Australia to provide detailed cloud-aerosol observations in this region in order to address the greatest source of uncertainty in climate models – atmospheric aerosols and how they influence cloud formation (Carslaw et al. 2013). In support of the ARM observations, an Australian Research Council (ARC)-funded project “Southern Ocean aerosols: sources, sinks and impact on cloud properties,” led by the Queensland University of Technology, complemented the ARM measurements with a suite of chemical measurements at the kennaook/Cape Grim site in northwestern Tasmania to provide more information on the processes controlling aerosol formation and growth. The deployment of the University of York LIF-SO2 instrument (Temple et al. 2025) in the ARM mobile facility container was part of this chemistry-focused deployment. Increased observational efforts are critical for understanding sources and sinks of Southern Ocean aerosols, in particular the role of marine micro-organisms (phytoplankton, algae) on aerosols formation, their properties and growth, cloud droplet formation, and the conversion of cloud droplets to ice crystals and precipitation. The observational focus of the ARC-funded project is aerosol chemical composition and their gaseous precursors. The remote nature of the Southern Ocean poses a significant analytical challenge when studying gaseous precursors, as low concentrations are often below the limits of detection of commercial instrumentation. Historically this has meant that observations have had to be time-averaged over days to weeks to achieve the limits of detection required. Although useful when considering overall average levels of aerosol precursors, this time-averaging obscures temporal variability that can provide insight into the controlling processes. Over recent years advances in analytical techniques have made high-time-resolution measurements of key gas-phase aerosol precursors achievable with sufficiently low limits of detection.
Recent progress in atomic-scale controlled plasma processing
Atomic-scale control in plasma processing is becoming increasingly critical for fabricating of advanced semiconductor devices, particularly as the industry shifts toward three-dimensional (3D) architectures and high-aspect-ratio (HAR) structures. This review presents a comprehensive overview of recent developments in atomic-scale controlled plasma processes, organized along two key directions: the hierarchical structure of plasma–surface interactions and the generational evolution of atomic layer processing (ALP) technologies. We examined the gas phase, where molecular design enables selective generation of ions and radicals; the boundary layer, where transport phenomena govern species delivery into nanoscale features, and the surface, where temperature-dependent reactions and cyclic processing determine etching selectivity and precision. Building on this foundation, we outline five generations of ALP—from thermal atomic layer deposition to transport-aware, temporally and structurally decoupled processes—highlighting the increasing sophistication of process control. The review further explores the transition from empirical recipe development to science-based, data-driven methodologies. By integrating quantum-chemical modeling, advanced diagnostics, and machine learning, we demonstrated how predictive models can link plasma species composition to process outcomes, enabling autonomous and adaptive control strategies. Finally, this review discusses the broader societal implications of plasma process innovation through the E4 quartet: energy and resource efficiency, environmental sustainability, evolutionary advancement, and educational promotion. These principles guide the development of sustainable and intelligent atomic-scale manufacturing technologies that are not only technically advanced but also socially responsible.
In situ characterization of material extrusion printing by near-infrared spectroscopy
Material extrusion printing of reactive resins and inks present a unique challenge due to the time-dependent nature of the rheological and chemical properties they possess. As a result, careful print optimization or process control is important to obtain consistent, high quality prints via additive manufacturing. Here, we present the design and use of a near-infrared (NIR) flow through cell for in situ chemical monitoring of reactive resins during printing. Differences between in situ and off-line benchtop measurements are presented and highlight the need for in-line monitoring capability. Additionally, in-line extrusion force monitoring and off-line post inspection using machine vision is demonstrated. By combining NIR and extrusion force monitoring, it is possible to follow cure reaction kinetics and viscosity changes during printing. When combined with machine vision, the ability to automatically identify and quantify print artifacts can be incorporated on the printing line to enable real-time, artificial intelligence-assisted quality control of both process and product. Together, these techniques form the building blocks of an optimized closed-loop process control strategy when complex reactive inks must be used to produce printed hardware.
PD21A680: Additive Manufacturing Process Optimization and Qualification FY21 Year-end Report
This project builds upon knowledge gained from previous projects on Additive Manufacturing (AM) operation, process control and monitoring, repeatability, and process improvement. This project will exclusively focus on metal powder bed additive manufacturing (PBAM). Objective 1: Advance metal powder bed AM R&D capabilities. Perform enhanced R&D on increased build volumes and throughput, safety and handling controls, process monitoring, and diagnostics with a focus on production end-states. Objective 2: Build upon knowledge gained from previous PDRD projects to develop deeper understanding of process controls, essential for transitioning metal AM processes for future applications. Objective 3: Maintain business development and research advantages through collaborations with external industry and university partners.
Emerging Threats and Technology Investigation: Industrial Internet of Things - Risk and Mitigation for Nuclear Infrastructure
Industries supporting the global nuclear infrastructure striving for cost savings, expansions in efficiency, and convenience are likely to adopt components (e.g., hardware, software) that comprise the Internet of Things (IoT) and Industrial Internet of Things (IIoT). These devices offer potential improvements along with security challenges. Modern conveniences achieved through application of technology have propagated through society in the form of interconnected devices, from doorbells to microwave ovens, commonly referred to as IoT. IoT devices are often Internet-connected devices that are designed to send data back to a cloud-based server, where a smart phone application then presents device status and control options. Home-based IoT applications carry a different set of risks when compared to a business or security environment, where there is also a history of convenience and interconnection. Industrial settings have long relied on specifically designed Supervisory Control and Data Acquisition (SCADA) systems for process control where IIoT devices are intended to inform business decisions and augment traditional processes. A recent National Institute of Standards and Technology (NIST) report provides a distinction between process control and IIoT in that traditional process control is not replaced by IIoT, but rather IIoT devices are intended to enhance industrial processes through additional monitoring of various sensors and application of data analytics models using artificial intelligence (AI) and machine learning (ML) (Fagan, Marron, et al. 2021) (Ross, et al. 2021).