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DOE OSTI2026

Environmental Durability Assessment and Development of Subcomponent Test Methods for Advanced Materials in Marine Energy Applications: Preprint

Marine energy developers are beginning to rely more heavily on advanced composite materials for their load bearing structures. Understanding how these materials respond and degrade in harsh marine environments is a complex problem. Much research has been performed at smaller laboratory scales to understand the fundamental physical and chemical degradation mechanisms, but little structural testing research has been performed at larger scales to understand how these physical and chemical interactions scale and how they should be accounted for in the design process. The Advanced Materials project is a multilaboratory research collaboration that has been addressing these issues with the intention of reducing risks and barriers to marine energy developers wanting to adopt advanced composite materials. The National Laboratory of the Rockies has been playing a leading role in developing larger scale testing infrastructure and test methods to validate complex numerical degradation models and standardize testing procedures to do so. This paper provides a review of past structural testing activities and how they have grown into current research activities and will continue to evolve into the future to directly address industry needs. This paper covers key research areas large-scale water absorption and subsequent structural validation testing, qualification of bolted and adhesive connections, and conducting combined submerged fatigue testing at increasing scales. This paper provides insights into the complex requirements for testing infrastructure and test method development to effectively qualify materials and certify marine energy structures for harsh marine environments. This research program paves the way for better guidance and standardization within the industry when adopting advanced composite materials.

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

Sparse Bayesian mass mapping with uncertainties: hypothesis testing of structure

ABSTRACT A crucial aspect of mass mapping, via weak lensing, is quantification of the uncertainty introduced during the reconstruction process. Properly accounting for these errors has been largely ignored to date. We present a new method to reconstruct maximum a posteriori (MAP) convergence maps by formulating an unconstrained Bayesian inference problem with Laplace-type l1-norm sparsity-promoting priors, which we solve via convex optimization. Approaching mass mapping in this manner allows us to exploit recent developments in probability concentration theory to infer theoretically conservative uncertainties for our MAP reconstructions, without relying on assumptions of Gaussianity. For the first time, these methods allow us to perform hypothesis testing of structure, from which it is possible to distinguish between physical objects and artefacts of the reconstruction. Here, we present this new formalism, and demonstrate the method on simulations, before applying the developed formalism to two observational data sets of the Abell 520 cluster. Initial reconstructions of the Abell 520 catalogues reported the detection of an anomalous ‘dark core’ – an overdense region with no optical counterpart – which was taken to be evidence for self-interacting dark matter. In our Bayesian framework, it is found that neither Abell 520 data set can conclusively determine the physicality of such dark cores at $99{{\ \rm per\ cent}}$ confidence. However, in both cases the recovered MAP estimators are consistent with both sets of data.

Price, M. A.↗

DOE OSTI2018

Nitride Layer Screening as Carrier-Selective Contacts for Silicon Heterojunction Solar Cells

A three-architecture method for screening new materials' viability as carrier-selective contacts for silicon solar cells is presented. Test-structure solar cells were fabricated with a standard silicon heterojunction contact for the front side, and one of three treatments on the back: bare silicon, intrinsic amorphous silicon (i-aSi:H), or n-type amorphous silicon on an i-aSi:H passivation layer. Then, the candidate contact material of interest was deposited on the back of each test structure and the cells were finished with evaporated Al. By analysing the current-voltage characteristics of each type of architecture, the carrier selectivity and surface passivation quality of novel contact materials or material stacks can be rapidly screened. To demonstrate the utility of this method, we present a preliminary investigation of nitride compounds as electron-selective contacts in silicon solar cells, in particular zinc tin nitride (ZnSnN2), which is naturally n-type and has favourable band alignments with c-Si. ZnSnN2 was deposited by reactive sputtering as an electron contact on each test structure. No passivation was observed, but decent electron-selectivity was observed when in direct contact with the silicon wafer. When combined with intrinsic amorphous silicon, poor performances were obtained with poor selectivity and the occurrence of an S-shape, likely due to insufficient selectivity of the ZTN. Similar results were obtained for 2 nm and 20 nm thick layers, indicating selectivity did not result from the Al over-layer, but was in fact due to the ZTN itself. Overall, this work shows the three-architecture screening method is a useful tool for assessing novel contact materials for silicon heterojunction solar cells.

14 SOLAR ENERGY↗

DOE OSTI2016

Joule heating induced thermomigration failure in un-powered microbumps due to thermal crosstalk in 2.5D IC technology

Thermal-crosstalk induced thermomigration failure in un-powered microbumps has been found in 2.5D integrated circuit (IC) circuit. In 2.5D IC, a Si interposer was used between a polymer substrate and a device chip which has transistors. The interposer has no transistors. If transistors are added to the interposer chip, it becomes 3D IC. In our test structure, there are two Si chips placed horizontally on a Si interposer. The vertical connections between the interposer and the Si chips are through microbumps. We powered one daisy chain of the microbumps under one Si chip; however, the un-powered microbumps in the neighboring chip are failed with big holes in the solder layer. We find that Joule heating from the powered microbumps is transferred horizontally to the bottom of the neighboring un-powered microbumps, and creates a large temperature gradient, in the order of 1000 °C/cm, through the un-powered microbumps in the neighboring chip, so the latter failed by thermomigration. In addition, we used synchrotron radiation tomography to compare three sets of microbumps in the test structure: microbumps under electromigration, microbumps under thermomigration, and microbumps under a constant temperature thermal annealing. The results show that the microbumps under thermomigration have the largest damage. Furthermore, simulation of temperature distribution in the test structure supports the finding of thermomigration.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

ADDITIVE MANUFACTURING AND REGULATORY TESTING OF CANISTERS FOR SPENT NUCLEAR FUEL MANAGEMENT

The back end of the fuel cycle focuses on the interim storage, transportation, and final disposition of the spent nuclear fuel from nuclear reactors. Commercial light water nuclear power stations across the United States operate with fuel assemblies being irradiated for up to 6 years (planned) in the reactor pressure vessel. After their planned irradiation, the fuel assemblies are moved to a spent fuel pool within the facility complex. After the spent nuclear fuel is removed from the fuel pool, it is typically inserted into a welded metal canister that can be transferred between overpacks for storage, transportation and possibly disposal. Most dry storage systems being used by industry today use dual purpose canisters (DPCs), designed for use in storage and transportation overpacks, but not specifically designed for disposal. Triple purpose-canisters, designed for disposal in addition to storage and transportation, have also been researched. Traditional manufacturing methods for spent fuel canisters involve fusion welding along the length or circumference of the canister which results in high tensile residual stresses in the joint weld zone (WZ) and heat affected zone (HAZ). In this paper, spent fuel canister designs were printed by wire arc additive manufacturing (AM) using the 316L SS welding wire to demonstrate: 1. Feasibility of spent nuclear fuel canister fabrication using this advanced manufacturing method, 2. Dynamic response of the additive manufacture canister design when subjected to the federally mandated Normal Conditions of Transport (NCT) and Hypothetical Accident Conditions (HAC) physical tests for Type B packages. This paper will focus on the canister printing design and structural tests. The AM 3D printed design, regulatory testing, and post-test evaluation of the canister tested to the 10 CFR 71.71 and 10 CFR 71.73 requirements will be presented. One AM canister design was subjected to the penetration, free drop, and puncture test. Before and after the dynamic structural tests, the AM canister design was scanned with a handheld scanner to capture a 3D CAD geometry to compare to the 3D printed canister design in the deformed shape. The scanned geometry was sectioned in areas with deformation and the cross-section profile was measured to determine accurate and repeated results of the deformed shape of the AM canister design.

Martinez, Oscar↗

DOE OSTI2019

Solving the structure of Lgl2, a difficult blind test of unsupervised structure determination

In the companion paper by Ufimtsev and Levitt [Ufimtsev IS, Levitt M (2019) Proc Natl Acad Sci USA , 10.1073/pnas.1821512116], we presented a method for unsupervised solution of protein crystal structures and demonstrated its utility by solving several test cases of known structure in the 2.9- to 3.45-Å resolution range. Here we apply this method to solve the crystal structure of a 966-amino acid construct of human lethal giant larvae protein (Lgl2) that resisted years of structure determination efforts, at 3.2-Å resolution. The structure was determined starting with a molecular replacement (MR) model identified by unsupervised refinement of a pool of 50 candidate MR models. This initial model had 2.8-Å RMSD from the solution. The solved structure was validated by comparison with a model subsequently derived from an alternative crystal form diffracting to higher resolution. This model could phase an anomalous difference Fourier map from an Hg derivative, and a single-wavelength anomalous dispersion phased density map made from these sites aligned with the refined structure.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2026

Interconnect: Cooperative Research and Development Final Report, CRADA Number CRD-13-00507 (Project 4)

This CRADA modification involves analyses on a variety of CdTe-PV related materials, test structures, solar cells, and modules produced at FSLR and/or NLR and adds analysis related to module degradation and reliability. Materials will be provided by FSLR, NLR, and/or by interleaving FSLR and NLR layers and processes. Module reliability activities will include technical risk assessment, materials characterization, module and test structure characterization, modeling, accelerated test development, and outdoor testing.

14 SOLAR ENERGY↗

DOE OSTI2016

Study of the structures of cleaved cross sections by Raman spectroscopy

Scanning confocal Raman spectroscopy is used to study the crystal structure of GaAs irradiated with Mn{sup +} ions with subsequent pulse laser annealing. The scanning of cleaved cross sections of samples shows that the structure completely recovers over the depth of implantation after the annealing. Scattering in the coupled phonon–plasmon mode is revealed, which is indicative of electrical activation of the impurity at Mn doses above 1 × 10{sup 16} cm{sup –2}. The study shows the possibilities of using scanning confocal Raman spectroscopy in investigations of cleaved cross sections of structures. Using a test structure with a single δ-doped C layer, we show that the lateral resolution of the technique is 300 nm.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Radiation Hard CMOS Sensors for Detector at High Energy Colliders

In this project we developed a radiation hard CMOS sensor architecture for High Energy Colliders. The key accomplishments were: 1. Developed a sensor architecture to support very high occupancy rate and hit rates 2. Developed, simulated (TCAD), and fabricated 20 different types of pixelated test structures for the quadruple well high resistivity substrate process. Measured performance of these pixel test structures; Dark currents were found to be close to physical limits; and Quantum efficiency were found to be close to ideal as well 3. Defined the scope for the PDK for the quadruple well process on high resistivity silicon Highlights of the new architecture are: Readout of pixel arrays with reconstruction efficiency >99% at hit rates of 500 MHits/cm 2 and array occupancy of 0.2%; Minimization of in-pixel signal storage requirement (data will be read out at frame rates of 1MHz); Low power dissipation through integration of fragmented projection architecture (Minimum analog power dissipation); Pixel array level data reduction (Hit location is encoded through shape of sub-block projections); Programmable resolution and frame rate (Pixels can be binned to increase frame rate); Minimum data overhead, encoded projection results for all sub-blocks are read out without location information

43 PARTICLE ACCELERATORS↗

DOE OSTI2016

Empirically testing vaterite structural models using neutron diffraction and thermal analysis

Otoliths, calcium carbonate (CaCO 3 ) ear bones, are among the most commonly used age and growth structures of fishes. Most fish otoliths are comprised of the most dense CaCO 3 polymorph, aragonite. Sturgeon otoliths, in contrast, have been characterized as the rare and structurally enigmatic polymorph, vaterite a metastable polymorph of CaCO 3 . Vaterite is an important material ranging from biomedical to personal care applications although its crystal structure is highly debated. We characterized the structure of sturgeon otoliths using thermal analysis and neutron powder diffraction, which is used non-destructively. We confirmed that while sturgeon otoliths are primarily composed of vaterite, they also contain the denser CaCO 3 polymorph, calcite. For the vaterite fraction, neutron diffraction data provide enhanced discrimination of the carbonate group compared to x-ray diffraction data, owing to the different relative neutron scattering lengths, and thus offer the opportunity to uniquely test the more than one dozen crystal structural models that have been proposed for vaterite. Of those, space group P6 5 22 model, a = 7.1443(4)Å , c = 25.350(4)Å , V = 1121.5(2)Å 3 provides the best fit to the neutron powder diffraction data, and allows for a structure refinement using rigid carbonate groups.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2019

Emplacement Room Mock-up Structure for Testing the Placement of Nuclear Waste Within a Deep Geologic Repository - 19271

The Nuclear Waste Management Organization (NWMO) has conceptualized a unique method of long-term storage for spent nuclear waste. The concept encompasses all aspects of the end-of-life process from the point the spent fuel is no longer in-service; including handling, shipping, containing, storing, monitoring, and finally decommissioning. The equipment developed for each process is unique and designed specifically for each operation. Since these methods have not been implemented before, it is required to prove each process and the related equipment through simulations and eventually practical tests to evaluate performance and to confirm effective and safe operation. The spent fuel will be stored in an underground repository several hundred meters below the surface using autonomous machinery. Considering the significant investment and labour involved in creating full-scale tests underground, it would be impractical at this project stage to attempt tests of the newly developed machinery and methods in other than a surface setting. Therefore, our scope was to provide a customizable mock-up structure to simulate the conditions and constraints an underground repository would present. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Pre-production results from ATLAS ITk Strip Sensors Quality Assurance Testchip

The production of strip sensors within the framework of the ATLAS Inner Tracker (ITk) development is a process which requires continuous evaluation during the full production period (about 4 years). Such an evaluation is divided into two different parts: Quality Control (QC), which focuses on the final product (the actual sensors) and tries to identify possible defects once the fabrication is completed, and Quality Assurance (QA), which aims to prevent deviations in the manufacturing process and uses specifically-designed test structures. The initial sensor pre-production consists of 5% (1041 sensors) of the total number of sensors expected during production. As part of pre-production, the collaboration has measured key parameters from miniature strip sensors (minis), monitor diodes (MD8), and the ATLAS Testchip, before and after irradiation. In this contribution we focus on the analysis of the results of the MD8 and the Testchip. All parameters have been obtained from the test structures (MD8, bias resistors, interdigitated structures, field oxide capacitors, coupling capacitors, punch-through protection structures and cross-bridge resistors) measured at the different test sites (KEK/Tsukuba, Birmingham, Toronto, Ljubljana, Valencia, Carleton, Prague, CNM-Barcelona). The results are compared to predefined pre- and post-irradiation specifications for each tested parameter.

47 OTHER INSTRUMENTATION↗

DOE OSTI2026

GaN Core-shell Nanofin Vertical Transistor (CoNVerT): A New Direction for Power Electronics (Final Scientific/Technical Report)

A novel power transistor architecture, the GaN c ore-shell n anofin ver tical transistor (CoNVerT) to address fundamental challenges in realizing the ultimate limit of GaN power transistor performance was explored experimentally. This technology promises ultra-high-efficiency high voltage/high power applications (e.g. DC/DC converters, motor control, fast charging, actuation), as well as to operate in harsh environments. The device exploits a vertical superjunction structure based on an experimentally-validated core-shell nanofin growth process in which lateral p-n heterojunctions are formed in a single growth step, while still maintaining vertical current flow for compact die size and low cost. The concept leverages the best properties of GaN for mid-range voltage applications: high mobility, high breakdown voltage, and native heterojunction enhancement-mode operation. Due to the crystallographic nature of the nanofin growth by molecular beam epitaxy, the sidewall heterojunctions occur on non-polar planes, resulting in ultra-smooth interfaces for high mobility, no sidewall etch damage and related surface/interface states, and elimination of piezoelectric effects that can limit reliability in conventional structures. This also facilitates superjunction formation for maximum device performance, and the selective-area growth of the nanofin results in dislocation-free growth, even on low-cost Si (111) substrate. In this program, core-shell nanofins were grown by molecular beam epitaxy, test structures to evaluate the doping, resistivity, and other electrical properties were fabricated, and the material and test structures were characterized in detail. The work identified clear potential (e.g., the doping was well controlled as required for superjunction concepts), but also additional areas that require additional effort to resolve (some unexpected crystal defects were encountered that require additional engineering to overcome). Simulation studies of the proposed concept validate that the fundamental approach is very promising, but additional effort in experimental realization is needed.

42 ENGINEERING↗

DOE OSTI2022

Voronoi Meshing to Accurately Capture Geological Structure in Subsurface Simulations

Mesh generation lies at the interface of geological modeling and reservoir simulation. Highly skewed or very small grid cells may be necessary to accurately capture the geometry of geological features, but the resulting poorly scaled or small grid cells can have a substantial negative impact on simulator accuracy and speed. One way to minimize numerical errors caused by gridding complex structures is to simulate on high-quality Voronoi meshes, which reduce grid orientation effects in fluid flow. This work presents a complete methodology to create Voronoi simulation grids, model fluid flow in complex geological systems, and visualize the results. A recently developed Voronoi meshing method that can automatically generate provably good unstructured meshes that conform to input surfaces creating closed volumes is used. Initially an analytical benchmark simulation is presented to validate the quality of the meshes and simulation results and demonstrate the superiority of simulation results using Voronoi meshes over flexed-hexahedral meshes on a domain with internal features. Next, meshes are created for test structures representing four of the most common geological features in the subsurface: layering, pinch-out, an interior lens that tapers to zero thickness on all sides and a fault with offset. Two benchmark flow simulations are run for each test structure. Finally, a realistic geological example for CO 2 injection into an anticline is simulated. Three realizations of the Voronoi mesh at the same resolution are generated for the simulations. Each mesh is highly refined near the injection wells and coarse in areas of less interest. These three meshes are used to model the CO 2 plume in the subsurface as it migrates to the top of the structure and then fills downward. Simulations on the meshes with randomly generated elements inside the input volumes each give slightly different fingering patterns for the viscous-unstable buoyant gas flow. The results presented in this work show a promising step towards utilizing fully automated Voronoi meshing for subsurface flow simulations in complex geology.

58 GEOSCIENCES↗

DOE OSTI2023

Design, Manufacture, and Testing of an Open-Source Benchmark Composite Hydrokinetic Turbine Blade: Preprint

In a trend toward clean energy alternatives, recent years have seen great strides in the marine energy space. Consequently, there is a pressing need for the design, development, and validation of novel energy harvesting technologies such as hydrokinetic devices, which capture kinetic energy from waves, tides, and currents. However, these devices span numerous concepts and designs that often lack solid benchmark research that can be freely referenced throughout their development. This work focuses on the design process of an open-source composite hydrokinetic turbine blade for a three-bladed marine turbine rotor assembly with a diameter of 2.5 m. The proposed blade consists of two structural composite skins that are bonded with an adhesive and filled with a foam core. This study also explores and contrasts the efficiency and resolution of low-fidelity rapid design methodologies and comprehensive high-fidelity approaches in the context of blade design, modeling, and analysis efforts, a key objective in this research. Blade hydrodynamic loads were modeled and applied to finite-element blade models to study deformations and potential failure. Ongoing and upcoming efforts will result in blade manufacture and structural testing at the National Renewable Energy Laboratory. In future work, multiple blades will be deployed at the Living Bridge site at the University of New Hampshire and will be compared to rigid aluminum blades of the same geometry, developed by Sandia National Laboratories. Ultimately, this research will lay foundational groundwork for researchers and manufacturers, establishing a baseline composite blade design that will serve as a benchmark in the development of future hydrokinetic turbine blades.

blade design↗

DOE OSTI2026

Characterization of Electronic Stress-Induced Changes in Multilayer MoS 2

Transition metal dichalcogenides like molybdenum disulfide (MoS 2 ) are compelling for next-generation electronic devices. In this work, we investigate the impact of electronic stress on MoS 2 to illustrate that observational and phenomenological information on multiple devices can be useful to describe changes in the device, and caution against the rationalization of paltry results as representative or correlative to device behavior. Here, we stress MoS 2 by applying a sustained 20 V DC bias to study the material’s response. Post-stress electronic characterization revealed nonuniform shifts in current–voltage (I–V) behavior alongside microscale changes. Complementary mechanical, spectroscopic, and scanning microwave impedance measurements showed that stress-induced features locally modulate stiffness, surface potential, Raman intensity, and charge carrier density. We correlated I–V behavior with morphological features (wrinkles, tears, folds, height) and device-level geometry (MoS 2 overlap with electrodes, channel area, contact length) on 50 test structures across five chips to move beyond anecdotal conclusions. We found no universal correlations before DC stress. However, device-level geometry was correlated with I–V behavior after DC stress, suggesting that electrode contacts play a more dominant role than morphology in determining performance. Delamination and thinning induced by DC stress led to localized reductions in charge carrier density within the affected regions. Further, delamination and thinning appear to map to I–V device performance in a few samples, but the correlation is lost when a larger sample size is considered. This suggests significant sample-to-sample variability in surface electronic states of the test structures. We also discuss how environmental factors introduced during fabrication may contribute to the observed heterogeneous device response. Progress will require high-resolution, multimodal analysis across many samples constructed under controlled, clean conditions. By building data sets that capture variability, we can better identify the true drivers of performance.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Charge collection in irradiated HV-CMOS detectors

Active silicon detectors built on p-type substrate are a promising technological solution for large area silicon trackers such as those at the High Luminosity LHC, but the radiation hardness of this novel approach has to be evaluated. Active n-in-p strip detector prototypes CHESS2 for ATLAS with different substrate resistivities in the range of 20-1000 Omega cm were irradiated with neutrons and protons up to a fluence of 2 x 10(15) n(eq) cm(-2) and 3.6 x 10(15) n(eq) cm(-2). Charge collection in passive test structures on the chip was evaluated using Edge-TCT and minimum ionising electrons from Sr-90. Results were used to assess radiation hardness of the detector in the given fluence range and to determine parameters of initial acceptor removal in different substrates.

active silicon detectors↗

DOE OSTI2020

Inserting a Low-Refractive-Index Dielectric Rear Reflector into PERC Cells: Challenges and Opportunities

One of the simplest and most effective ways to reduce the operating temperature of photovoltaic systems in the field is to reflect unusable, 'sub-bandgap' light with energies below the cell absorber's bandgap energy. In this work, low-refractive index SiO2 nanoparticle films inserted between c-Si wafers and metal electrodes significantly increase the reflectance of sub-bandgap light in fabricated test structures. These films are then integrated into the standard PERC fabrication sequence, revealing that the reflection benefits remains after some processing steps but are lost in certain conditions. The SiO2 nanoparticle films are easily ablated during laser contact opening, but are undesirably etched during post-laser cleaning. After Al metallization, the fully fabricated devices show enhanced sub-bandgap reflection when annealed at moderate temperatures, but energy-dispersive X-ray spectroscopy shows that high-temperature firing causes unwanted Al penetration into the SiO2 nanoparticle film, compromising reflection.

14 SOLAR ENERGY↗