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626 records · Page 33

Investigating Dual Electrospinning as a Means of Enhancing Passive Thermal Control Coatings for Cryogenic Propellant Storage in Extraterrestrial Environments

Passive thermal control is necessary as space exploration becomes increasingly widespread. Materials with superior optical properties (high solar reflectance and infrared emittance) are critical for passive thermal control because they can reject most of the incident solar radiation and promote thermal emission from cryogenic propellant storage tanks, enabling the extraterrestrial storage of cryogens. We have demonstrated in previous studies that electrospun nanofibers exhibit exceptional optical properties, offering significant benefits for passive radiative cooling in space. Particularly, electrospun polyvinylidene fluoride-co-hexafluoropropylene PVDF-HFP nanofibers demonstrate exceptionally high solar reflectance (>99%) and strong thermal emittance (measured at ~300 K). However, they exhibit nanostructural changes in the presence of atomic oxygen, which is prevalent in Low Earth Orbit. This study focuses on creating a unique blend of polymeric (PVDF-HFP) and ceramic-based (silica) nanofibers by leveraging the chemical stability and atomic oxygen resistance of silica, using the dual electrospinning manufacturing method. This approach aims to preserve the structural properties of the polymeric counterpart without compromising its optical performance, thereby providing an innovative method for manufacturing environmentally resilient passive thermal control nanofibers with desirable optical and thermal control functionalities for extraterrestrial storage of cryogenic propellants.

Chieloka Ibekwe

Artemis II Mission Performance of the Orion Active Thermal Control System

The Orion spacecraft has recently completed Artemis II, the first crewed mission around the moon in 54 years. This test flight demonstrated vehicle capability as the foundation for all future missions under the Artemis program. As a major system of Orion, the Active Thermal Control System (ATCS) successfully managed crew and vehicle heat loads to provide adequate cooling and thermal comfort for the duration of the Artemis II mission. Thermal control on the Orion vehicle is managed through two redundant cooling loops in the Crew Module (CM) that absorb heat loads from the cabin and Air Revitalization System (ARS) heat exchangers, the Liquid Cooling Garment (LCG) heat exchanger, and the avionics cold plates, and then transfer those heat loads to the Service Module (SM) radiator loops and/or the Phase Change Material (PCM) and ammonia boilers when required through thermal configuration or mission phase. During Artemis II, Orion did not necessitate any supplemental cooling from ammonia boilers until service module separation, allowing the maximum availability of ammonia cooling prior to entry. This presentation will provide an overview of the Orion ATCS major subsystems, highlight the performance during key mission phases, and comment on the applicability of the observed thermal response to future Artemis missions.

Ellie Thurston

Tensorized Interior Radiative Heat Transfer for a Scalable and Calibrated Building Energy Simulator

Building energy simulation is a critical tool for developing and testing advanced control strategies, such as Reinforcement Learning (RL), to provide demand flexibility and affordable energy costs. The recently introduced Smart Buildings Control Suite (sbsim) provides a lightweight, scalable, and data-calibrated simulation environment based on a 2D finite-difference model. However, the initial model primarily focused on conductive and convective heat transfer, neglecting the significant impact of long-wave radiative heat exchange between interior surfaces. This paper presents a significant extension to the sbsim framework by incorporating a physically-grounded model for interior radiative heat transfer. Our primary contribution is the development and integration of a fully tensorized radiative heat transfer module, which preserves the computational efficiency and scalability of the original simulator. This was achieved by developing a pipeline for view factor calculation, including an algorithm to identify directly seeing surfaces within complex floor plans, and formulating the net radiation equations for efficient execution on modern hardware accelerators. We validate the numerical accuracy of our tensorized implementation by comparing its results against a traditional iterative approach, demonstrating identical outcomes. This enhancement increases the physical fidelity of sbsim, enabling more accurate training of RL agents for building energy optimization.

Ham, Sang woo

Chapter 19A – Radar Cross Section

The material in this Section will provide the novice Flight Test Engineer (FTE) with a brief overview of the radar cross section (RCS) concept. Brief details of radar range descriptions, operations, target calibrations, and data reduction are included. It is noted that these range operations concentrate on the "static" test range rather than the much more sophisticated "dynamic" test range. The dynamic test range is what the FTE will probably work with. Radar reflectivity measurement has developed over the last two decades from a relatively simple endeavor involving the measurement of target RCS amplitude statistics to involving wide band, coherent systems that can measure high resolution images of targets as well as, in many cases, the polarization and phasing properties. This rapid growth in RCS technology has occurred because of the increased use of radar in today's commercial and military systems. In general, the goal for commercial systems is to enhance radar reflectivity, whereas the military goal is to reduce radar reflectivity. Also, classification and identification are important for military purposes because in adverse weather radar may be the only system that may be capable of separating enemy targets from friendly ones. This Section will discuss the fundamentals of RCS. Since the flight test techniques associated with RCS measurements are very similar to those of antenna pattern measurements, both will be presented at the same time in Section 19B Antenna Radiation Pattern Measurements.

Robert W Borek

Development and Validation of a High-Vacuum Thermal Conductivity Testbed for Aerospace Interface Materials

Spacecraft thermal margins depend on the temperature penalty of installed interfaces, yet catalog conductivity omits bondline thickness, mating surfaces, preload, and environment. The Testbed for Advanced Interface Materials in Vacuum (TAIMV) addresses this engineering-data gap by converting ambient/vacuum temperature fields from a four-coupon stack into quantities usable in spacecraft thermal models. Its 17-node steady-state model resolves axial conduction, parasitic fixture paths, grease-filled contact, radiation, and ambient convection. Four monolithic checks gave axial heat-rate ratios of 0.90–1.02, and Braycote calibration self-recovery gave 2.20% casewise mean absolute percentage error (MAPE) and 2.85% maximum difference. With transferable fixture terms frozen, Krytox LVP tested cross-material transfer against a manufacturer-derived external relation. The six Krytox cases gave 2.28% MAPE, 5.10% maximum difference, and full-field residual root-mean-square values of 0.553 °C ambient and 1.306 °C vacuum. Installed-joint resistance spanned 6.39–7.15 × 10⁻⁴ m²·K/W for Braycote and 4.09–4.49 × 10⁻⁴ m²·K/W for Krytox, corresponding to 2.33–6.66 K per modeled interface over the tested heat-flux range. TAIMV therefore supplies directly usable installed-joint resistance and conductance, plus apparent installed conductivity and explicitly model-conditioned grease conductivity/contact terms.

heat transfer

Space Shuttle Main Engine Propellant Path Leak Detection Using Sequential Image Processing

Initial research in this study using theoretical radiation transport models established that the occurrence of a leak is accompanies by a sudden but sustained change in intensity in a given region of an image. In this phase, temporal processing of video images on a frame-by-frame basis was used to detect leaks within a given field of view. The leak detection algorithm developed in this study consists of a digital highpass filter cascaded with a moving average filter. The absolute value of the resulting discrete sequence is then taken and compared to a threshold value to produce the binary leak/no leak decision at each point in the image. Alternatively, averaging over the full frame of the output image produces a single time-varying mean value estimate that is indicative of the intensity and extent of a leak. Laboratory experiments were conducted in which artificially created leaks on a simulated SSME background were produced and recorded from a visible wavelength video camera. This data was processed frame-by-frame over the time interval of interest using an image processor implementation of the leak detection algorithm. In addition, a 20 second video sequence of an actual SSME failure was analyzed using this technique. The resulting output image sequences and plots of the full frame mean value versus time verify the effectiveness of the system.

L Montgomery Smith

Lepto-axiogenesis with light right-handed neutrinos

We study lepto-axiogenesis in theories where the right-handed neutrino is light enough that its dynamics affect the determination of the baryon asymmetry. When compared with theories of high-scale lepto-axiogenesis where the Majorana neutrino mass may be treated as an effective dimension-five operator, we find that the predicted saxion mass is lower. Two distinct scenarios emerge. In the first, processes that generate the baryon asymmetry are in equilibrium down to the mass of the right-handed neutrino. In the second, the relevant processes never reach equilibrium; the baryon number freezes in. We comment on implications for supersymmetric spectra and discuss constraints on late decays of supersymmetric relics and from dark radiation. In contrast to high-scale lepto-axiogenesis, which predicts superpartners with masses of 10–100 TeV or more, we find this scenario is consistent with a wider range of superpartner masses, all the way down to current direct search bounds.

Axions and ALPs

Mechanics and Cooling of the CMS Phase-II Tracker Barrel

The CMS upgrade for the High-Luminosity LHC (HL-LHC) era will allow for an incredibly high rate of data collection, to be used in the next generation of precision measurements and searches for beyond the standard model physics. A key element of this upgrade is the full replacement of the silicon strip tracker to enable level-1 triggering on track level primitives, produced by pixel-strip (PS) and strip-strip (2S) modules, tiled together to form the new detector. Mechanically supporting and cooling these modules is not trivial, as material budget in the tracker volume is highly constrained, and as the modules accrue radiation damage they risk becoming entirely non-functional if the silicon sensors are not sufficiently cooled. To address this, each region of the tracker has a bespoke solution for housing and cooling their modules, mostly depending on carbon-fiber and carbon-foam structures, with dual phase CO2 cooling. For the most central part of the tracker, the Flat Barrel with PS modules (Flat TBPS) covers the pseudorapidity range out to $|\eta|=0.4$, and the mechanical structures are manufactured, assembled, and tested entirely by Fermilab and UC Davis. This presentation will describe the intense design and testing requirements for these components, and how they will ensure strong performance of the tracker through the HL-LHC era.

Cosby, Christopher [Fermilab]

Assessing the Adhesion of Nanofibrous PVDF-HFP as Passive Thermal Control Coatings for the Extraterrestrial Storage of Cryogenic Propellants

Cryogenic propellant passive thermal management techniques in space are essential complements to active thermal management methods, helping reduce absolute dependence on the latter. Particularly, materials with superior optical properties (high solar reflectance and infrared emittance) would be beneficial for passive thermal control to reject most of the incident solar radiation and enhance thermal emission from the storage tank, leading to self-cooling. We developed a nanofibrous, porous passive thermal control material by electrospinning polyvinylidene fluoride-co-hexafluoropropylene (PVDF-HFP) co-polymer onto an aluminum foil substrate. The material exhibits a very high solar reflectance (>99%) and infrared emittance (~86%) when characterized in the ultraviolet-visible-near infrared and mid-infrared wavelengths. This study focuses on the adhesion of the nanofibrous PVDF-HFP to the substrate. We incorporated in-lab fabricated and commercial adhesives, under normal room conditions, between the nanofibers and the aluminum foil substrate to improve their adhesion. Some samples were also exposed to space-like conditions – vacuum and thermal cycling, to investigate their effects on the strengths of adhesives. Subsequently, adhesion peel tests were conducted on all the samples to assess the peel strengths of the bonds. Peel test strengths after space environment conditioning of the adhesives were generally higher than those observed in the pristine, unaged samples. The results are discussed in this study.

Chieloka Ibekwe

Space Suit Material Compatibility with Space Vehicle Coolant PMS-1.5R

During a survey of 82P on February 11, 2023, a shiny substance was detected on the Progress vehicle. The suspected material was PMS-1.5R, a low volatility silicone oil coolant used in the vehicle. Crew exposure to the coolant was a concern as the low volatility would increase residence time, the time a material will stay on a surface after exposure to vacuum. A review of space suit materials revealed several materials with compatibility concerns that could impact Extravehicular Activity (EVA) operations and safety. To understand the risk, space suit materials were exposed to a simulant and tested. This testing provided the basis for rationale generated to continue with EVA operations for US EVA 86 on April 2, 2023. This testing also served as the basis to assess impacts to ISS EMU hardware due to potential contamination brought inside ISS on Russian space suits during RS EVA 61 on October 25, 2023, following an ISS Russian Multipurpose Lab Module (MLM) radiator leak of the same fluid on October 9, 2023. This paper will discuss the testing performed and analyze test results impacts to EVA operations. Additional work was conducted to determine coolant evaporation rates in space vacuum and demonstrate that no significant unreacted coolant from the MLM leak would remain on ISS surfaces long enough to contaminate the EMU or affect the ISS ECLSS water separator.

Space Suit Materials

Photophoretic Propulsion Enabling Mesosphere Exploration NIAC Phase I Final Report

This Phase I report presents a comprehensive study on photophoretic flyers—innovative, ultralight, solar-powered vehicles that harness photophoretic forces generated via Knudsen pumping to achieve sustained flight in the mesosphere (50–80 km altitude). By integrating advanced materials such as nanocardboard— characterized by its extremely low areal density (~1 g/m²) and high bending stiffness—with ultrathin light-absorbing coatings, the project converts incident solar radiation directly into a directed thrust. Extensive experimental investigations, coupled with high-fidelity computational fluid dynamics (CFD) simulations using ANSYS Fluent, validate the concept across various three-dimensional geometries, including spherical, conical, and rocket-shaped configurations. These simulations bridge the gap between free-molecular and continuum flow regimes, demonstrating that optimized designs can generate lift forces sufficient to support kilogram-scale payloads even in low-pressure environments. At the heart of this innovation is the use of Knudsen pumping, where temperature gradients across porous surfaces induce directional gas flow, creating a modest overpressure that provides lift. The report introduces an analytical framework that interpolates between the well-known low-Reynolds number drag regime and the high-Reynolds number momentum theory. This model accurately predicts lift based on design parameters such as microchannel dimensions, porous wall geometry, areal density, and nozzle exit area. For instance, simulations indicate that 10-meter-scale structures with carefully engineered porous walls can achieve the necessary pressure differential to support scientifically significant payloads (~1 kg). The study also explores a hybrid propulsion approach that combines solar buoyancy with photophoretic lift. Initially, solar heating creates a buoyant force that elevates the flyer to mesospheric altitudes. Once in the optimal pressure range, the photophoretic mechanism—powered by Knudsen pumping—takes over as the primary source of lift, ensuring stable, long-duration flight. This dual-mode operation not only facilitates the deployment of photophoretic flyers but also broadens the potential applications for mesospheric exploration. In addition to propulsion, the report investigates the integration of photophoretic thrusters for trajectory control of existing research balloons in the upper stratosphere. By dynamically adjusting the nozzle orientation and controlling the flow-through velocity, these thrusters provide precise maneuverability, enabling the flyers to counteract atmospheric disturbances and adjust their flight paths in real time. For example, a photophoretic thruster approximately 7.5 by 7.5 meters in size could be unfolded below a payload gondola of a 60 million-cubic-foot zero-pressure balloon. Such a thruster can provide horizontal speed control of approximately 1 m/s using only sunlight and no moving parts (except those needed to track the Sun and control the jet direction). Importantly, photophoretic thrusters operate more efficiently at higher altitudes, which is complementary to known trajectory control techniques, such as propellers and tethered wings, which are more effective at lower altitudes. Finally, the report identifies three scientific research thrusts where mesospheric aircraft technology can have a profound impact: atmospheric tides, characterization of gravity waves, and investigation of mesospheric instabilities. Overall, the findings of this Phase I project represent a significant advancement in photophoretic propulsion technology. By demonstrating that large-scale, ultralight structures can be powered solely by solar radiation—via carefully engineered Knudsen pumping—this work lays a robust foundation for scalable, near-space flight architectures. Future refinements in material fabrication, structural optimization, and integrated trajectory control are expected to further enhance performance, paving the way for operational demonstrations that could revolutionize atmospheric science, remote sensing, and communication networks.

Knudsen Pump

Metrology for femtosecond pulsed x-ray heating in diamond anvil cell experiments at the European XFEL: Revisiting the iron phase diagram up to 150 GPa

The development of pulsed intense x-ray sources, such as free electron laser, offers new avenues for high pressure experiments. Here, we study the feasibility and metrology of x-ray heating in diamond anvil cells at the European x-ray free electron laser. This method enables one to volumetrically heat the sample while inhibiting chemical migration and probing the crystallographic structure of the sample throughout the heating with a high repetition rate. We focus our study on iron, whose phase diagram is well established up to 100 GPa, to explore the possibilities and limitations of this technique. We volumetrically heat iron samples at starting pressures ranging from 10 to 138 GPa, using the x-ray beam pulsed at 4.5 MHz in a serial pump-and-probe experimental design. Experimental challenges arise from temperature gradients within the sample, changes in temperature at the 100 ns timescale, the difficulty of direct temperature estimates, the effect of thermal pressure, and the presence of metastable crystallites due to rapid cycles of heating and cooling. Hence, we develop a multi-crystal-like data processing method that allows us to account for sample heterogeneity in probed conditions. We then calibrate our measurements using known physical properties of iron under pressure. Thermal pressure in our experiments increases from 4% of the isochoric prediction at 10 GPa to 23% at 138 GPa, and we show that our data are in agreement with most previous observations of iron in this pressure range. The method can now be implemented at higher pressures and temperatures and on materials with unknown phase diagrams.

Materials science

Combustor Technology for Future Small Gas Turbine Aircraft

To enhance fuel efficiency, future advanced small gas turbine engines will utilize engine cycles calling for overall engine pressure ratios, leading to higher combustor inlet pressures and temperatures. Further, the temperature rise through the combustor and the corresponding exit temperature are also expected to increase. This report describes future combustor technology needs for small gas turbine engines. New fuel injectors with large turndown ratios which produce uniform circumferential and radial temperature patterns will be required. Uniform burning will be of greater importance because hot gas temperatures will approach turbine material limits. The higher combustion temperatures and increased radiation at high pressures will put a greater heat load on the combustor liners. At the same time, less cooling air will be available as more of the air will be used for combustion. Thus, improved cooling concepts and/or materials requiring little or no direct cooling will be required. Although presently there are no requirements for emissions levels from small gas turbine engines, regulation is anticipated in the near future. This will require the development of low emission combustors. In particular, nitrogen oxides will increase substantially if new technologies limiting their formation are not evolved and implemented. For example, staged combustion employing lean, premixed/prevaporized, lean direct injection, or rich burn-quick quench-lean burn concepts could replace conventional single stage combustors. Due to combustor size considerations, staged combustion is more easily accommodated in large engines. The inclusion of staged combustion in small engines will pose greater combustor design challenges.

Valerie J Lyons

xEMU Spacesuit Boot Lunar South Pole Thermal Vacuum Testing

The Exploration Extravehicular Mobility Unit (xEMU) spacesuit lunar boot was evaluated in the Jet Propulsion Lab (JPL) CITADEL thermal vacuum chamber at lunar South Pole conditions. The JPL CITADEL chamber provides a radiation environment and contact plate temperature of 48K, simulating the temperature of a lunar Permanently Shadowed Region (PSR) at the South Pole of the Moon. The main objectives of the test series are: to evaluate the risk lunar PSRs pose to advanced spacesuit boots, validate the xEMU lunar boot thermal model, and to develop a test methodology to evaluate lunar spacesuit boots. To simulate the thermal effects of a crewmember’s foot inside the boot, a thermal manikin foot was developed to inject heat into the spacesuit boot. Thermal data was collected through a variety of sensors including thermocouples, thermistors, heat flux sensors, and infrared cameras. A test matrix was developed to investigate the variables of foot contact force, simulated skin temperature, external contact plate temperature, and ventilation flowrate. The JPL CITADEL chamber includes a loadlock (airlock) that afforded the ability to simulate the transition of the boot from a thermally neutral IVA condition to a cold EVA condition within seconds. This paper will document the test design, test objectives, success criteria, test support equipment, spacesuit boot to chamber interfaces, and configuration of the test article. Additionally, this paper will document the high-level results of the testing. More detailed test results will be presented in a different paper.

Ben Swartout

xEMU Spacesuit Boot Lunar South Pole Thermal Vacuum Testing

The Exploration Extravehicular Mobility Unit (xEMU) spacesuit lunar boot was evaluated in the Jet Propulsion Lab (JPL) CITADEL thermal vacuum chamber at lunar South Pole conditions. The JPL CITADEL chamber provides a radiation environment and contact plate temperature of 48K, simulating the temperature of a lunar Permanently Shadowed Region (PSR) at the South Pole of the Moon. The main objectives of the test series were: to evaluate the risk lunar PSRs pose to advanced spacesuit boots, validate the xEMU lunar boot thermal model, and develop a test methodology to evaluate lunar spacesuit boots. To simulate the thermal effects of a crewmember’s foot inside the boot, a thermal manikin foot was developed to inject heat into the spacesuit boot. Thermal data was collected through a variety of sensors including thermocouples, thermistors, heat flux sensors, and infrared cameras. A test matrix was developed to investigate the variables of foot contact force, simulated skin temperature, external contact plate temperature, and ventilation flowrate. The JPL CITADEL chamber includes a loadlock (airlock) that afforded the ability to simulate the transition of the boot from a thermally neutral IVA condition to a cold EVA condition within seconds. This paper will document the test design, test objectives, success criteria, test support equipment, spacesuit boot to chamber interfaces, and configuration of the test article. Additionally, this paper will document the high-level results of the testing. More detailed test results will be presented in a different paper.

TVAC

HTGR Multiphysics Application Drivers FY26 Updates

This report summarizes FY26 progress under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program's high-temperature gas-cooled reactor (HTGR) application driver work, covering a wide range of activities such as code validation and multi-physics code assessment. 1) A detailed SAM model of the High-Temperature Engineering Test Reactor (HTTR) was developed using a unique-block grouping approach, with an extended parallel thermal network method to capture block-to-block conduction and radiation heat transfer, and applied to steady-state simulations of the HTTR 30~MW and 9~MW cases. 2) In another activity, SAM's newly implemented multi-component gas flow model was validated against the Natural convection Shutdown heat removal Test Facility (NSTF) argon ingress experiment, correctly capturing the density-driven suppression and thermal recovery of natural circulation observed when argon is introduced into the air-cooled Reactor Cavity Cooling System (RCCS) loop. 3) For the OECD/NEA High Temperature Test Facility (HTTF) benchmark, we co-led the international benchmark activities as well as the OECD/NEA final benchmark report to be released at the end of this year. 4) Finally, the coupled Griffin-SAM modeling capability for pebble-bed HTGRs was advanced by verifying the Griffin neutronics solution against Serpent Monte Carlo for a realistic non-uniform temperature distribution, resolving several deficiencies in the SAM-to-Griffin temperature transfer scheme, and enabling distinct fuel kernel, moderator, and coolant temperatures for cross section feedback. These new features were demonstrated in a PBR load-following transient.

Lee, Alvin

Hybrid Modeling Study on Grain Evolution in the Metal Welding Process and Its Potential Lunar Application

Metal is most commonly used structural material in a wide range of spacecraft, and welding is the principal method for joining metal components into functional systems. However, conducting welding experiments under extreme environments—such as microgravity or vacuum conditions in space—is prohibitively expensive and experimentally challenging. To overcome these limitations, multi-physics computational welding models provide a cost-effective and versatile alternative. In this work, the authors have developed a coupled thermal (fluid) microstructure simulation framework to model metal welding under varying gravity conditions. The framework integrates a mixed-mode heat transfer formulation (conduction, convection, and radiation) with molten pool fluid dynamics, enabling accurate prediction of temperature fields and weld-pool geometry. A grain growth model is further incorporated to capture the spatial and temporal evolution of microstructure, including grain size distribution and morphological transitions during solidification. This approach provides detailed insight into molten pool evolution and grain-level microstructure development throughout the welding process. By explicitly parameterizing environmental conditions, the model supports extrapolation to off-Earth manufacturing scenarios such as welding on the lunar surface. Tantalum—chosen in this study due to its high melting point, oxidation resistance, and mechanical stability at elevated temperatures—serves as the material system for model demonstration. Beyond Tantalum, the integrated multi-physics framework offers broad applicability for predictive welding simulations of various structural and refractory metals or alloys used in extreme terrestrial or extraterrestrial environments.

kinetic Monte Carlo (SPPARKS)

HydraGNN_Predictive_GFM_2026 - Ensemble of predictive graph foundation models for atomistic materials modeling

This release contains data and parameters of HydraGNN-based graph foundation models trained as a result of the work published in the pre-print "Exascale Multi-Task Graph Foundation Models for Imbalanced, Multi-Fidelity Atomistic Data" by M. Lupo Pasini et al. (https://arxiv.org/abs/2604.15380). We jointly train on 16 open first-principles datasets (544+ million structures covering 85+ elements) using a multi-task architecture with per-dataset heads and a scalable ADIOS2/DDStore data pipeline. On Frontier, we execute six large-scale DeepHyper hyperparameter optimization campaigns in FP64 and promote the top-performing message-passing models to sustained 2,048-node training, yielding a PaiNN-based lead model. The version of HydraGNN used to generate the outputs provided in this release is HydraGNN v5.0 (https://github.com/ORNL/HydraGNN/releases/tag/v5.0) The list of datasets used for the training of the graph foundation model is the following: 1) Alexandria [1] 2) ANI1x [2] 3) MPTrj [3] 4) Open Catalyst 2020 (OC20) [4] 5) Open Catalyst 2022 (OC22) [5] 6) Open Catalyst 2025 (OC25) [6] 7) Open Direct ir Capture 2023 (ODAC23) [7] 8) Open Materials 2024 (OMat24) [8] 9) Open Molecules 2025 (OMol25) [9] 10) OMol25-neutral (subset of OMol25 that contains only molecules with zero total charge) 11) OMol25-non-neutral (subset of OMol25 that contains only molecules with non-zero total charge) 12) Open Polymers 2026 (OPoly2026) [10] 13) Nabla2DFT [11] 14) QCML [12] 15) QM7X [reference 13] 16) transition1x [14] Dataset references: [1] J. Schmidt et al., “A dataset of 175k stable and metastable materials calculated with the PBEsol and SCAN functionals,” Scientific Data, vol. 9, p. 64, 2022. [2] J. S. Smith et al., “The ANI-1ccx and ANI-1x data sets, coupled-cluster and density functional theory properties for molecules,” Scientific Data, vol. 7, p. 134, 2020. [Online]. Available: https: //www.nature.com/articles/s41597-020-0473-z [3] A. Jain et al., “Commentary: The Materials Project: A materials genome approach to accelerating materials innovation,” APL Materials, vol. 1, no. 1, p. 011002, 07 2013. [Online]. Available: https://doi.org/10.1063/1.4812323 [4] L. Chanussot et al., “Open catalyst 2020 (oc20) dataset and community challenges,” ACS Catalysis, vol. 11, no. 10, pp. 6059–6072, 2021. [Online]. Available: https://doi.org/10.1021/acscatal.0c04525 [5] K. Tran et al., “Open catalyst 2022 (oc22) dataset and challenges for oxidation electrocatalysts,” ACS Catalysis, vol. 13, no. 5, pp. 3066–3084, 2023. [Online]. Available: https://doi.org/10.1021/acscatal.2c05426 [6] S. J. Sahoo et al., “The open catalyst 2025 (oc25) dataset and models for solid-liquid interfaces,” arXiv preprint arXiv:2509.17862, 2025. [Online]. Available: https://arxiv.org/abs/2509.17862 [7] A. Sriram et al., “The open DAC 2023 dataset and challenges for sorbent discovery in direct air capture,” ACS Central Science, vol. 10, no. 5, pp. 923–941, 2024. [8] L. Barroso-Luque et al., “Open materials 2024 (omat24) inorganic materials dataset and models,” 2024. [Online]. Available: https://arxiv.org/abs/2410.12771 [9] D. S. Levine et al., “The open molecules 2025 (OMol25) dataset, evaluations, and models,” 2025. [Online]. Available: https://arxiv.org/abs/2505.08762 [10] D. S. Levine et al., The open polymers 2026 (OPoly26) dataset and evaluations,” arXiv preprint arXiv:2512.23117, 2025. [Online]. Available: https://arxiv.org/abs/2512.23117 [11] K. Khrabrov et al., “Nabla2dft: A universal quantum chemistry dataset of drug-like molecules and a benchmark for neural network potentials,” in NeurIPS 2024 Datasets and Benchmarks Track, 2024. [Online]. Available: https://openreview.net/forum?id=ElUrNM9U8c [12] S. Ganscha et al., “The QCML dataset, quantum chemistry reference data from 33.5M DFT and 14.7B semi-empirical calculations,” Scientific Data, vol. 12, p. 406, 2025. [13] J. Hoja et al., “QM7-X, a comprehensive dataset of quantum-mechanical properties spanning the chemical space of small organic molecules,” Scientific Data, vol. 8, p. 43, 2021. [Online]. Available: https://www.nature.com/articles/s41597-021-00812-2 [14] M. Schreiner et al., “Transition1x - a dataset for building generalizable reactive machine learning potentials,” Scientific Data, vol. 9, p. 779, 2022. The folder "datasets_ADIOS2_format" contains the set of pre-processed datasets in Adaptable I/O System (ADIOS) format (https://www.exascaleproject.org/research-project/adios/) that have been used for the development and training of GFMs in this work. The "datasets_ADIOS2_format" directory contains 2 sub-directories, one for the version "v1" of the datasets and one for the version "v2" of the datasets. The version "v1" of the datasets provides values of the total energy as they are extracted from the original data as it was released by the respective institutions. The version "v2" of the datasets provides values of the energy that have been realigned. The realignment was performed by training a linear regression model that predicts the total energy as a function of the chemical composition of the atomistic structure, and then subtract such prediction from the original value of the total energy. Both folders "v1" and "v2" contain 16 sub-directories, each corresponding to an ADIOS2-formatted dataset The folder "DeepHyper-results" contains the configurational files and model's parameters for all the 186 HPO trials that were successfully completed by the scalable hyperparameter optimization (HPO) runs on Frontier. The content of the folder "DeepHyper-results" I structured as follows: 1) task-list.txt: list of mpnn name, jobid, and deephyper task id 2) gfm_${MPNN}_${JOBID}_0.${TASKID}: run directory with checkpoint files 3) gfm_${MPNN}: deephyper summary directory (*.csv) for each specific MPNN type 4) deephyper-experiment-${JOBID}: output and error logs for each job The file "deephyper-sorted.csv" contains the details of each HydraGNN model built and tested by HPO, obtained by merging the (*.csv) filed from each HPO run executed. Out of all the HPO trials, we selected 10 to continue the training of the respective HydraGNN models. Due to limited computational budget available in the LRN070 allocation we could not complete the training till convergence for all these 10 selected models. The folder "models" contains multiple sub-folders, one per each HydraGNN model trained. Each model sub-folder contains the parameters of each HydraGNN model, with multiple checkpoint-restarts. The list of sub-folders are as follows: 1) multidataset_hpo-BEST1-fp64 2) multidataset_hpo-BEST2-fp64 3) multidataset_hpo-BEST3-fp64 4) multidataset_hpo-BEST4-fp64 5) multidataset_hpo-BEST5-fp64 6) multidataset_hpo-BEST6-fp64 7) multidataset_hpo-BEST7-fp64 8) multidataset_hpo-BEST8-fp64 9) multidataset_hpo-BEST9-fp64 10) multidataset_hpo-BEST10-fp64 Within each one of these folders, additional auxiliary log files are provided with descriptions about how the training proceeded. The lead PaiNN-model is contained inside "multidataset_hpo-BEST6-fp64". The file "mlp_branch_weights" contains the parameters of the multi-layer perceptron (MLP) used to reconcile the predictions of the 16 output decoding heads of the HydragNN architectures. The MLP takes in input the chemical composition of the atomistic structure and predicts averaging weights to linearly mix the predictions of each output decoding head toward consolidating them into a single one. The folder "1.1billion-structure-inference" contains 1.1 billion atomistic structures randomly generated. Each structures is associated with energy and forces predicted with the lead-PaiNN model combined with the MLP model for reconciliation of the multi-branch predictions generated by the 16 output decoding heads. The folder "1.1billion-structure-inference" contains 9,300 (*.tar.gz) subdirectories, one per Frontier compute node used to execute the inference at exascale. Once uncompressed, each (*.tar.gz) subdirectory contains an ADIOS2 (*.bp) file container, where each atomistic structure is stored as a PyTorch-Geometric Data object. The file "export_dataset_environment_variables.sh" contains the environment variables that need to be set before running the HydraGNN code to reproduce the results provided in this dataset release. The code that can be used to load the ADIOS2 files, load HydraGNN models, and run inference is available at: https://github.com/ORNL/HydraGNN/releases/tag/v5.0

36 MATERIALS SCIENCE