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

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At least 595 records · Page 33

Targeted Adaptive Design

Modern advanced manufacturing and advanced materials design often require searches of relatively high-dimensional process control parameter spaces for settings that result in optimal structure, property, and performance parameters. The mapping from the former to the latter must be determined from noisy experiments or from expensive simulations. Here, we abstract this problem to a mathematical framework in which an unknown function from a control space to a design space must be ascertained by means of expensive noisy measurements, which locate control settings generating desired design features within specified tolerances, with quantified uncertainty. We describe targeted adaptive design (TAD), a new algorithm that performs this sampling task efficiently. TAD creates a Gaussian process surrogate model of the unknown mapping at each iterative stage, proposing a new batch of control settings to sample experimentally and optimizing the updated expected log-predictive probability density of the target design. TAD either stops upon locating a solution with uncertainties that fit inside the tolerance box or uses a measure of expected future information to determine that the search space has been exhausted with no solution. TAD thus embodies the exploration-exploitation tension in a manner that recalls, but is essentially different from, Bayesian optimization and optimal experimental design.

97 MATHEMATICS AND COMPUTING↗

Development of Industrial Scale Rare Earth Master Alloys from Their Native Oxides for Magnet Production

The objective of the project is to develop an energy-efficient, reduced cost, and single-step critical metal oxide reduction and alloying methodology for the production of NdFeB and SmCo magnets to facilitate the establishment of a sustainable domestic critical materials supply chain. The method consists of an immiscible molten salt flux layer and a higher density molten metal alloy pool (FeB or Co). The rare earth (RE) oxide and a reductant are added to the molten salt layer, where the reductant first strips the oxygen from the rare earth oxide. Subsequently, the separated RE metal diffuses into the molten metal pool below, creating a RE-saturated master alloy. Towards this end, thermodynamic calculations of the reactions between RE oxides, metallic reducing agent, and molten salt bath chemistry have been performed, and the ideal feeds and conditions for extraction and diffusion to produce master alloys were established. Small-scale and scaled experimentation was performed to validate and optimize the feasibility of viable reactions, temperatures, and process conditions with regards to yield, composition, and process efficiency. Finally, full-scale experiments for the production of NdFeB and SmCo magnets were performed, and their performance characteristics were established.

36 MATERIALS SCIENCE↗

Influence of the as-built microstructure on the recrystallization of an additively manufactured Inconel939 Ni-based superalloy

This study investigates the influence of the as-built microstructure on the recrystallization (RX) behavior and mechanical properties of the Ni-based superalloy Inconel 939 produced by laser powder bed fusion (PBF-LB/M). Two distinct as-built microstructures were obtained by varying the hatch distance (h d ): a columnar, strongly textured condition (h d =50, termed h d 50) and an equiaxed, weakly textured condition (h d =70, termed h d 70)). Both were subjected to nine solution treatments combining three temperatures (1100, 1150, and 1200 °C) and three holding times (1, 4, and 8 h). Comprehensive microstructural characterization was conducted to assess grain morphology, texture, grain boundary character, dislocation density, and precipitate distribution. Recrystallization was found to be significantly slower than in cast counterparts, requiring higher temperatures and longer times for completion. The initial microstructure plays a decisive role: full RX was achieved only in hd70 specimens after treatment at 1200 °C for 8 h, whereas hd50 samples exhibited delayed and incomplete RX under identical conditions. This behavior is attributed to the finer grain size and higher fraction of high-angle grain boundaries in hd70, which promote recrystallization. Mechanical testing revealed that hd70 samples subjected to a 1200 °C/8 h treatment followed by standard double ageing show higher yield and tensile strengths across the investigated temperature range than both printed and cast Inconel939 processed under conventional conditions, albeit with slightly reduced ductility. The enhanced mechanical performance is attributed to the larger grain size, which limits grain boundary sliding. These results demonstrate the critical importance of controlling the as-built microstructure and tailoring post-processing strategies to optimize high-temperature performance of PBF-LB/M Inconel939.

Inconel939↗

ZEUS: An Efficient GPU Optimization Method Integrating PSO, BFGS, and Automatic Differentiation

We introduce a novel, efficient computational method, ZEUS, for numerical optimization, and provide an open-source implementation. It has four key ingredients: (1) particle swarm optimization (PSO), (2) the use of the Broyden-Fletcher-Goldfarb-Shanno (BFGS) method, (3) automatic differentiation (AD), and (4) GPUs. Our approach addresses the computational challenges inherent in high-dimensional, non-convex optimization problems. In the first phase of the algorithm, we get a potentially good set of starting points using PSO. Thereafter, we run BFGS independently in parallel from these starting points. BFGS is one of the best-performing algorithms for numerical optimization. However, it requires the gradient of the function being optimized. ZEUS integrates automatic differentiation into BFGS thus avoiding the need for the user to calculate derivatives explicitly. The use of GPUs allows ZEUS to speed up the calculations substantially. We carry out systematic studies to explore the trade-offs between the number of PSO iterations taken, starting points, and BFGS iteration depth. We show that a handful of iterations of PSO can improve global convergence when combined with BFGS. We also present performance studies using common test functions. The source code can be found at https://github.com/fnal-numerics/global-optimizer-gpu.

Soos, Dominik [Old Dominion U.]↗

Superlative mechanical energy absorbing efficiency discovered through self-driving lab-human partnership

Energy absorbing efficiency is a key determinant of a structure’s ability to provide mechanical protection and is defined by the amount of energy that can be absorbed prior to stresses increasing to a level that damages the system to be protected. Here, we explore the energy absorbing efficiency of additively manufactured polymer structures by using a self-driving lab (SDL) to perform >25,000 physical experiments on generalized cylindrical shells. We use a human-SDL collaborative approach where experiments are selected from over trillions of candidates in an 11-dimensional parameter space using Bayesian optimization and then automatically performed while the human team monitors progress to periodically modify aspects of the system. The result of this human-SDL campaign is the discovery of a structure with a 75.2% energy absorbing efficiency and a library of experimental data that reveals transferable principles for designing tough structures.

42 ENGINEERING↗

Selective capture and recovery of uranium oxide colloids from aqueous soil suspensions using high gradient magnetic filtration

High Gradient Magnetic Filtration (HGMF) is a promising method for the selective capture and recovery of uranium oxide from surface soils. To date, however, magnetic filtration of uranium oxide has only been demonstrated at a proof-of-principle scale using relatively small filters (<5 cm 3 ) at low flowrates (<60 mL/min). Here, to explore the efficacy of magnetic filtration of uranium oxide at a larger scale, a newly designed HGMF apparatus that is more than an order of magnitude larger than our earlier filters (106 cm 3 ) was designed, fabricated, and tested at relatively high flowrates. Filtration experiments were performed using aqueous uranium oxide particle suspensions with Arizona Road Dust (ARD) as a soil simulant. At a flowrate of 125 mL/min, the apparatus’ uranium capture rate was exceptionally high (96 %), but selectivity was poor due to the high rate of capture for diamagnetic soil constituents (e.g., 77 % for silicon). All particles were captured at a lower rate when the flowrate was increased to 250 mL/min, but uranium selectivity was significantly increased due to the more substantial reduction in diamagnetic particle capture (i.e., capture rate of 77 % and 15 % for uranium and silicon, respectively). When backwashing the apparatus at the same flowrates used during filtration experiments, the rate of uranium recovery tended to be fairly low. Nevertheless, higher flowrates (1 L/min) and sonication were both shown to be highly effective methods of increasing uranium recovery. Magnetic field simulations were also performed to investigate potential optimizations to the design of the apparatus. These simulations showed that the intensity of the applied magnetic field could be increased by increasing the thickness of the steel magnetic housing. Additionally, stochastic trajectory simulations were performed to investigate the potential mechanisms of particle capture.

HGMF↗

Assessing the Performance and Impact of PV Technologies on Storage in Hybrid Renewable Systems

Traditional monofacial photovoltaic (mPV) systems are commonly adopted and well-documented because of their lower upfront costs in comparison to bifacial photovoltaic (bPV) systems. This study investigates how PV technologies impact energy storage in grid-scale hybrid renewable systems, focusing on optimizing and assessing the performance of mPV and bPV technologies integrated with pumped storage hydropower. Using Ludington City, Michigan as a case study and analyzing real-world data such as solar irradiance, ambient temperature, and utility-scale load profiles, the research highlights the operational and economic benefits of bPV systems. The results reveal that bPV systems can pump approximately 10.38% more water annually to the upper reservoir while achieving a lower levelized cost of energy ($0.0578/kWh for bPV vs. $0.0672/kWh for mPV). This study underscores the outstanding potential of bPV systems in enhancing energy storage and management strategies, contributing to a more sustainable and resilient renewable energy future.

13 HYDRO ENERGY↗

Rapid neutron and gamma-ray source localization using machine learning

Rapid localization of radiation sources is critical for applications including nuclear emergency response, safeguards, and security. However, conventional imaging systems such as neutron scatter cameras and Compton cameras depend on rare coincidence events, which often result in long acquisition times. In this work, we address the challenge of rapid source localization by developing a machine learning approach to predict the direction of a single radiation source using only count rates from an array of neutron and gamma-ray detectors. The proposed model is a fully connected neural network (FCNN) trained using Monte Carlo simulation data from a 252 Cf source. The model hyperparameters are optimized with a small set of routine 252 Cf measurements. We benchmarked the performance of the trained and optimized machine learning model using additional 252 Cf , 137 Cs , and PuBe measurements under laboratory conditions with varying source-detector configurations. For these measurements, the machine learning model achieved a mean localization error smaller than 30° with 3 x 10 3 system counts, corresponding to 8 s measurement time for the imaging system used in this work. In this low-statistics regime, the method outperformed traditional scatter-based imaging by more than 75% in localization accuracy for the evaluated measurement configurations. These results demonstrate that a machine learning-based approach can significantly reduce the time required for accurate single-source localization, providing a robust and computationally efficient alternative to traditional imaging systems in time-critical nuclear security and emergency response scenarios.

Gamma-ray imaging↗

Enabling Efficient Sparse Computations using Linear Algebra Aware Compilers

This project developed the LAPIS compiler framework, built on the Multilevel Intermediate Representation (MLIR), to optimize sparse linear algebra operations and support performance portability across diverse architectures. The main innovation of LAPIS is the Kokkos dialect, which allows for lowering codes from a high productivity language to different architectures in an elegant way. The dialect also allows the conversion of lower-level MLIR code to C++ Kokkos code, facilitating the integration of scientific machine learning (SciML) models into applications. To extend LAPIS for distributed memory architectures, a new partition dialect was created to manage the distribution of sparse tensors and express communication patterns for sparse linear algebra operations. This dialect also supports the distributed execution of operators and includes algorithmic optimizations to minimize communication to improve performance. The project also demonstrates that MLIR can enable effective linear algebra-level optimizations, improving performance on different GPUs for both sparse and dense linear algebra kernels. Key applications of LAPIS include sparse linear algebra and graph kernels, TenSQL, a relational database management solution built on GraphBLAS, and the development of subgraph isomorphism and monomorphism kernels, showcasing performance portability. In summary, the LAPIS framework supports productivity, performance, portability, and distributed memory execution, while also enabling linear algebra-level optimizations that are challenging in traditional programming languages, with successful applications ranging from simple sparse linear algebra to complex graph kernels.

97 MATHEMATICS AND COMPUTING↗

Empirical thermophotovoltaic performance predictions and limits

Significant progress has been made in the field of thermophotovoltaics, with efficiency recently rising to over 40% due to improvements in cell design and material quality, higher emitter temperatures, and better spectral management. However, inconsistencies in trends for efficiency with semiconductor bandgap energy across various temperatures pose challenges in predicting optimal bandgaps or expected performance for different applications. To address these issues, here we present realistic performance predictions for various types of single-junction cells over a broad range of emitter temperatures using an empirical model based on past cell measurements. Our model is validated using data from different authors with various bandgaps and emitter temperatures, and an excellent agreement is seen between the model and the experimental data. Using our model, we show that in addition to spectral losses, it is important to consider practical electrical losses associated with series resistance and cell quality to avoid overestimation of system efficiency. Here, we also show the effect of modifying various system parameters such as bandgap, above and below-bandgap reflectance, saturation current, and series resistance on the efficiency and power density of thermophotovoltaics at different temperatures. Finally, we predict the bandgap energies for best performance over a range of emitter temperatures for different cell material qualities.

14 SOLAR ENERGY↗

Quantification of trace iodine using laser-induced breakdown spectroscopy for real-time monitoring of nuclear off-gas streams

This study evaluated the potential of laser-induced breakdown spectroscopy (LIBS) for real-time monitoring of trace gas-phase iodine, which is an element of high significance in nuclear applications due to its long radioactive half-life (as iodine-129), volatility, and biological impact. In anticipation of iodine evolving into off-gas systems in molten salt reactor and nuclear fuel recycling applications, this research aimed to assess LIBS performance in flowing argon and helium matrices; optimize measurement parameters using a multichannel spectrometer; and perform calibrations to assess predictive capabilities and limits of detection (LODs). Experimental results successfully measured gas-phase iodine in flowing argon and helium; however, trace iodine was not detected in air. Optimal delay times were determined to be 10 µs for argon and 1 µs for helium, which are consistent with the expected shorter plasma lifetime in helium relative to argon. An emission line survey was provided with the 206.16, 804.37, 902.24, and 905.83 nm peaks, which were identified as the strongest emission peaks. Calibration models were successfully built in both helium and argon, achieving LODs down to 3 ppm in helium and 5 ppm in argon. The iodine emission at 905.83 nm emerged as the most robust for calibration and was subsequently applied to a time series dataset in argon. The predictive trace confirmed the feasibility of employing LIBS for continuous, online quantification of trace iodine in flowing gas systems.

Andrews, Hunter B. [Oak Ridge National Laboratory ↗

Benders Decomposition Using Graph Modeling and Multi-Parametric Programming

Benders decomposition is a widely used method for solving large and structured optimization problems, but its performance is affected by the repeated solution of subproblems. We propose a flexible and modular algorithmic framework for accelerating Benders decomposition. Specifically, we express the problem structure by using a graph-theoretic modeling abstraction in which nodes represent optimization subproblems and edges represent connectivity between subproblems. A key innovation of our approach is that we embed multiparametric programming (mp) surrogates for node subproblems, which maps the exact analytical map of the subproblem solution space. The use of mp surrogates allows us to replace subproblem solves with fast look-ups and function evaluations for primal and dual variables during the iterative Benders process. We formally show the equivalence between classical Benders cuts and those derived from the mp solution. We implement our framework in the open-source PlasmoBenders.jl software package. To demonstrate the capabilities of the proposed framework, we apply it to a two-stage stochastic programming problem, which aims to make optimal capacity expansion decisions under market uncertainty. We evaluate both single-cut and multicut variants of Benders decomposition and show that the use of mp surrogates achieves substantial speedups in subproblem solve time, while preserving the convergence guarantees of Benders decomposition. We highlight advantages in solution analysis and interpretability that is enabled by mp critical region tracking; specifically, we show that these reveal how decisions evolve geometrically across the Benders search. Our results aim to demonstrate that combining surrogate modeling with graph modeling offers a promising and extensible foundation for structure-exploiting decomposition. In addition, by decomposing the problem into more tractable subproblems, the proposed approach also aims to overcome scalability issues of mp. Finally, the use of mp surrogates provides a unifying and modular optimization framework that enables the representation of heterogeneous node subproblems as modeling objects with a homogeneous structure.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Correlating Nb-SRF Surface Processing with Evolution of Surface Electronic States

The few nanometers of the surface exposed to RF field plays a major role in defining the RF performance of superconducting cavities. Over the past two decades, several pioneering surface treatment and processing methods have emerged, enabling remarkable improvements in cavity performance by simultaneously achieving high Q with increasing Eacc. These processing methods include: thermal treatment under ultra-high vacuum (UHV) conditions across lo¬¬¬¬¬¬¬w-, mid-, and high-temperature ranges and high temperature treatments under controlled N2 atmosphere. These processes also produce distinct surface oxide configurations with different valence states, thicknesses, and uniformity, as well as different oxygen concentration profiles in bulk Nb. In this work, we are trying to understand how do surface-processing methods and the resulting oxide/oxygen profiles affect the electronic structure of surface and the mechanism of superconductivity? With the help of Fermilab’s in-house X-ray photoemission facility and, in collaboration with the synchrotron-based angle-resolved photoemission (ARPES) facility at Argonne National Laboratory, we are investigating how the valence band structure and density of states (DoS) near the Fermi level modify with different surface treatments. Our observations show that different surface-processing methods lead to distinct evolutions of the valence-band states near the Fermi level during the superconducting transition. This behavior suggests variations in Nb-O orbital hybridizations and points towards the possibility of different underlying mechanisms of superconductivity governed by the surface chemistry and oxide configuration. We also correlate these distinct superconducting mechanisms with RF cavity performance, specifically focusing on measured surface resistance, the nature of the Q-slope, and quench fields observed in SRF measurements. These results will enable us to identify the potential limiting factors and relevant controllable parameters that can be further optimized to improve the performance of SRF cavities.

Tripathi, Malvika [Fermilab]↗

Binder-Coated Carbon Cloth Electrodes for All-Vanadium Redox Flow Batteries

Vanadium redox flow batteries (VRFBs) are a promising solution for integrating intermittent renewable energy sources into the existing power grid. However, enhancing the electrochemical performance of VRFBs is critical for their widespread adoption in grid-scale energy storage. This study investigates the impact of adding a porous binder to a carbon-cloth electrode, with a focus on optimizing thermal activation conditions. The electrochemical performance of the binder-coated electrodes compared to uncoated electrodes is evaluated through electrochemical impedance spectroscopy, polarization curve measurements, and charge-discharge cycling. The surface morphology and structural integrity of the binder-coated electrodes at each activation stage are examined using various material characterization techniques to assess the effects of thermal activation. The results are benchmarked against the experiments using non-coated electrodes to determine the performance improvements offered by the binder coating. Notably, the study reveals that binder-coated electrodes exhibit significantly lower resistance and improved efficiency compared to their uncoated counterparts, with optimal activation conditions enhancing performance metrics crucial for VRFB applications. These findings provide valuable insights for further optimizing electrode design and activation strategies, advancing the development of more efficient VRFB systems for large-scale energy storage.

Caiado, Ashley A.↗

Correlating Surface Processing of Nb Superconducting RF Cavities with the Evolution of Surface Electronic States

Superconducting-radio frequency (RF) cavities provide an efficient way to accelerate particle beams with extremely high acceleration gradients while generating very small power dissipation. The few nanometers of the surface play a critical role in defining the RF performance of superconducting Nb based cavities. Over the past two decades, several pioneering surface treatment and processing methods have emerged, enabling remarkable improvements in superconducting cavity performance by simultaneously achieving high quality factors with increasing maximum acceleration gradients. These processing approaches include chemical polishing, distinct multi-step thermal treatments under ultra-high vacuum (UHV) conditions over low to high temperature regimes, as well as high-temperature treatments under controlled nitrogen atmospheres. Beyond their macroscopic impact on RF performance, these methods produce distinct surface oxide configurations characterized by different valence states, oxide thicknesses, chemical uniformity, and oxygen concentration profiles extending into the near-surface bulk of niobium. In this work, we are trying to understand how the surface-processing methods and the resulting oxide/oxygen profiles affect the electronic structure of surface and the mechanism of superconductivity. Using a combination of X-ray photoemission and X-ray absorption spectroscopies, we investigate how the valence-band structure and the electronic density of states (DoS) near the Fermi level evolve under different surface treatments. By employing tunable photon energies across multiple elemental absorption edges, we use resonant photoemission to disentangle and identify the elemental contributions to specific valence-band features. Our observations show that different surface-processing methods lead to distinct temperature evolutions of the DoS and valence-band states near the Fermi level. Our results suggest variations in different Nb-O orbital hybridizations in distinct processes and point towards the possibility of different underlying mechanisms of superconductivity governed by surface chemistry and oxide configuration. We also correlate these distinct superconducting mechanisms with RF cavity performance, specifically focusing on measured surface resistance, the nature of the Q-slope, and quench fields observed in superconducting RF measurements. These results will enable us to identify the potential limiting factors and relevant controllable parameters that can be further optimized to improve the performance of superconducting RF cavities.

Tripathi, Malvika [Fermilab] (ORCID:00000001989251↗

When more data hurts: Optimizing data coverage while mitigating diversity-induced underfitting in an ultrafast machine-learned potential

Machine-learned interatomic potentials (MLIPs) are becoming an essential tool in materials modeling. However, optimizing the generation of training data used to parametrize the MLIPs remains a significant challenge. This is because MLIPs can fail when encountering local environments too different from those present in the training data. The difficulty of determining a priori the environments that will be encountered during molecular dynamics simulation necessitates diverse, high-quality training data. Here, this study investigates how training data diversity affects the performance of MLIPs using the Ultra-Fast force field (UF 3 ) to model amorphous silicon nitride. We employ expert and autonomously generated data to create the training data and fit four force field variants to subsets of the data. Our findings reveal a critical balance in training data diversity: insufficient diversity hinders generalization, while excessive diversity can exceed the MLIP's learning capacity, reducing simulation accuracy. Specifically, we found that the UF 3 variant trained on a subset of the training data, in which nitrogen-rich structures were removed, offered vastly better prediction and simulation accuracy than any other variant. By comparing these UF 3 variants, we highlight the nuanced requirements for creating accurate MLIPs, emphasizing the importance of application-specific training data to achieve optimal performance in modeling complex material behaviors.

ab initio molecular dynamics↗

Improving tubular protonic ceramic fuel cell performance by compensating Ba evaporation via a Ba-excess optimized proton conducting electrolyte synthesis strategy

Protonic ceramic fuel cells (PCFCs) are emerging as a promising technology for reduced temperature ceramic energy conversion devices. The BaCe 0.4 Zr 0.4 Y 0.1 Yb 0.1 O 3–δ (BCZYYb4411) electrolyte is notable for its high proton conductivity. However, the tendency of barium to volatilize in BCZYYb4411 during high-temperature sintering compromises its chemical stability and performance. This study investigates the effects of intentionally incorporating excess barium into BCZYYb4411, formulated as Ba 1+x Ce 0.4 Zr 0.4 Y0.1Yb 0.1 O 3–δ (where x = 0, 0.1, 0.2, and 0.3), with the aim of compensating barium evaporation and enhancing the physical and chemical properties. We find that excess barium results in a greater shrinkage rate, facilitating a denser electrolyte structure. This barium-enriched electrolyte demonstrates improved electrochemical performance by effectively counteracting the deleterious effects of barium evaporation. Applying this strategy to tubular PCFCs, we achieved a peak power density of 480 mW•cm –2 at 600 °C. This unique approach provides a simple, tunable, and easy-to-implement processing modification to achieve high-performance tubular PCFC.

25 ENERGY STORAGE↗