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DOE OSTI2024

Decarbonizing Building Thermal Systems: A How-to Guide for Heat Pump Systems and Beyond

Buildings account for a substantial portion of carbon emissions, primarily due to the widespread use of fossil fuels in heating systems. Decarbonization of heating is essential to meet climate targets and reduce the environmental impact of buildings. Heat pumps are capable of leveraging renewable energy sources and can provide heating and cooling in an energy-efficient manner. By leveraging heat pump technology, buildings can significantly reduce their carbon footprint, minimize energy consumption, and decrease their reliance on fossil fuels. The design and construction community plays a pivotal role in facilitating the transition to heat pump systems for heating and cooling. However, this transition requires specialized knowledge and expertise. This resource was developed for architects, engineers, and contractors in response to an industry need for a comprehensive technical resource that guides them through the intricacies of heat pump system design, installation, and maintenance. This resource provides detailed information on system sizing, selection of appropriate heat systems, heat sources, and integration with existing building systems. Moreover, it emphasizes best practices for ensuring operational efficiency, system longevity, and reliability. The development of this recourse was a collaborative effort between NREL/DOE Better Buildings Design and Construction Allies and ASHRAE Task Force for Building Decarbonization. This resource is composed of two complimentary portions that will be completed and released on separate time frames. The first portion will be completed and released in 2023, while the second portion will be released in 2024.

building thermal systems↗

DOE OSTI2026

Influence of cellular redox reactions on the structure and function of light harvesting and photosystems

Photosynthesis enables the conversion of one of the most abundant and free forms of energy, sunlight, into chemical bonds through the utilization of highly tailored protein complexes. These enzymes work in unison to absorb, convert, and transform light into high-energy electrons which are used for various functions important to metabolism and cellular protection. Over the last ∼50 years, photosynthetic organisms, such as cyanobacteria, have been adapted and engineered to produce valuable compounds like hydrogen and ethylene, among others. Often this is performed by removing native and/or adding in exogenous energy utilization pathways so that light energy is re-directed towards the synthesis of desired compounds. However, the interplay between primary light capture, conversion reactions, and the downstream electron utilization sinks is not fully understood. Further complicating these strategies are the plethora of compensatory mechanisms that facilitate steady electron flow and the maintenance of photosynthesis under dynamic conditions. This manifests as structural and functional plasticity of the photosynthetic machinery, often seen in modulations of oligomeric compositions or changes in protein-protein interactions and coupling with redox enzymes. Understanding these mechanisms is crucial to biotechnology applications because re-engineering electron utilization sinks has profoundly different effects on the light capture and conversion reactions of photosynthesis. Optimization requires a molecular-level understanding of the functional interrelationships between electron sinks and photosynthetic components that influence photosynthetic efficiencies to realize potential improvements in product yields. Here, we aim to highlight how perturbation of reductive reactions is revealing the functional plasticity in key components of the photosynthetic energy transduction pathway.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2026

Data for "Quantifying the Propagation of Parametric Uncertainty on Flux Balance Analysis"

In the repository are example scripts that perform uncertainty injection and propagation to flux balance analysis with outputs for a small sample size (for demonstration purpose only). For proper analysis, user should download the scripts and run for a large sample size (e.g., 10,000 samples). If you use the scripts, please cite the following Metabolic Engineering article: “Quantifying the propagation of parametric uncertainty on flux balance analysis” (https://doi.org/10.1016/j.ymben.2021.10.012) There are two subdirectories: /uncFBA/uncBiom: injection of normally distributed noise to biomass precursor coeffcients and ATP maintenance (growth-associated ATP maintenance (GAM) and non-growth associated ATP maintenance (NGAM)) /uncFBA/uncRHS: departure from steady-state by adding noise drawn from normal distribution to the RHS terms of mass balance constraints

Metabolomics↗

DOE OSTI2024

Cyber Informed Engineering (CIE) Principles Slide Presentation [Slides]

This document describes the concept and application of Cyber-Informed Engineering (CIE), a methodology that integrates cyber threat awareness into all stages of the systems engineering life cycle. It delineates how CIE enhances the security posture of critical infrastructure systems, which are increasingly targeted by sophisticated cyber threats. The exposition proceeds to methodically walk through the twelve foundational principles of CIE, each serving as a strategic guidepost for embedding cybersecurity into the fabric of system design, development, operation, and maintenance. The principles highlight the importance of proactive and comprehensive security measures that span from risk assessment to continuous improvement, ensuring that systems are not only designed with security in mind but are also resilient in the face of evolving cyber threats.

42 ENGINEERING↗

DOE OSTI2024

A Survey of Open Source Software Repositories in the U.S. Department of Energy’s National Laboratories

There are 17 national laboratory systems in the United States operating under the auspices of the U.S. Department of Energy (DOE). These government labs employ tens of thousands of people engaging in research software engineering activities across a variety of missions. To support this work, many open source projects are maintained. Further, many of these projects have broad utility to the computing community at large and domain scientists in a variety of fields. However, the complexity and decentralized nature of the laboratory system has resulted in a situation where no one entity even knows about all the open source software projects in this ecosystem, let alone crude metrics of their health. In this article, we do the first external inventory of open source software repositories with a nexus to DOE labs. We posit that a project’s need for sustainability support can be determined by comparing measures of active use to measures of active maintenance.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Engineering Services in a Mission Critical Environment: Engineering Services - Science and Technology Operations’ Infrastructure Support at Los Alamos National Laboratory

As an engineering team within a facilities-driven organization, Engineering Services – Science and Technology Operations (ES-STO), supports Los Alamos National Laboratory (LANL), playing a pivotal role in the U.S. nuclear stockpile mission. This report outlines ES-STO’s contributions through the installation of crucial systems such as HVAC units, compressors, and scientific specialty equipment, as well as providing expert consultation to optimize laboratory operations. ES-STO’s goal is to ensure that LANL's infrastructure and research facilities are aligned with mission-critical needs, supporting both operational efficiency and safety in the nuclear stockpile management and maintenance. This report discusses the installation processes, ongoing consultations, and the significant impact of our efforts on national security objectives.

42 ENGINEERING↗

DOE OSTI2024

WETO Software Stack Best Practices

Wind energy researchers typically share one key characteristic: a passion for increasing wind energy in the global energy mix. The U.S. Department of Energy (DOE) supports this mission in a number of ways including allocating funding directly to various aspects of wind energy research through the Office of Energy Efficiency and Renewable Energy (EERE) via the Wind Energy Technologies Office (WETO). While the traditional output of research is academic publication, software development efforts are increasingly a major focus. Software tools in the research environment allow researchers to describe an idea and quickly increase the scope and scale as they study it further. As a product of research, these tools represent a direct pipeline from researcher to industry practitioners since they are the implementation of ideas described in academic publications. Given this vital role in wind energy research and commercial development, the broad research software portfolio supported by WETO must maintain a minimum level of quality to support the wind energy field in the growing transition to renewable energy. This report outlines a series o f best practices to be adopted by all WETO-supported software projects, as well as expectations that the communities interacting with these projects should have of the developers and tools themselves. Wind energy research software has a unique standing in the field of scientific software. The stakeholders are varied with a subset being: (1) DOE EERE leadership, (2) DOE WETO leadership and program managers, (3) National lab leadership, (4) Associated project principle investigators, (5) Research software engineers, (6) Wind energy researchers in academia (including graduate students, post docs, and national lab staff), (7) Industry researchers and practitioners, (8) Commercial software developers, and (9) The general public interested in wind energy. These software are typically the end-user of other generic software libraries, so the funding cycles are often tied to applied research rather than the development of the software itself. Since the developers are also wind energy researchers, these tools are typically designed in a way that closely resembles the application in which they're used. Additionally, the expertise and incentives for the developers have a high variability, and often neither are aligned with software engineering or computer science. Given the unique environment in which wind energy research software is produced and consumed, it is critical for model owners to understand the context of their software. A framework for developing this understanding is to answer the following questions of a given software project: What is it's purpose? What is its role in the field of wind energy? What is the profile of the expected users? For how long will it be relevant? What is the expected impact? These questions allow model owners to identify the appropriate methods for the design, development, and long term maintenance of their software. Additionally, the answer provide context for future planners to understand why particular decisions were made and discern the consequences of changing course. The information is aggregated from experience within WETO-supported software development groups as well as external organizations and efforts to define the craft of research software engineering. These best practices aim to make the collaborative development process efficient and effective while improving the model understanding across stakeholders. Additionally, the general adoption of a common framework for software quality ensures that the end users of WETO software can trust these tools and accurately understand the risks to workflow integration.

17 WIND ENERGY↗

DOE OSTI2025

Immersive Digital Twin Laboratory for Engineering Education (CRADA Final Report)

This project aimed to create an immersive digital twin laboratory that incorporates advanced tracking and visualization capabilities. In collaboration with Fort Lewis College, NREL designed a state-of-the-art physical visualization laboratory, developed a software platform to enable interaction with tracked physical objects in the laboratory, and provided proof-of-concept curricula that included manipulating these tracked objects. The project was initiated to address the growing need for innovative educational tools in engineering education. As renewable energy systems, particularly solar installations, become more complex, there is a pressing need to bridge the gap between theoretical knowledge and practical application. Traditional methods of teaching solar engineering concepts often fall short of providing students with a comprehensive, hands-on understanding. This immersive digital twin laboratory was conceived to fill that gap by creating a safe, non-energized setting where students can interact with augmented solar installation objects, gaining valuable insights into system performance, design, and maintenance. The project utilized extended reality (XR) technologies, including head-mounted displays (HMDs) and a whole-room optical motion tracking system, to connect physical objects with their digital twins in real time. The laboratory was equipped with MagicLeap 2 HMDs, supported by a Vicon Vero 2.2 Optical Tracking System, which provided precise 6-degrees-of-freedom (6-DOF) tracking. We developed a software platform to manage the interaction between the tracked physical objects and their virtual counterparts, enabling real-time data synchronization, object recognition, and virtual overlays. We designed the system to be flexible and extendable, allowing for future integration of additional objects and curriculum. This research advances the field of engineering education by demonstrating the potential of immersive digital twin environments. The laboratory provides a dynamic learning space where students can experiment, collaborate, and learn without the risks associated with live experimentation. The ability to simulate and manipulate solar installation objects under various conditions has broad implications for workforce development, particularly in renewable energy. The project also highlights the economic feasibility of using XR technologies in educational settings, offering a cost-effective solution for institutions looking to enhance their curriculum. By fostering a deeper understanding of solar energy systems, this work contributes to the broader goal of supporting the global energy transition and preparing the next generation of engineers and technicians.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

A data-driven framework for predicting machining stability: employing simulated data, operational modal analysis, and enhanced transfer learning

Chatter, a self-excited vibration phenomenon, presents a significant challenge in machining operations, particularly in high-speed milling, where it can degrade tool life, reduce material removal efficiency, and compromise workpiece quality. Addressing this challenge requires a reliable predictive model that can accommodate the complex dynamics of various machining scenarios. This study introduces a novel, data-driven approach to predicting machining stability, leveraging over 140,000 simulated datasets and employing advanced techniques such as operational modal analysis (OMA), enhanced transfer learning (TL), and receptance coupling substructure analysis (RCSA). By integrating these methodologies, the framework effectively classifies and predicts chatter across diverse operational modes, achieving robust and accurate outcomes. Our model utilizes a Random Forest (RF) classifier trained with the comprehensive dataset, which demonstrates substantial improvements in both predictive accuracy and robustness. Specifically, the RF model achieved an accuracy rate of 85%, an area under the curve (AUC) of 0.90, and an F1 score of 0.88, underscoring its capability to adapt to varying machining configurations. These results highlight the framework’s potential to enhance operational efficiency and machining quality by providing reliable chatter predictions across a broad range of machining parameters. In conclusion, this research thus offers a significant advancement in predictive maintenance for machining processes, enabling more stable and efficient manufacturing operations.

42 ENGINEERING↗

DOE OSTI2024

Software Quality Assurance Plan ANSYS LSDYNA Version 2023R1

ANSYS Inc. develops and markets engineering simulation software and services used in the aerospace, automotive, manufacturing, electronics, biomedical, energy, defense, and many other industries. ANSYS is dedicated to engineering simulation and is the world’s leading software provider. ANSYS was founded in 1970 and is headquartered in Canonsburg, Pennsylvania. ANSYS provides an engineering analysis tool combining structural, thermal, computational fluid dynamics, acoustic and electromagnetic simulation capabilities. ANSYS LS-DYNA is the most used explicit simulation program capable of simulating the response of materials to short periods of severe loading. Its many elements, contact formulations, material models, and other controls can be used to simulate complex models with control over all the details of the problem. ANSYS LS-DYNA has a vast array of capabilities to simulate extreme deformation problems using its explicit solver. Engineers can tackle simulations involving material failure and look at how the failure progresses through a part or through a system. Models with large amounts of parts or surfaces interacting with each other are also easily handled, and the interactions and load passing between complex behaviors are modeled accurately. Using computers with higher numbers of CPU cores can drastically reduce solution times. In addition, many consulting firms and hundreds of universities use ANSYS for analysis, research, and educational purposes. ANSYS is recognized worldwide as one of the most widely used and capable programs of its type. ANSYS has successfully passed over 100 customer quality system audits against American Society of Mechanical Engineers (ASME) NQA-1 and 10 CFR Part 50, Appendix B, since the company was founded, over 60 of which have been since 1997. ANSYS has successfully passed over 100 International Organization for Standardization (ISO) 9001 assessments. ANSYS design analysis software is the first created within a quality system with ISO 9001 certification, which is the internationally accepted quality standard. Product development, testing, maintenance, and support processes also meet the US Nuclear Regulatory Commission’s (NRC’s) quality requirements, as they have for nearly four decades. ANSYS staff perform more than 60,000 software verification tests before releasing each new product. ASME NQA-1-2012 (Subpart 2.7 is specific to software) is the industry- and NRC-accepted approach (consensus standard) for meeting 10 CFR Part 50, Appendix B, requirements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Report on Preliminary Detailed Experimental Plan for Neutron Irradiation of A709 at ATR and HFIR

Advanced nuclear power technologies will use higher temperatures as a means to extract energy at a higher efficiency than current plants and therefore put a larger demand on the structural materials. Improved performance of structural materials could enable greater safety margins, longer plant lifetimes, and reduce maintenance costs. Alloy 709 is championed as the next generation of austenitic alloys for advanced nuclear reactors. In parallel to the ASME code case pursued, the AMMT program is initiating a neutron irradiation campaign to provide first-of-a-kind engineering data to establish operational design parameters and how the mechanical response is modified by environmental factors. This document refines the AMMT neutron irradiation campaign to a 4 year program to support the generation of creep knockdown factors for Alloy 709 and welded Alloy 709. The campaign is divided among two national laboratories, Oak Ridge National Laboratory and Idaho National Laboratory, to use the strengths of each laboratory. Through a cooperative plan, time-independent properties and time-dependent properties will be obtained across a large temperature window, nominally 300°C to 800°C, damage levels up to 10 dpa, and with and without the impacts of transmutation produced helium.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2026

Report on Preliminary Detailed Experimental Plan for Neutron Irradiation of A709 at ATR and HFIR

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Success Path Method: Conformance with Safety Management Systems

All industrial facilities deal with safety hazards such as equipment failures, chemical and toxic releases, and fires and explosions just to name a few. A disciplined framework for managing the integrity of operating systems and processes that handle hazardous substances by applying good design principles, engineering, and operating practices is called process safety. The goal of such framewoks is to prevent the release of energy or material that could cause harm to people or damage to equipment and/or environment. Process safety covers all aspects of facility operation also including design, maintenance, and human and organizational factors that could possibly have effect on process safety. As it will be seen from the discussion below, process safety is just one of the pieces of the much bigger matter, a safety culture. Many industries have long recognized the importance of safety culture in their day-to-day operation. Although the definition of safety culture can slightly differ from organization to organization, in general, a safety culture is how things are done to demonstrate a commitment to safety by everyone involved. An organization acquires safety culture over time as the product of individual and group values, actions, and behaviors toward overall safety. It is important to note that safety culture should not be viewed as some static state that an organization wants to reach. It is more like a constantly evolving level of “how things are done when nobody is watching.” Safety culture is an inherent characteristic of an organization, it is always present, but the level can range on a continuum from undesirable to desirable or more commonly used, from negative to positive. An example for an undesirable, negative safety culture would be a company in which accidents resulting in harm (physical and/or emotional) of its employees, equipment or surrounding environment and community occur frequently. At the other end of the spectrum would be a company in which such accidents are rare or do not occur at all (desired or positive safety culture). Every company/industry exists somewhere within this spectrum.

42 ENGINEERING↗

DOE OSTI2025

DriveSense: A Noise-Resilient Framework for Driving Mode Identification

Accurate drive mode classification is essential for enhancing the reliability and predictive maintenance of heavy-duty electric trucks. This study proposes a novel fuzzy logic-based framework, DriveSense, for real-time drive mode classification, addressing key challenges such as sensor noise, transitional behaviors, and computational efficiency. The proposed approach integrates a two-stage filtering pipeline, combining adaptive outlier removal and a dynamic Kalman filter to enhance data quality. A fuzzy inference system with smoothened trapezoidal membership functions is then applied to classify driving modes into standstill, constant speed, acceleration, and deceleration while mitigating the effects of noise and edge cases. Performance evaluation using real-world and simulated drive cycles demonstrates significant improvements in classification accuracy (up to 97.8%), F1-score (up to 0.97), and robustness against noise, while reducing false positives. Comparative analysis against baseline models, demonstrates DriveSense’s superior accuracy and generalizability across diverse driving patterns. The framework’s lightweight and interpretable fuzzy inference engine operates with low computational latency, ensuring compatibility with real-time embedded systems typical of heavy-duty electric trucks. Moreover, DriveSense models transitional behaviors through overlapping fuzzy sets and adaptive borderline classification logic, enabling smooth identification of subtle shifts such as rolling stops or gradual deceleration. These results highlight DriveSense’s potential to enhance predictive maintenance strategies, reduce downtime, and support scalable, fleet-wide diagnostics.

Kumar, Praveen [Oak Ridge National Laboratory (ORN↗

DOE OSTI2026

Pumped Storage Hydropower Operation & Maintenance Cost Estimation

The National Laboratory of the Rockies (NLR) develops and hosts a pumped storage hydropower (PSH) cost model that is the most detailed bottom-up PSH cost model available to the public. It is available both as a spreadsheet and an interactive web tool, enabling users with a variety of PSH interests to transparently characterize costs of alternative PSH sites and designs. The NLR PSH cost model was designed originally to consider only upfront capital costs only. This slide deck describes methodology to expand the cost model to include operations and maintenance (OM) costs. OM costs are characterized as five distinct components with unique sources and methods for cost estimation. By combining methods for each of these components into a cumulative OM cost estimate, these methods allow a more complete estimation of total OM costs that agrees with existing literature values. The methods are scalable and transparent, allowing them to be readily to applied to any prospective PSH facility for a representative preliminary OM cost estimate in advance of detailed site-specific engineering and other studies.

13 HYDRO ENERGY↗

DOE OSTI2024

The Maintainable Fusion Pilot Plant

The US fusion community has coalesced around the goal of building an FPP as described by the National Academies of Science, Engineering, and Medicine (NASEM). In addition to demonstrating the viability of the technologies necessary to operate such a plant, including demonstration of net energy and electricity production, NASEM found that a “fusion pilot plant will need to demonstrate the ability to efficiently perform remote maintenance and replacement in support of the design of a power plant, taking into account details of the consequences of the fusion environment, such as material activation and tritium retention in components.” Current designs of fusion demonstration reactors do usually foresee a regular exchange of their first wall modules, including the tritium breeding blankets. In the European Power Plant Conceptual Studies, it is assumed that a fusion reactor will need to change its divertor every 2 years and its first wall blanket module every 5 to 6 years to reach acceptable availability. Underlying this capability are remote-handling technologies to keep the outage for the exchange of these components short. There are many uncertainties in the remote-handling schemes, and most schemes are at a preconceptual level at best. In addition, the exchange of these components would either produce an enormous rad-waste stream or would require an enormous refurbishment activity with huge cost-prohibitive hot-cells. Past Fusion Nuclear Science Facility (FNSF) preconceptual studies have led to hot cell dimensions of an unbelievable size, likely costing tens of billions of dollars. Already at The Way (previously International Thermonuclear Experimental Reactor, ITER), hot-cells have become cost-prohibitive, demanding redesigns of the ITER first wall to reduce the toxic rad-waste/inventory. In this in-situ PFC repair project, a concept for a long-life, maintainable first wall module concept is developed and tested. This first wall concept relies on innovative remote handling to repair the first wall modules in-situ, avoiding costly refurbishments outside of the tokamak vessel. This approach was highlighted in the Fusion Energy Sciences Advisory Committee (FESAC) report on Transformative Enabling Capabilities for Efficient Advance Toward Fusion Energy. In general, the damage of the first wall armor is due to particle and radiation exposures. Load conditions vary from one fusion reactor design to another. In tokamaks, first wall Plasma Facing Components (PFCs) are exposed to far-Scrape-Off-Layer plasma fluxes, electromagnetic radiation, energetic CX neutrals, and potentially runaway electron beams. Protecting the first wall to the worst-case load conditions would require the design of a very thick first wall armor. Transient heat and particle fluxes due to disruptions or edge localized modes can lead to excessive heat loads resulting potentially in melting PFCs down to the cooling channel. Catastrophic events like these need to be avoided by appropriate disruption mitigation systems. However, failure of these systems will still put a first wall at an unacceptable risk. Hence, a first wall design needs to accommodate the occasional transient heat loads by introducing sacrificial limiters, which will absorb these transients.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

The Benefits and Weaknesses of Containerizing Software for HPC

Containerization technology has emerged as a transformative tool for software engineers, offering consistent development and deployment environments, simplifying dependency management, and enhancing scalability and portability across diverse systems. However, its application in High-Performance Computing (HPC) presents unique challenges, including the management of virtualization overhead, the need for efficient resource allocation, and the maintenance of optimal performance for compute-intensiv

Ho, Eric Victor [Sandia National Laboratories (SNL↗

DOE OSTI2026

High Yield nTOF Spec A and NP Filter Holders Static and Seismic Analysis

The Neutron Time-of-Flight (nTOF) detectors located in the Alcove and at the North Pole (Spec A and Spec NP respectively) need filtering in the beam path to enable them to take data at NIF yields above 5MJ. The filtering consists of 12cm of filter material divided into four, 3cm thick “pucks.” The pucks are 7cm in diameter. Each puck is mounted into a rotatable stage, also called a Filter Flipper, that can bring it into and out of the beam path, see Figure 1-1. These stages are bolted onto a plate that connects the filter stages to the mounting hardware used to position them in the NIF Target Bay. The top-level filter mount assemblies will be permanently mounted in the facility; removal is possible if needed for NIF maintenance, but the design intent is for the assemblies to remain in their locations after alignment is completed.

42 ENGINEERING↗