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DOE OSTI2026

Bio-inspired alula-based winglet design for enhanced heat transfer in high temperature fin-and-tube heat exchangers

Fin-and-tube heat exchangers (FTHEs) are widely used for high-temperature flue-gas heat recovery, but their performance is often limited by wake regions and non-uniform fin-surface temperatures. This study proposes and numerically evaluates four bio-inspired longitudinal vortex generator (VG) configurations in a high-temperature FTHE with flue-gas inlet temperature ∼1230 K: double-delta, curved double-delta, alula, and a new curved-alula geometry. The reference fin is not hydraulically plain; it already incorporates leading-edge separation columns and convex protrusions, so the alula-type winglets are assessed as downstream add-ons acting on a strongly disturbed flow. In a second step, perforations (one, two and three circular holes) are introduced into the curved-alula VGs to further tailor the flow field. Three-dimensional simulations with the Shear Stress Transpor (SST) $k - ω$ model, temperature-dependent flue-gas properties and conjugate conduction are carried out for gas-side Reynolds numbers $Re_g ≈ 8.0$ x $10^2 - 3.6$ x $10^3$ (mass flow rates 0.5 – 2.5 g/s), and the designs are compared in terms of surface heat flux, Nusselt number, friction factor and hydrothermal performance factor (HTPF). For this already-promoted fin, the additional downstream winglets provide moderate, incremental hydrothermal gains. At the highest Reynolds number, the best non-perforated design (curved-alula) increases surface heat flux from 1630.9 to 1794.7 kW/m² (∼ 10 % gain) and the Nusselt number from 227.6 to 242.6 (∼ 7 % gain), while the friction factor rises from 0.26 to about 0.30, yielding HTPF values close to unity (∼ 0.9 – 1.0). Introducing circular perforations into the curved-alula winglets acts mainly as a wake-bleeding refinement: the three-hole configuration provides a heat flux of 1824.7 kW/m² and a pressure drop of 127.9 Pa, with HTPF in the range ∼ 1.03 – 1.14 and a small (∼ 1 – 3 %) improvement over the solid curved-alula design. Flow-field analysis shows that the perforated curved-alula VGs shrink tube-wake regions, thin the thermal boundary layer and homogenize the fin-surface temperature (outlet-gas temperature ∼ 510 – 520 K and fin-surface temperature ∼ 420 – 421 K for the three-hole case). An optimal flue-gas mass flow rate of ∼ 1 g/s ($Re_g ≈ 1.5$ x $10^3$) is identified, beyond which additional heat-transfer gains are offset by rapidly increasing pressure losses. Overall, the results highlight that initial fin geometry and VG placement are as important as VG shape: alula-based winglets are expected to yield larger relative gains on simpler flat-fin layouts or when positioned closer to the fin leading edge and tube

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Toward the application of the Risk-Based Maintenance approach to a hydrogen-fueled manufacturing plant

Safety, reliability, and maintenance of hydrogen-based equipment, including Risk-Based Maintenance (RBM), have recently gained increasing attention, as hydrogen, while key to decarbonizing hard-to-abate sectors, raises safety concerns. However, two literature gaps limit the development of risk-based strategies for hydrogen technologies. First, existing RBM methodologies do not account for hydrogen-specific components, such as electrolyzers, which differ from conventional equipment. Second, available studies on electrolyzer reliability remain largely qualitative or laboratory-scale. This study addresses these gaps by proposing an adapted RBM methodology tailored to hydrogen-fueled manufacturing facilities. Integrating qualitative tools (e.g., FMEA) with probabilistic models (e.g., Bayesian Networks) enables comprehensive hazardous scenarios identification and likelihood estimation. A conceptual layout of a glass furnace supplied by a 3 MW PEM electrolyzer is considered as a case study to demonstrate the feasibility of the adapted RBM framework in identifying high-risk components and enabling maintenance prioritization, potentially improving plant safety.

08 HYDROGEN↗

DOE OSTI2025

Status of the Mu2e experiment

The Mu2e experiment at Fermilab searches for the coherent, neutrino-less conversion of a μ − to e − in the Coulomb field of Al nuclei, that represents one of the cleanest Charged Lepton Flavor Violating (CLFV) processes for exploring Beyond the Standard Model (BSM) physics. Mu2e aims to improve previous sensitivity by four orders of magnitude, with a distinctive signature provided by identifying mono-energetic electrons with energy slightly below the muon rest mass. To reach this goal, the experiment will use the highest intensity pulsed muon beam in the world, with up to 6 × 1 0 9 stopped muons/sec. This is achieved using the Fermilab proton beam and the design and realization of a unique 25 m long superconducting solenoidal system. The high beam intensity relies upon minimizing beam losses in the slow extraction region, indicating an opportunity of using bent crystals for shadowing. A high-resolution straw tracker and a fast CsI crystal calorimeter identify the conversion electron. Both detectors are inserted behind the Stopping Target in the last solenoid section. A Cosmic Ray Veto covers a large part of the solenoids to suppress background produced by cosmic rays. In this paper, we report the details of the experimental layout, the construction status of the magnetic system and detectors, and a short description of the simulation and realization of the bent crystals. Performing crystal channeling in front of the first slow extraction septa will allow beam shadowing and largely reduce beam losses. •Charge Lepton Flavor Violation processes: μ − → e − conversion.•Large Superconducting Solenoid system.•High-Intensity beams•High precision detectors.•Crystal channeling.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2027

Conceptual design of highly-constrained splitters for the FFA@CEBAF energy upgrade study

The Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab is investigating a significant energy upgrade utilizing Fixed-Field Alternating-gradient (FFA) recirculating arcs. This upgrade requires the design of complex horizontal beam splitters to manage up to six concurrent beam passes. This paper presents the conceptual design of these splitters, which are subject to severe physical constraints imposed by the existing accelerator tunnel and multifaceted beam dynamics requirements for matching into the permanent-magnet FFA arcs. The design methodology, centered on multi-pass simulations in the Bmad toolkit, is detailed from the initial geometric layout through the advanced optics matching. Key results include a robust geometric arrangement that fits within the spatial boundaries and the development of multiple, flexible optics matching solutions. Furthermore, the design integrates a viable scheme for extracting high-energy beams for the experimental halls, a critical operational requirement. This work establishes a comprehensive and viable conceptual design, forming a baseline for future engineering and performance optimization studies.

Bodenstein, R.M. [Thomas Jefferson National Accele↗

DOE OSTI2026

The forward physics facility: Physics opportunities and conceptual design

The Forward Physics Facility (FPF) is a proposed extension of the HL-LHC program designed to exploit the unique scientific opportunities offered by the intense flux of high energy neutrinos, and possibly new particles, in the far-forward direction. Located in a well-shielded cavern 627 m downstream of one of the LHC interaction points, the facility will support a broad and ambitious physics program that significantly expands the discovery potential of the HL-LHC. Equipped with four complementary detectors -- FLArE, FASER$ν$2, FASER2, and FORMOSA -- the FPF will enable breakthrough measurements that will advance our understanding of neutrino physics, quantum chromodynamics, and astroparticle physics, and will search for dark matter and other new particles. With this Letter of Intent, we propose the construction of the FPF cavern and the construction, integration, and installation of its experiments. We summarize the physics case, the facility design, the layout and components of the detectors, as well as the envisioned collaboration structure, cost estimate, and implementation timeline.

Astroparticle physics↗

DOE OSTI2024

Shared mooring system designs and cost estimates for wave energy arrays

For floating renewable energy devices to become more cost-efficient and commercially scalable, their mooring system designs must be low-cost and suited for large-scale installations. Large arrays of floating devices, such as wave energy converters (WECs), will likely be designed with an individual mooring system for each device in the array. However, new mooring technology advancements provide options to use shared mooring lines to connect adjacent devices to one another, reducing the total number of anchors in the array, thereby reducing material use and cost. Here, this paper explores the design, modeling, and cost analysis of shared mooring systems for various sizes of arrays consisting of heaving oscillating water column (OWC) WECs. Shared mooring systems for WEC arrays sized in 2 x N and N x N grid layouts are designed to meet the relevant design standards, checking their performance with a nonlinear time-domain dynamic simulation, and the costs of each are calculated and compared. Several assumptions are taken in the design process to produce efficient results, providing a preliminary optimization for guidance on design decisions rather than a full, detailed design analysis. Mooring system costs per WEC were found to decrease as the number of WECs in the array increase, up to certain array sizes. The 2 x 3 array had the lowest mooring system cost per WEC out of all arrays considered, with a 60% cost reduction relative to using individual mooring systems. The 3 x 3 and 4 x 4 arrays achieved a 50% cost per WEC reduction. In addition to these significant cost reductions, the shared mooring system designs can provide advantages through smaller mooring system footprints, lower installation times, and less seabed disturbance.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Characterizing in-stream turbulent flow for tidal energy converter siting in Cook Inlet, Alaska

Cook Inlet in Alaska is the most promising location for tidal energy development in the U.S. due to its significant tidal range of approximately 10 meters and high volume flux. The inlet's unique geometry and flow characteristics make it the most energetic tidal stream in the nation, with GW-scale potential energy capacity. With the growing interest in tidal energy converter (TEC) deployment in this area, we implemented a regional-scale, 3D hydrodynamic modeling framework to predict tidal current and turbulence characteristics that can assist TEC designers and project managers. We validated the model results extensively using various datasets collected with bottom-mounted acoustic Doppler current profilers and velocimeters. The comparison between the model outputs and observational data highlighted the effectiveness of the 3D FVCOM model and the Mellor-Yamada Level 2.5 Turbulence Model in accurately assessing macro-scale kinetic energy, turbulence intensity, and the production and dissipation rates at a prospective TEC site. Using two months of model simulation data, we examined the channel cross-section for TEC deployment, focusing on undisturbed power density and macro-scale turbulent properties. Further, our findings indicate that understanding the turbulence characteristics and flow properties can enhance Stage I/II resource characterization by identifying optimal locations for TECs and their layouts within the channel. Furthermore, we demonstrated that TEC designers can utilize macro-scale turbulence data from 3D coastal models as boundary conditions for other turbulence models, allowing for a more detailed resolution of the turbulence structure at TEC siting locations. Ultimately, this work emphasizes the importance of estimating flow and turbulence conditions in energetic systems to understand turbulent sites better and improve resource characterization.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Exploring Micro-Environmental Conditions of Urban Agrivoltaics: Advancing Sustainable Green Spaces and Agriculture in Temperate Cities

Agrivoltaics, the integrated land use combining renewable energy production and agriculture, can potentially address key challenges faced by urban communities, including limited access to vacant land, fresh produce, and electricity. However, urban agrivoltaics has rarely been considered a viable solution, primarily due to a lack of experimental systems demonstrating the functionality of urban food production or green spaces alongside solar energy production. To evaluate the potential of solar photovoltaics to help mitigate heat stress on urban agriculture and green spaces in a temperate climate, we examined the microclimatic changes introduced by an urban agrivoltaics system (UrAV) when combined with vegetable crops and turfgrass, respectively. Accordingly, we installed an experimental setup instrumented with environmental sensors to compare full-sun conditions with those of an agrivoltaics system designed for urban environments. We found minimal differences for both land cover types between the control and agrivoltaics sites in air and soil temperature. However, during periods of intensified summer heat, temperatures beneath the panels cooled due to reductions in wind speed and relative humidity, which impeded the movement of hot, moist air and reduced reference evapotranspiration. Further, soil moisture in UrAV was highly spatially heterogeneous, influenced by the layout of the photovoltaic panels and their support structure, which redistributed rainfall and controlled where solar radiation could penetrate and drive evapotranspiration. Overall, our results suggest that PV-induced environmental changes in temperate climates are compatible with cultivating turfgrass or appropriate crops. These findings can help planners and designers integrate agrivoltaics into community gardens, farms, and green spaces in temperate cities.

14 SOLAR ENERGY↗

DOE OSTI2025

Leveraging Radiofrequency Identification Success Beyond Hazardous Material Inventory Management at a National Laboratory

Effective inventory management can be overshadowed by conflicting priorities in organizational procedures, particularly in research-focused institutions such as national laboratories that handle expensive, delicate, and hazardous materials. Here, this study investigated the potential of radiofrequency identification (RFID) technology, currently used for hazardous chemical inventory, in applications with higher metal interference and absorption, specifically pressure release device (PRD) compliance and nuclear container management, at Lawrence Livermore National Laboratory (LLNL). This study was done to document best practices to enhance inventory identification speeds for inventory reconciliation and inventory recall and to explore optimal configurations for RFID implementation compared to traditional manual methods of equipment management. Tests were conducted to determine the ideal RFID tag orientation (read at angles of 0°, 90°, and 270°), various container layouts (linear, separated, curved, operational), and ID methods such as manual, barcode, and RFID performing three trials per method per orientation. Results indicated that 0° was the optimal read angle for minimizing metallic interference, and the operational and curved arrangements significantly outperformed the linear and separated configurations in read speed. 3D printed mounts were developed and tested, increasing the read range of the RFID reader by up to 235% in cases of high metallic interference. The RFID technology demonstrated an average speed increase of 65% over a simplified manual identification, which supports the conclusion that RFID is a more efficient method for large hazardous inventory management and equipment reconciliation. Additionally, capturing meta-data, such as location and date, can be used to query for inventory recall and automated updating of record information.

42 ENGINEERING↗

DOE OSTI2025

Quantum Sensing in Micro-Architected Scaffolds

Quantum sensing with nitrogen-vacancy centers in diamond has emerged as a powerful tool for measuring diverse physical parameters, yet the versatility of these measurement approaches is often limited by the achievable layout and dimensionality of bulk-crystal platforms. Here, in this study, we demonstrate a versatile approach to creating designer quantum sensors by surface-functionalizing multiphoton lithography microstructures with NV-containing nanodiamonds. We showcase this capability by fabricating a 150 μm × 150 μm × 150 μm triply periodic minimal surface gyroid structure with millions of attached nanodiamonds. We demonstrate a means to volumetrically image these structures using a refractive index matching confocal imaging technique and extract ODMR spectra from 1.86 μm × 1.86 μm areas of highly concentrated nanodiamonds across a cross-section of the gyroid. Furthermore, the high density of sensing elements enables ensemble temperature measurements with a sensitivity of 0.548 ± 0.084 K/√Hz at 5 mW excitation power. This approach to creating quantum-enabled microarchitectures opens new possibilities for multimodal sensing in complex three-dimensional environments.

Materials science↗

DOE OSTI2025

Dynamic motion trajectory control with nanoradian accuracy for multi-element X-ray optical systems via laser interferometry

The past decades have witnessed the development of new X-ray beam sources with brightness growing at a rate surpassing Moore’s law. Current and upcoming diffraction limited and fully coherent X-ray beam sources, including multi-bend achromat based synchrotron sources and high repetition rate X-ray free electron lasers, puts increasingly stringent requirements on stability and accuracy of X-ray optics systems. Parasitic motion errors at sub-micro radian scale in beam transport and beam conditioning optics can lead to significant loss of coherence and brightness delivered from source to experiment. To address this challenge, we incorporated optical metrology based on interferometric length and angle sensing and real-time correction as part of the X-ray optics motion control system. A prototype X-ray optics system was constructed following the optical layout of a tunable X-ray cavity. On-line interferometric metrology enabled dynamical feedback to a motion control system to track and compensate for motion errors. The system achieved sub-microradian scale performance, as multiple optical elements are synchronously and continuously adjusted. This first proof of principle measurement demonstrated both the potential and necessity of incorporating optical metrology as part of the motion control architecture for large scale X-ray optical systems such as monochromators, delay lines, and in particular, X-ray cavity systems to enable the next generation cavity-based X-ray free electron lasers.

47 OTHER INSTRUMENTATION↗

DOE OSTI2026

Ultra-thick three-dimensional interpenetrating graphene electrode architectures for high volumetric density energy storage

For electrochemical energy storage, increasing the electrode thickness is an effective approach to achieving higher energy density from a given material. However, this often compromises ion transport, leading to diminished performance. Here, in this study, we present a novel platform for fabricating complex 3D interpenetrating electrode structures via photo-polymerization 3D printing, integrated with computational structural optimization for energy storage. The platform employs an acrylate resin system infused with graphene oxide (GO), enabling high-fidelity printing of optimized porous structures and facilitating efficient electron and ion transport in ultra-thick electrodes. The optimized 3D layouts substantially enhance energy and power densities compared to conventional configurations, ensuring superior material utilization and minimal ohmic losses. Supercapacitors fabricated using this approach achieved an exceptional energy density of 4.7 Wh L−1 at a power density of 1689.0 W L−1, surpassing traditional designs. This work underscores the transformative role of structural optimization in advancing electrochemical performance and establishes a versatile pathway for developing next-generation energy storage systems with exceptional efficiency and functionality.

Wang, Zhen [University of California, Berkeley, CA↗

DOE OSTI2024

Application of performance portability solutions for GPUs and many-core CPUs to track reconstruction kernels

Next generation High-Energy Physics (HEP) experiments are presented with significant computational challenges, both in terms of data volume and processing power. Using compute accelerators, such as GPUs, is one of the promising ways to provide the necessary computational power to meet the challenge. The current programming models for compute accelerators often involve using architecture-specific programming languages promoted by the hardware vendors and hence limit the set of platforms that the code can run on. Developing software with platform restrictions is especially unfeasible for HEP communities as it takes significant effort to convert typical HEP algorithms into ones that are efficient for compute accelerators. Multiple performance portability solutions have recently emerged and provide an alternative path for using compute accelerators, which allow the code to be executed on hardware from different vendors. We apply several portability solutions, such as Kokkos, SYCL, C++17 std::execution::par, Alpaka, and OpenMP/OpenACC, on two mini-apps extracted from the mkFit project: p2z and p2r. These apps include basic kernels for a Kalman filter track fit, such as propagation and update of track parameters, for detectors at a fixed z or fixed r position, respectively. The two mini-apps explore different memory layout formats. We report on the development experience with different portability solutions, as well as their performance on GPUs and many-core CPUs, measured as the throughput of the kernels from different GPU and CPU vendors such as NVIDIA, AMD and Intel.

Kwok, Ka Hei Martin↗

DOE OSTI2026

Automatic Lane-Level Road Network Extraction from Aerial Imagery for Transportation Digital Twins

Accurate road networks are essential for credible traffic microsimulation and transportation digital twins, yet high-definition maps are often difficult to obtain due to limited availability, high cost, or proprietary restrictions. Some build networks from crowdsourced data, such as OpenStreetMap, but these sources often contain geometric and semantic inconsistencies. Others create networks manually, a process that is labor-intensive and difficult to scale. To address these limitations, this work presents an end-to-end pipeline that automatically extracts georeferenced, lane-level road networks from publicly available high-resolution satellite imagery and converts them into simulation-ready assets. The developed end-to-end pipeline has three primary modules: (1) A computer-vision-based module first detects directed lane geometries and intersection layouts. (2) A heuristic-based topology construction module then identifies approach and exit legs and establishes conflict-free lane-to-lane connections. (3) Finally, an automatic simulation-building module converts the extracted network into standard formats, e.g., OpenDRIVE, and generates routable SUMO networks. The framework supports both complete network construction from scratch and local-scale refinement of existing networks through lane-count correction, transition recovery, and geometric regularization. The proposed pipeline provides a practical pathway to generate traffic simulation networks from satellite imagery, significantly reducing manual reconstruction effort and enabling scalable, continuously updated transportation digital twins.

Guo, Hetian [University of Georgia, Athens] (ORCID↗

DOE OSTI2024

3-center and 4-center 2-particle Gaussian AO integrals on modern accelerated processors

We report an implementation of the McMurchie–Davidson (MD) algorithm for 3-center and 4-center 2-particle integrals over Gaussian atomic orbitals (AOs) with low and high angular momenta l and varying degrees of contraction for graphical processing units (GPUs). This work builds upon our recent implementation of a matrix form of the MD algorithm that is efficient for GPU evaluation of 4-center 2-particle integrals over Gaussian AOs of high angular momenta (l ≥ 4) [A. Asadchev and E. F. Valeev, J. Phys. Chem. A 127, 10889–10895 (2023)]. The use of unconventional data layouts and three variants of the MD algorithm allow for the evaluation of integrals with double precision and sustained performance between 25% and 70% of the theoretical hardware peak. Performance assessment includes integrals over AOs with l ≤ 6 (a higher l is supported). Preliminary implementation of the Hartree–Fock exchange operator is presented and assessed for computations with up to a quadruple-zeta basis and more than 20 000 AOs. The corresponding C++ code is part of the experimental open-source LibintX library available at https://github.com/ValeevGroup/libintx.

Chemistry↗

DOE OSTI2024

Fast photodiode arrays for high frequency fluctuation measurements of reconnecting flux ropes

An array of compact, high-bandwidth (>200 MHz) and low-cost optical photodiodes has been developed and implemented on the PHASe MApping (PHASMA) experiment. Using purpose-built electronics, an array of 16 photodetectors was constructed and used to monitor broadband (1–5 MHz) fluctuations in light intensity emitted by flux ropes undergoing electron-only magnetic reconnection. These measurements reveal a swath of oscillatory behavior, including wave propagation inward toward the diffusion region at approximately the local electron Alfvén speed. Custom 3D-printed collection optics and mounting hardware allow quick reconfiguration of the array for radial or axial measurements. The electronics design is flexible enough to be used with other current-sourcing transducers, such as avalanche photodiodes; silicon photomultipliers; and infrared, x-ray, and UV photodiodes. A noise-rejecting electrical layout allows for low-noise operation close to pulsed plasma discharges. A 16-channel, 64-pixel tomographic array was constructed and initial reconstructions are presented.

Instruments & Instrumentation↗

DOE OSTI2025

Advanced Simulation of ITER Core X-ray Crystal Spectroscopy

X-Ray Simulation Analysis (XRSA) is an analytical ray-tracing mixed code developed specifically for the ITER Core X-Ray Crystal Spectroscopy (XRCS-Core) diagnostic, which employs a dual-reflection configuration incorporating multiple pre-reflectors made of Highly Oriented Pyrolytic Graphite (HOPG) and spherically curved analyzing crystals. The ITER XRCS-Core is designed for high spectral resolution measurement in specific wavelength ranges, including narrow bands around 1.354 Å for W 64+ , 2.19 Å for Xe 51+ , and 2.555 Å for Xe 44+ and Xe 47+ , enabling diagnostic capability across a broad electron temperature range in the ITER plasma. XRSA facilitates efficient simulation of the spectral performance of this complex X-ray spectroscopic system. Recent updates to the XRSA code have incorporated two critical effects: auto-focusing, which specifically applies to HOPG, and polarization. These two effects are particularly important in the dual-reflection configuration used in the ITER XRCS-Core system to provide more accurate modeling results. Here, simulations conducted with the updated code demonstrate that polarization has a substantial impact on the performance of the dual-reflection system. Additionally, the combined influence of polarization and system layout introduces performance variations across channels through the same crystal.

Computer graphics↗

DOE OSTI2025

Testing strong-field QED with the avalanche precursor

A two-beam high-power laser facility is essential for the study of one of the most captivating phenomena predicted by strong-field quantum electrodynamics (QED) and yet unobserved experimentally: the avalanche-type cascade. In such a cascade, the energy of intense laser light can be efficiently transformed into high-energy radiation and electron–positron pairs. The future 50-petawatt-scale laser facility NSF OPAL will provide unique opportunities for studying such strong-field QED effects, as it is designed to deliver two ultra-intense, tightly focused laser pulses onto the interaction point. In this work, we investigate the potential of such a facility for studying elementary particle and plasma dynamics deeply in the quantum radiation-dominated (RD) regime, and the generation of QED avalanches. With three-dimensional particle-in-cell simulations, we demonstrate that QED avalanche precursors can be reliably triggered under realistic laser parameters and layout (namely, focusing f/2, tilted optical axes, and non-ideal co-pointing) with the anticipated capabilities of NSF OPAL. We demonstrate that seed electrons can be efficiently injected into the laser focus by using targets of three types: a gas of heavy atoms, an overcritical plasma, and a thin foil. A strong positron and high-energy photon signal is generated in all cases. The cascade properties can be identified from the final particle distributions, which have a clear directional pattern. At increasing laser field intensity, such distributions provide signatures of the transition, first, to the RD interaction regime, and then to a QED avalanche. Our findings can also be used for designing related future experiments.

Lasers↗