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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Metal Scrap Upcycling with Shear Assisted Processing and Extrusion (ShAPE)

The overarching objective of this project is to convert metal scraps, such as aluminum, titanium, and other alloys provided by the industry, into extruded tubing, wires, and rods. Upcycling of scrap will be accomplished using Shear Assisted Processing and Extrusion (ShAPE). This approach is a new solution for recycling. The specific aims of this project are as follows: 1. Receive metal scrap under a Material Transfer Agreement (MTA), in the form of billets, from select industry partners that meet the following requirements: outer diameter of 1.245 inches (+/-0.003 inches), inner diameter drilled with a 0.404-inch drill bit, and a length of 4.0 inches (+/-0.01 inches). The billet must be cast or compacted to greater than 98% density. If the industry partner does not have the capabilities to prepare the billets, PNNL can make introductions to third-party entities as needed. Industry partners will also provide a composition analysis as weight percent. 2. Extrude metal scrap via the ShAPE process at PNNL. 3. Evaluate and benchmark the extrudate material properties per the ASTM B557-15 – Testing Tubulars Standard or similar wire and rod standards. 4. Characterize the extrudate microstructure for any of the following: grain size, second phase composition, and texture. Additional testing may include corrosion per the ASTM B117 standard and electro-potential. 5. Deliver specimens to industry partners under an MTA for additional third-party evaluations. Industry partners will, in return, provide a non-proprietary report on any testing, including testing per the ASTM B557-15, ASTM B117, and other industry standards. 6. PNNL will develop data and insights to support intellectual property capture, a published non-proprietary technical report, research collaborations, and commercialization opportunities.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Understanding drivers of oil and gas well integrity issues in the greater wattenberg area of Colorado

Well integrity is critically important to maintain to minimize the environmental impacts of oil and gas development and other subsurface energy operations. The Wattenberg Field of Colorado—a top producing field with >40,000 wells—has one of the most robust publicly reported well integrity programs in the country. Here, in this study, we analyzed annular pressure and annular-fluid geochemical test results collected from Wattenberg wells through the end of 2019 to characterize the frequency and spatial variability of integrity issues in the field and understand their drivers. Estimated frequencies of integrity issues among tested wells were 8.2-17.1% between 1955 and 2019 and 6.1-11.4% in 2019 alone. The frequency of integrity issues was nearly four times greater in wells located above the Longmont Wrench Fault Zone. Potential drivers of integrity issues were identified using ensemble decision tree models trained with a broad set of relevant information. Models show that well integrity issues are spatially clustered on regional and sub-regional scales and suggest the relatively high frequency of integrity issues observed is likely attributed to geologic factors. These findings are valuable for regulatory agencies and operators seeking to inform well integrity monitoring, plugging, and emissions reduction efforts and design future subsurface energy projects.

03 NATURAL GAS↗
DOE OSTI2024

Subsurface Energy Systems Mapping Inquiry Tool (MapIT)

The Subsurface Energy Systems Mapping Inquiry Tool (MapIT) is an online web mapping tool designed to help users discover available public-sourced data to facilitate data exploration for subsurface energy exploration and characterization efforts for resource identification (e.g. critical minerals, hydrocarbons, geothermal) as well as injection of geologic sequestration of carbon dioxide (e.g. enhanced oil recovery, saline storage, etc.). Modules within the tool curate data related to geology, faults, fractures, injection and confining zones, hydrologic information, groundwater, groundwater wells, geomechanical and petrophysical data, and geochemical data. User documentation on how to use the tool is also provided. Data have been collected from authoritative national, state, and local sources and made available in this tool. The data is also available as a data catalog and Esri Geodatabase at: https://edx.netl.doe.gov/dataset/mapit-database Disclaimer: There is no guarantee of completeness or appropriateness for individual user’s requirements. Use of this tool is solely at the discretion of the user. See full Federal Disclaimer for further information (https://netl.doe.gov/home/disclaimer). This project was funded by the United States Department of Energy, National Energy Technology Laboratory, in part, through a site support contract. Neither the United States Government nor any agency thereof, nor any of their employees, nor the support contractor, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. https://www.netl.doe.gov/home/disclaimer

Carbon Sequestration↗
DOE OSTI2025

A formaldehyde and nitrogen dioxide toxics monitor for environmental justice

DOE’s Integrated Field Laboratories (IFLs) require a vast array of measurements to measure urban air quality. Nitrogen dioxide (NO2) and formaldehyde (HCHO) are ubiquitous pollutants with numerous sources, most notably vehicle exhaust. High-spatial density measurements are critical to understanding how certain neighborhoods are more adversely impacted by pollutants. This report describes the results of a Phase I SBIR project to develop and demonstrate a rapid, affordable, low-power monitor to provide high spatial resolution mobile measurements of formaldehyde and nitrogen dioxide at street-level, where people live and walk. The spatial density will be achieved via rapid measurements on a mobile platform. This sensor will quantify spatial disparities in cities of the toxics, HCHO and NO2, as well as carbon monoxide and carbon dioxide for better source identification. These species are detected in the mid infrared by laser absorption spectroscopy, and fiberoptics are used. Tasks accomplished include identification and testing of the appropriate spectroscopic regions; coupling of laser light into a fiberoptic system; development of software to control miniature electronics to scan and control two lasers simultaneously; coupling of the mid infrared fiber into a multipass cell for enhanced pathlength and sensitivity; characterization of sources of instrument noise; and design work for a Phase II prototype.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Ultra-High Efficiency and Stable All-Perovskite Tandem Solar Cells

In the project period, the research team has fabricated more than 6,000 single-junction wide-bandgap (wide-E g ) and low-bandgap (low-E g ) perovskite solar cells (PSCs) and more than 2,000 all-perovskite tandem solar cells (APTSCs). The best-performing wide-E g and low-E g PSCs and APTSCs showed PCEs greater than 19%, 23%, and 30%, respectively. The average PCEs for wide-E g and low-E g PSCs and APTSCs fabricated by the benchmark processes are (18.5 ± 0.4)%, (21.9 ± 0.8)%, and (26.8 ± 2.1)%, respectively. We have demonstrated APTSCs with T 80 lifetime of more than 1,000 h, which were measured by maximum power point tracking (MPPT) under one sun operation in the air. The team has also utilized various advanced characterization techniques to study the optical and electrical properties of wide-E g and low-E g perovskite materials and devices, developing a better understanding of the unique working principle and degradation mechanism of APTSCs. The team has met most GNG decision criteria except for the stability goal of APTSCs under 85 °C/85 RH accelerated lifetime test (ALT). The shortfall of the device ALT stability is mainly limited by the intrinsic instability of Sn-Pb perovskites under illumination at elevated temperatures. The team discussed with stakeholders in the PV academic and industry about these durability concerns and concluded that this is the major technical barrier preventing the market entry of APTSCs. Future fundamental study and R&D work are needed to advance this promising technology.

14 SOLAR ENERGY↗
DOE OSTI2026

Doping Metallic Grain Boundaries to Control Atomic Structure and Damage Tolerance

Grain boundaries often act as sites for crack and void nucleation during plastic deformation of metallic materials. While it is known that grain boundary character and structure can greatly influence this damage nucleation process, the current level of control over such details is limited. The objective of this project was to obtain a fundamental understanding of how metallic grain boundary structure can be controlled through intelligent doping, with the idea of inducing planned amorphous grain boundary phases or complexions. The effect of amorphous complexion structure on dislocation accommodation mechanisms was studied, to improve the field’s understanding of damage nucleation at a promising type of interface. Different microstructural descriptors were studied, as grain boundaries can have large variations and complexity of local structure, and influence the mechanical damage resistance of these features was tested. Nanocrystalline systems that contain amorphous grain boundary complexions were prioritized, as these have more extreme variations in interfacial structure and damage tolerance, with an emphasis on isolating the importance of complexion population (type, thickness, etc.), network topology, local structure, and local chemistry. This research used a combination of computational, experimental, and characterization techniques to isolate and understand the importance of nanoscale grain boundary structure and interfacial chemistry. Amorphous grain boundary complexions were found to clearly increase a material’s resistance to mechanical damage, with the local distribution of structural short-range order within the complexions found to be an important descriptor for damage and the proposed focus of future work in this area.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Soil Temperature and Moisture within the Kougarok Fire Complex, Kougarok Road Mile Marker 86, Seward Peninsula, Alaska, 2019-2023

Daily averages of soil temperature and moisture measured once every hour at different heights located at Intensive Monitoring Stations within the Kougarok Fire Complex, Kougarok Road Mile Marker 86 site. Data were retrieved annually from 2019-2023. Package contains 21 *.CSV data files plus a file level metadata *.CSV, data dictionary *.CSV, data file inventory *.CSV, and sensor location site map *.JPG. Data files have header rows, NaN fields indicate invalid or missing data, and negative vertical offsets are above ground.The Kougarok tundra fire complex (KFC) is located north of Nome and the Kigluaik Mountains, near Quartz Creek and the Kougarok River. The site is accessed by foot from the end of the Nome-Taylor Highway (mile marker 86; also called the Kougarok or Beam Road). The KFC burned in six major fires in the decades since 1950 (Alaska Interagency Coordination Center, unpublished data). Lightning ignited five of these fires (1971, 1997, 2015, and 2019) and one was human caused (2002). The mosaic of overlapping fire scars allows for the study of repeat fires in the tundra which, until recently, was not a common phenomenon outside the boreal forest in Alaska. Our reference unburned tundra fire site is south of the KFC located at mile marker 80 of the Nome-Taylor Highway.The two most recent fires are the Mingvk Lake (2015; 21,698 acres burned from 7/27/2015 to 9/28/2015) and Garfield Creek (2019; 422 acres burned from 7/31/2019 to 8/20/19). The Mingvk Lake fire scar includes areas that burned 1-4x (1971, 1997, 2002), while the entirety of the Garfield Creek fire scar has burned 2x previously (1971, 2002).Previous research at the KFC focused on permafrost (Liljedahl et al. 2007; Narita et al. 2015; Iwahana et al. 2016; Tsuyuzaki, Iwahana, and Saito 2017) and vegetation (Narita et al. 2015; Hollingsworth et al. 2021) response to fire. The central Seward Peninsula is characterized by continuous permafrost with a thickness of 15 to 30 m and a mean active layer thickness of 56 cm (Hinzman et al. 2003). Sloping hills with mixed shrub–tussock tundra and tussock tundra vegetation in the uplands are characteristic of the region. Three micrometeorological towers near the Kougarok field site recorded a mean annual temperature of −2.4°C, mean January temperature of −23.1°C, mean July temperature of +11°C, and mean summer rainfall (June–August) of 94 mm from 2000 to 2006 (Liljedahl et al. 2007).The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research.The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska.Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Multicriteria screening evaluation of geothermal resources on mine lands for direct use heating

Abstract Direct use of geothermal energy is the oldest and most versatile form of utilizing geothermal energy. In the last decade, this utilization has significantly increased, especially with the installation of geothermal (ground-source) heat pumps. Many current and inactive mine land sites across the U.S. could be redeveloped with clean energy technologies such as direct use geothermal, which would revitalize former mining communities, help with reducing greenhouse gas emissions, and accelerate the transition to a clean energy economy. We present a multicriteria screening framework to evaluate various aspects of direct-use geothermal projects on mine lands. The criteria are divided into three categories: (1) technical potential, (2) demand and benefits, and (3) regulatory and permitting. We demonstrate the framework using publicly available data on a national scale (continental U.S.). Then, using an example of abandoned coal mines in Illinois and focusing on resource potential, we illustrate how this evaluation can be applied at the state or more local scales when a region’s characteristics drive spatial variability estimates. The strength of this approach is the ability to combine seemingly disparate parameters and inputs from numerous sources. The framework is very flexible—additional criteria can be easily incorporated and weights modified if input data support them. Vice versa, the framework can also help identify additional data needed for evaluating those criteria. The multicriteria screening evaluation methodology provides a framework for identifying potential candidates for detailed site evaluation and characterization.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

On High-Temperature Dynamometer Test Stand Development

RePED is a novel prototype alternator that has been designed and built to operate at 35 kW under 250 degrees C ambient temperature conditions. The operating efficiency will be measured using a 225-kW motor to drive the machine in a back-to-back configuration. The goal is to determine if the RePED alternator can deliver 35 kW at a rotational speed of 1,000 rpm while operating in 250 degrees C ambient temperature and have a minimum efficiency of 60%. Dynamometer testing of a high-temperature alternator for geothermal drilling presents several unique challenges, especially around maintaining and managing the various sources and types of energy passing through the system without impacting data quality. The objectives of this report are to (1) describe the test stand in detail, the relative orientation of each major component, and the data acquisition system and (2) discuss the behavior of the test stand components such that this report can serve as a reference document for future projects.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

geoPFA: A Python-Based Open-Source Software for 3D Geothermal PFA

This work presents a novel Python-based framework, geoPFA, for conducting 3D play fairway analysis (PFA) tailored to superhot geothermal systems. The workflow has been applied to the Nesjavellir field in Iceland, a candidate site for the third Iceland Deep Drilling Project's superhot production scenarios. This application demonstrates the value of modular, transparent, and extensible workflows for integrating geological, geophysical, and simulation-derived datasets in high-enthalpy environments. Preliminary results indicate favorable zones consistent with known hydrothermal activity. The geoPFA library will soon be publicly available, offering a scalable and reproducible approach to geothermal exploration across varied geological contexts.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Mechanistic Modeling of TEG Dehydrator Emissions in Oil and Gas Industry

This work presents a mechanistic modeling approach for simulating methane emissions from triethylene glycol (TEG) dehydrators used in oil & gas (O&G) operations. The model was developed as a modular component of the Mechanistic Air Emissions Simulator (MAES) tool, incorporating species-specific absorption and emission dynamics through two-level, second-order polynomial regression (PR) models trained on ProMax simulation data: (1) species-level regression models that track the transfer rates of individual gas species within the dehydrator unit streams, and (2) outlet flow stream regression models that predict the fraction of inlet gas distributed among the outlet streams of the dehydrator unit. These behaviors were characterized over a range of glycol circulation ratios, wet gas pressures, and temperatures. The model was validated using root mean square error (RMSE) analysis. The species-level PR achieved low root mean square error (RMSE) values (<0.03) for light hydrocarbon species across all dehydrator components, ranging from 0.0009 for methane to 0.029 for normal pentane. Similarly, the outlet-level PR yielded RMSE values below 0.002 for the dry gas fraction, 0.001 for the flash tank fraction, and 0.002 for the still vent fraction, demonstrating strong agreement between predicted and reference ProMax values. When deployed at field facilities, the model significantly improved MAES-simulated dehydrator emissions, revealing that gas-assisted glycol pump emissions are the dominant contributors to both dehydrator-level and site-level methane emissions under uncontrolled conditions. Further analysis of the 154 dehydrator units reported by operators under the AMI 2024 project showed that 54 units (31%) used gas-driven glycol pumps, of which 6 units (11%) operated with uncontrolled flash tanks, and 22 units (40.7%) were identified as potentially oversized. Of the six dehydrator units with uncontrolled gas-assisted pumps, pump emissions accounted for 90.25% of total dehydrator emissions and 63.10% of total site-level emissions. These findings highlight substantial opportunities for emissions mitigation through equipment upgrades.

MAES↗
DOE OSTI2024

Seismic Monitoring near Ithaca, New York, Reveals Nonuniform Distribution of Microseismicity in an Intraplate Region

Abstract Cornell University intends to use a deep direct-use geothermal system to heat its Ithaca, New York, campus. In preparation for this project, the Cornell Seismic Network has been monitoring the background seismicity in this intraplate region since 2019. From January 2020 to June 2023, 95 events were detected within 20 km of the proposed geothermal well site, with local magnitudes ranging from −1.02 to 0.56. None of these events appear in regional or national catalogs. Events locate in a narrow geographic band, with one-fourth exhibiting multimodal hypocentral probability peaks both near the surface and at 1–4 km depth. We relocate events with a joint hypocenter and 1D velocity model inversion, in addition to a fully nonlinear method, and then compare observations with synthetic waveforms. Together, these approaches provide strong evidence for >95% of events locating at the surface or within the 3-km-thick sedimentary sequence. We explore how anthropogenic activity and regional topographic stress may contribute to frequent surficial events. This information is critical for characterizing the background microseismicity for comparison during future geothermal operations. Ithaca’s geology of Paleozoic sediments overlying Precambrian crystalline basement is typical of many continental interiors, so these results also provide insight into intraplate microseismicity patterns.

Geochemistry & Geophysics↗
DOE OSTI2026

WHONDRS Surface Water and Sediment Geochemistry and Organic Matter Characterization Data from Streams across HJ Andrews Experimental Forest, Oregon (v2)

This dataset supports a broader study developing conceptual models for river corridor critical zone processes across spatial scales and was generated in collaboration with the HJ Andrews River Corridor Critical Zone Workshop in 2025. The dataset provides surface water geochemistry (dissolved organic carbon, total dissolved nitrogen) from 48 sites across the HJ Andrews Experimental Forest, Oregon (https://andrewsforest.oregonstate.edu). Some of the sites have been impacted by the Holiday Farm Fire and the Lookout Fire in 2020 and 2023, respectively. Related data were collected as part of the workshop and will be published separately in collaboration with other workshop attendees and available at http://www.hydroshare.org/resource/b274c4a234bf4b12b7cb8a54a696c629. Related genomic data can be found on the National Center for Biotechnology Information (NCBI) under BioProject PRJNA1503030 (see critical details section below for more information). Additional related data collected in 2016 from a similar effort can be found at https://data.ess-dive.lbl.gov/datasets/doi:10.15485/3377027 and http://www.hydroshare.org/resource/ea6c0832885a46c3939e7bb22e48e754 and are described within https://doi.org/10.5194/essd-11-1-2019 (Ward et al., 2019). This data package was originally published in March 2026. It was updated in August 2026 (v2; new and modified files). See the change history section in the readme for more details. For details on how to navigate data packages generated by this project, see https://data.ess-dive.lbl.gov/portals/PNNLRiverCorridorSFA/About. In addition to a readme, this data package also includes a file-level metadata (FLMD) file that describes each file and a data dictionary (DD) that describes all column/row headers and variable definitions. This dataset is comprised of (1) a folder of field photos, (2) a folder of raw Fourier transform ion cyclotron resonance mass spectrometry (FTICR-MS) data, (3) a data checks report, (4) a folder of sample data, (5) file-level metadata, (6) data dictionary, (7) field metadata, (8) readme, (9) international generic sample number (IGSN) mapping file; and (10) field protocol. The sample data subfolder contains surface water and sediment (1) dissolved organic carbon (DOC, measured as non-purgeable organic carbon, NPOC) data and averages, (2) total dissolved nitrogen data and averages, (3) methods codes, (4) FTICR-MS methods; and (5) a subfolder of 9.4 Tesla (9.4T) FTICR-MS data. This folder contains the CoreMS processed data and seven subfolders, thee containing .xml files for each sample type (sediment, surface water and blank samples), three containing the sediment CoreMS output files for each sample type (sediment, surface water and blank samples), and the other containing instructions and scripts for processing the files in CoreMS (https://github.com/EMSL-Computing/CoreMS). All files are .csv, .pdf, .R, .xml, .Rmd, .py, .cal, .json, .jpg, or .jpeg.

Biogeochemistry↗
DOE OSTI2025

Study and improvement of the trigger system in ICARUS

In recent years, intriguing experimental neutrino anomalies have emerged. If confirmed, they could hint at the presence of additional sterile neutrino states playing in neutrino mixing. The Short-Baseline Neutrino project at Fermilab aims to delve into these anomalies, utilizing three Liquid Argon Time Projection Chamber detectors along the Booster Neutrino Beam. The SBND detector serves as nearby instruments, while MicroBooNE and ICARUS function as far detectors and also explore the NuMI beam off-axis. A relevant aspect in the functioning of all SBN detectors is the trigger system, that determines which interactions are recorded. In particular, in ICARUS, it relies on the synchronization of prompt signals from scintillation light within the LAr-TPC, detected by a system of Photo-Multiplier Tubes, with the proton beam’s spill extraction. The existing majority-based logic of the trigger system could potentially be enhanced through adder boards that sum analog signals from PMTs in groups of 15. This sum-based triggering might aid in identifying events near TPC walls, where light is abundant but captured by only a few PMTs, potentially bypassing the majority condition. Comprehensive tests have been performed to characterize these adder boards.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Fabrication of neutron absorbing metal hydride entrained ceramic matrix shield composites

With significant improvement in High Temperature Superconductors (HTS), several projects are adopting HTS technology for fusion power systems. Compact HTS tokamaks offer potential advantages including lower plant costs, enhanced plasma control, and ultimately lower cost of electricity. However, as compact reactors have a reduced radial build to accommodate shielding, HTS degradation due to radiation damage or heating is a significant and potentially design limiting issue. Shielding must mitigate threats to the superconducting coils: neutron cascade damage, heat deposition and potentially organic insulator damage due x-rays. Unfortunately, there are currently no hi-performance shielding materials to enable the potential performance enhancement offered by HTS. In this work, we present a manufacturing method to fabricate a new class of composite shields that are high performance, high operating temperature, and simultaneously neutron absorbing and neutron moderating. The composite design consists of an entrained metal-hydride phase within a radiation stable MgO ceramic host matrix. We discuss the fabrication, characterization, and thermophysical performance data for a series of down-selected composite materials inspired by future fusion core designs and their operational performance metrics. To our knowledge these materials represent the first ceramic composite shield materials containing significant metal hydrides.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Microstructural Engineering and Accelerated Test Method Development to Achieve Low Cost, High Performance Solutions for Hydrogen Storage and Delivery

This project made advancements in developing lower cost steel alloys with novel microstructural design for use in hydrogen refueling infrastructure such as storage, compressors, and dispensing components, and utilizing accelerated test methods to efficiently evaluate variations in alloy and microstructure design. The project specifically sought to design alloys with lower nickel contents to reduce alloy cost, which was accomplished through substituting manganese for nickel along with other alloy additions to control deformation characteristics known to be important for hydrogen embrittlement resistance. Through Mn substitutions for nickel, austenitic and duplex austenite-ferrite steels were successfully developed with lower cost than currently available commercial stainless steel products that are employed for hydrogen refueling infrastructure. The steels were processed to achieve comparable strength and toughness in hydrogen environments as the commercially available steels containing high Ni contents. To evaluate mechanical performance in hydrogen, a testing methodology was employed to compare ubiquitous laboratory testing using electrochemical hydrogen charging in a liquid electrolyte to less accessible high pressure gaseous testing. While the application of these steels is in high pressure gaseous environments, the electrochemical hydrogen charging tests produced comparable results. Additionally, the Los Alamos Neutron Scatting Center enabled characterization of deformation mechanisms of the steel alloys in the presence of hydrogen, which has been associated with steel alloy characteristics associated with hydrogen embrittlement. Finally, a fracture mechanics based test bed model was developed to predict the influence of hydrogen gas pressure and fatigue conditions on fatigue lifetimes of pressure vessel steels. Together, these developments can be employed to enable lower cost hydrogen fueling infrastructure and more reliable prediction of steel alloy components in hydrogen service conditions. In particular, the newly alloys have the potential to replace stainless steels, having demonstrated comparable performance at substantially reduced cost.

08 HYDROGEN↗
DOE OSTI2025

Impacts of PV Module Connector Failures on Cost and Performance of Utility Scale Photovoltaic Systems

The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.

14 SOLAR ENERGY↗
DOE OSTI2025

Studies of the trigger performance of the ICARUS T600 detector at Fermilab

In recent years, experimental neutrino anomalies were reported: if confirmed, they could hint at the existence of additional sterile neutrino states participating in the mixing phenomenon. The future Short-Baseline Neutrino (SBN) project at Fermilab will pursue sterile neutrino searches, by exploiting three Liquid Argon (LAr) Time Projection Chamber (TPC) detectors located on-axis along the Booster Neutrino Beam (BNB). Aside from SBND and MicroBooNE, ICARUS will be the far detector and will also be interested by the NuMI beam (off-axis). The trigger system is a key component of the detector: it is based on the coincidence of prompt signals from scintillation light in the LAr-TPC (recorded by a system of PhotoMultiplier Tubes, PMTs) with the proton spill extraction of the beam. The present system exploits a majority-based logic and may be complemented by a trigger system based on adder boards, that add the analog signals of the PMTs in groups of 15. Triggering on the sum may help in identifying events closer to the TPC walls, in which there is plenty of light collected by few PMTs and for which the majority condition may not be satisfied. Many tests were carried out to characterize the adder boards, both on the hardware and software sides.

43 PARTICLE ACCELERATORS↗