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DOE OSTI2021

Machine learning accelerated discrete element modeling of granular flows

Granular flows are widely encountered in many industrial processes and natural phenomena. Discrete Element Modeling (DEM) is a useful tool for understanding and troubleshooting devices, which handle granular materials. However, its applicability is significantly limited by the huge computational cost associated with detecting and computing collisions. In this research, the computation speed of DEM was accelerated by orders of magnitude using a convolutional neural network to replace the direct calculation of particle-particle and particle-boundary collisions. The MFiX software was used to generate the training and testing dataset. Additionally, a GPU accelerated TensorFlow model was used to train the neural network and test the results. The model fluctuations caused by different training steps were reduced with a multi-scale loss function. The accuracy was improved with more frames within one training step. The modeling of a rotating drum and a hopper demonstrated the accuracy and efficiency of this machine learning accelerated DEM in the simulation of granular flows.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

An atomic cluster expansion potential for twisted multilayer graphene

Twisted multilayer graphene, characterized by its moiré patterns arising from inter-layer rotational misalignment, serves as a rich platform for exploring quantum phenomena. Machine learning interatomic potentials (MLIPs) are a promising approach to model such systems. Our work develops a method to generate training and test datasets for fitting MLIPs that capture all possible misalignments but remain small-scale to facilitate efficient data generation and parameter estimation. To achieve this, we generate configurations with periodic boundary conditions suitable for density functional theory calculations, and then introduce an internal twist and shift within those supercell structures. Using this technique, supplemented with an active learning workflow, we fit an Atomic Cluster Expansion potential for simulating twisted multilayer graphene and test it for accuracy and robustness on a range of simulation tasks.

2D materials↗

DOE OSTI2025

Influence of Control and Limiter Schemes on Sequence-Domain Fault Models of Grid-Forming Inverter-Interfaced Distributed Generators

Unlike synchronous generators, the fault response of grid-forming (GFM) inverter-interfaced distributed generators (IIDGs) is notably governed by the selection of control and current limiting strategies rather than inherent physical traits. While recent research has focused on the sequence domain fault model of GFM IIDGs, a research gap exists in elucidating the influence of control and current limiting schemes on this model's characteristics. This article aims to fill this void by examining how different control and current limiting schemes influence the positive and negative sequence impedances in the phasor-domain fault model of GFM IIDGs. This investigation encompasses droop-based, virtual synchronous machine-based, and virtual oscillator-based reference generation controls alongside rotating and stationary reference-frame-based voltage controls. Furthermore, saturation-based, latching-based, circular and virtual impedance-based current limiting schemes are analyzed. To achieve this goal, a thorough numerical simulation study is conducted. Findings indicate that outer reference generation controls exhibit minimal impact. Conversely, the choice of voltage control and various current limiting schemes emerge as the predominant factors shaping the sequence models of GFM IIDGs. These analyses and results are instrumental in devising reliable protection strategies within inverter-based grids, as a comprehensive understanding of electrical elements in the sequence domain is imperative for effective protective measures.

current limiters↗

DOE OSTI2020

Gripper Test Assembly Status Report (FY2020)

Refueling systems for fast reactors are designed to handle fresh and used core assemblies (fuel, reflector, and shield core assemblies) within the reactor vessel in an opaque coolant environment without visual reference. These refueling machines are designed to work in a sodium (or other fast reactor coolant) and argon vapor space environment and are engineered with the rotatable plug system to allow for the movement of fresh and spent fuel into and out of the reactor core. The refueling machines are a critical component in any reactor and thus need to undergo extensive testing in a prototypic environment to ensure that they will meet all of the system functions and requirements. Argonne has developed an innovative compact refueling system design for the Advanced Fast Reactor-100 that is based upon some mechanisms used in previous reactor designs, such as the U.K.’s Prototype Fast Reactor (PFR) and some mechanisms that have not been used in sodium. This compact refueling machine supports the reduction in size of the AFR-100’s reactor vessel, and if fully developed, would support and inform the development of the in-vessel refueling machines for such commercial reactors as the GEH PRISM reactor plant, the ARC Clean Energy’s ARC-100 reactor, and the Natrium reactor, among others. This refueling system is a vital component of a fast reactor that supports reducing the cost of the reactor and increasing its reliability. During the development of the compact fuel handling machine conceptual design for the AFR-100, a lack of testing data for many mechanical components in sodium under typical in-reactor loads and conditions was discovered. The reduction in lifetime of the various mechanical components in the liquid sodium environment needs to be quantified versus the calculated component lifetimes under normal conditions in the testing while they are subjected to typical loading profiles experienced in the past. The Gripper Test Assembly discussed here includes a full-size gripper device with appropriate mechanical features that will be tested in sodium to provide this testing data. The Gripper Test Assembly is used to test various mechanical fuel handling components submerged in high temperature liquid sodium. These mechanisms are gears, bearings, gripper jaws and head, universal joints and shafts, ball screws, among others. These components will be tested under the typical sodium environmental conditions experienced during refueling operations with appropriate loading conditions that simulate the removal and insertion of core assemblies into a fast reactor grid plate structure. This Gripper Test Assembly is the second in a series of refueling system mechanisms developed for testing in sodium. The first test assembly is the Gear Test Assembly (GTA) which was used to test the performance of gears and bearings operating in sodium. Because of the successful testing conducted with the GTA, it was decided to continue with the development of the Gripper Test Assembly which uses the same gears and bearings tested in GTA. Using the data collected during operation of this gripper test assembly, lifetime reduction factors of the various mechanical components can be calculated for the material combinations selected. These lifetime reduction factors can be used in the design of future mechanical systems which operate in these environments to accurately predict component end of life. In addition, an understanding of the ability of these components and mechanisms to operate under-sodium with the chosen materials will be accomplished. Again, this Gripper Test Assembly is the follow-on test article to the Gear Test Assembly which was testing the ability of gears and bearings operating in a sodium environment. Once fabricated and qualified, it will be tested in the Mechanism Engineering Test Loop (METL) facility located in Building 308 at Argonne National Laboratory.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Point-particle drag, lift, and torque closure models using machine learning: Hierarchical approach and interpretability

Developing deterministic neighborhood-informed point-particle closure models using machine learning has garnered interest recently from the dispersed multiphase flow community. The robustness of neural models for this complex multibody problem is hindered by the availability of particle-resolved data. Here, the present work addresses this unavoidable limitation of data paucity by implementing two strategies: (1) by using a rotation and reflection equivariant neural network and (2) by pursuing a physics-based hierarchical machine learning approach. The resulting machine-learned models are observed to achieve a maximum accuracy of 85% and 96% in the prediction of neighbor-induced force and torque fluctuations, respectively, for a wide range of Reynolds number and volume fraction conditions considered. Furthermore, we pursue force and torque network architectures that provide universal prediction spanning a wide range of Reynolds number (0.25 ≤ Re ≤250) and particle volume fraction (0 ≤ φ ≤0.4). The hierarchical nature of the approach enables improved prediction of quantities such as streamwise torque, by going beyond binary interactions to include trinary interactions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

Dual magnetic phase material rings for AC electric machines

An AC electric machine that includes a dual magnetic phase material ring is disclosed. The AC electric machine includes a stator assembly and a rotor assembly positioned within the stator assembly and configured to rotate relative thereto, the rotor assembly comprising a rotor core including a stack of rotor laminations that collectively form the rotor core, the rotor core including a plurality of rotor poles separated by gaps therebetween. The AC electric machine also includes a dual magnetic phase material ring positioned about the stack of rotor laminations, the dual magnetic phase material ring comprising a first ring portion comprising a magnetic portion and a second ring portion comprising a non-magnetic portion.

42 ENGINEERING↗

DOE OSTI2022

Computational optimal transport for molecular spectra: The semi-discrete case

Comparing a discrete molecular spectrum to a continuous molecular spectrum in a quantitative manner is a challenging problem, for example, when attempting to fit a theoretical stick spectrum to a continuous spectrum. In this paper, the use of computational optimal transport is investigated for such a problem. In the optimal transport literature, the comparison of a discrete and a continuous spectrum is referred to as semi-discrete optimal transport and is a situation where a metric such as least-squares may be difficult to define except under special conditions. The merits of an optimal transport approach for this problem are investigated using the transport distance defined for the semi-discrete case. A tutorial on semi-discrete optimal transport for molecular spectra is included in this paper, and several well-chosen synthetic spectra are investigated to demonstrate the utility of computational optimal transport for the semi-discrete case. Among several types of investigations, we include calculations showing how the frequency resolution of the continuous spectrum affects the transport distance between a discrete and a continuous spectrum. We also use the transport distance to measure the distance between a continuous experimental electronic absorption spectrum of SO 2 and a theoretical stick spectrum for the same system. The comparison of the theoretical and experimental SO 2 spectra also allows us to suggest a theoretical value for the band origin that is closer to the observed band origin than previous theoretical values.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2020

Production of Medium-Scale Metal Additive Geometry With Hybrid Manufacturing Technology

Oak Ridge National Lab’s (ORNL) Metal Big Area Additive Manufacturing (mBAAM) and Hybrid Manufacturing teams in the Manufacturing Demonstration Facility (MDF) was tasked with developing a part that exceeded 24 inches in length and 100lbs in weight on a laser hotwire welding system. The Mazak VC-500A/5X AM HWD hybrid 5-axis CNC laser hotwire system was leveraged to complete the task. The proposed geometry was manufactured with 410 stainless steel on AISI1018 steel substrate in just over 36 hours of build time. The proposed geometry was sliced and additively manufactured in three segments; the base, and two extrusions measuring 10 inches in length and 14 inches in length. Production of this component demonstrated hybrid capabilities requiring fixed 5-axis rotations to complete geometry that exceeded the defined build volume of the machine. Multiple repairs of the part were conducted in-situ leveraging the additive and subtractive capabilities of the Mazak hybrid system. Significant overbuilding challenges were encountered and manually addressed by leveraging subtractive capabilities of the hybrid system. Future processes are presented for development to reduce overheating of top layers. Final part measurements exceeded 107 lbs. in weight and 24.5 inches in length along the principal axis; the largest and heaviest part created by a hybrid system at the MDF.

Saleeby, Kyle↗

DOE OSTI2020

Scroll-type machine

A scroll-type displacement machine, e.g. scroll compressor, has fixed and orbiting scrolls and an Oldham ring to prevent relative rotation between scrolls. A drive module positioned between the orbiting scroll and drive shaft incorporates an eccentric drive system and first and second counterweights for dynamic balancing. The motor, motor bearings, and motor shaft (i.e., drive shaft) are packaged as a separate, modular unit (e.g. “off-the-shelf” motor) that attaches to the compressor frame. The machine is configured as a high-side machine with a low-pressure port at a radial outer portion of the fixed scroll and a high-pressure port or discharge port located in the floor of the orbiting scroll at its axis, with high pressure flow passing over and around the eccentric drive bearing and drive mechanism. The Oldham ring is distributed on a lateral or radial plane of the scroll pair with a portion surrounding a portion of the fixed scroll and another portion surrounding a portion of the orbiting scroll. The ring may be formed as four arcuate members arranged on two levels, to occupy otherwise unused space in the scroll-type machine.

42 ENGINEERING↗

DOE OSTI2026

Contrasting Carbon–Water–Energy Dynamics in Perennial and Annual Bioenergy Agroecosystems Using Eddy Covariance and Interpretable Machine Learning

Understanding how agroecosystems respond to environmental variability is fundamental to predicting productivity and sustainability under a changing climate. We analyzed 55 site-years of high-frequency eddy covariance observations from five agroecosystems—two perennial grasses (miscanthus and switchgrass), two annual rotation systems (maize–soybean and sorghum–soybean), and a restored native prairie—to examine ecosystem-scale carbon, water, and energy fluxes. Using an interpretable machine-learning framework with regression tree ensembles, Shapley Additive Explanations, and Accumulated Local Effects, we quantified how environmental and temporal factors regulate gross primary productivity (GPP), evapotranspiration (ET), water-use efficiency, and the Bowen ratio. Perennials exhibited stronger physiological buffering and maintained fluxes across a broader range of temperature and moisture conditions, reflecting deeper rooting and persistent canopy cover. Annuals, in contrast, showed greater short-term variability and stronger coupling to atmospheric demand, with GPP and ET declining rapidly under low humidity or soil moisture. Differences in temperature sensitivity of Bowen ratio further revealed that perennials sustained proportionally greater sensible heat flux under cool conditions, whereas annuals exhibited constrained energy exchange when evaporative demand was low. Together, these results demonstrate that crop life cycle and canopy structure are fundamental determinants of ecosystem-scale carbon–water–energy coupling. By integrating long-term flux observations with interpretable machine learning, this study identifies the environmental drivers that shape agroecosystem function and highlights how conversion from annual to perennial feedstocks can enhance climatic resilience and alter land–atmosphere energy feedbacks. These findings provide a data-driven basis for improving crop and Earth-system models and for guiding bioenergy landscape design under future climate scenarios.

Accumulated Local Effects↗

DOE OSTI2024

Sparsified time-dependent Fourier neural operators for fusion simulations

This paper presents a sparsified Fourier neural operator for coupled time-dependent partial differential equations (ST-FNO) as an efficient machine learning surrogate for fluid and particle-based fusion codes such as NIMROD (Non-Ideal Magnetohydrodynamics with Rotation - Open Discussion) and GTC (Gyrokinetic Toroidal Code). ST-FNO leverages the structures in the governing equations and utilizes neural operators to represent Green's function-like numerical operators in the corresponding numerical solvers. Once trained, ST-FNO can rapidly and accurately predict dynamics in fusion devices compared with first-principle numerical algorithms. In general, ST-FNO represents an efficient and accurate machine learning surrogate for numerical simulators for multi-variable nonlinear time-dependent partial differential equations, with the proposed architectures and loss functions. The efficacy of ST-FNO has been demonstrated using quiescent H-mode simulation data from NIMROD and kink-mode simulation data from GTC. The ST-FNO H-mode results show orders of magnitude reduction in memory and central processing unit usage in comparison with the numerical solvers in NIMROD when computing fields over a selected poloidal plane. The ST-FNO kink-mode results achieve a factor of 2 reduction in the number of parameters compared to baseline FNO models without accuracy loss.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Simulating pitch angle scattering using an explicitly solvable energy-conserving algorithm

Particle distribution functions evolving under the Lorentz operator can be simulated with the Langevin equation for pitch angle scattering. This approach is frequently used in particle based Monte-Carlo simulations of plasma collisions, among others. However, most numerical treatments do not guarantee energy conservation, which may lead to unphysical artifacts such as numerical heating and spectra distortions. In this paper, we present a novel structure-preserving numerical algorithm for the Langevin equation for pitch angle scattering. Similar to the well-known Boris algorithm, the proposed numerical scheme takes advantage of the structure-preserving properties of the Cayley transform when calculating the velocity-space rotations. The resulting algorithm is explicitly solvable, while preserving the norm of velocities down to machine precision. We demonstrate that the method has the same order of numerical convergence as the traditional stochastic Euler-Maruyama method. The numerical scheme is benchmarked by simulating the pitch angle scattering of a particle beam, and comparing with the analytical solution. Benchmark results show excellent agreement with theoretical predictions, showcasing the remarkable long time accuracy of the proposed algorithm.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Simulating pitch angle scattering using an explicitly solvable energy-conserving algorithm

Particle distribution functions evolving under the Lorentz operator can be simulated with the Langevin equation for pitch angle scattering. This approach is frequently used in particle based Monte-Carlo simulations of plasma collisions, among others. However, most numerical treatments do not guarantee energy conservation, which may lead to unphysical artifacts such as numerical heating and spectra distortions. We present a novel structure-preserving numerical algorithm for the Langevin equation for pitch angle scattering. Similar to the well-known Boris algorithm, the proposed numerical scheme takes advantage of the structure-preserving properties of the Cayley transform when calculating the velocity-space rotations. The resulting algorithm is explicitly solvable, while preserving the norm of velocities down to machine precision. We demonstrate that the method has the same order of numerical convergence as the traditional stochastic Euler-Maruyama method.

Zhang, Xin↗

DOE OSTI2020

Tailoring the cavities of hydrogen-bonded amphidynamic crystals using weak contacts: towards faster molecular machines

This work describes the use of C–H∙∙∙F–C contacts in the solid-state from the stator towards the rotator to fine-tune their internal motion, by constructing a set of interactions that generate close-fitting cavities in three supramolecular rotors 1–3I. The crystal structures of these rotors, determined by synchrotron radiation experiments at different temperatures, show the presence of such C–H∙∙∙F–C contacts between extended carbazole stators featuring fluorinated phenyl rings and the 1,4-diazabicyclo[2.2.2]octane (DABCO) rotator. According to the 2 H NMR results, using deuterated samples, and periodic density functional theory computations, the rotators experience fast angular displacements (preferentially 120° jumps) due to their low rotational activation energies (E a = 0.8–2.0 kcal mol -1 ). The higher rotational barrier for 1 (2.0 kcal mol -1 ) is associated with a larger number of weak C–H∙∙∙F–C contacts generated by the stators. This strategy offers the possibility to explore the correlation among weak intermolecular forces, cavity shape, and internal dynamics, which has strong implications in the design of future fine-tuned amphidynamic crystals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Delamination and Buckling Analysis of a Laminated Component in a High-speed Permanent Magnet Motor

High-speed permanent magnet (PM) machines are widely used because of their high-power density and high efficiency. The high rotation speed also inevitably subjects the PMs to high centrifugal load, which might damage them due to their inherent mechanical vulnerability, such as a much lower tensile strength than the compressive strength. To robustly transfer the torque from the magnet to the shaft, the outer diameter of the laminated rotor core is larger than the inner diameter of the rotor frame to ensure tight contact while working at 20,000 rpm. Motor manufacturing requires the shrink-fit method to assemble the rotor frame and rotor core. However, after the shrink-fit assembly, unexpected local delamination and buckling are observed on the rotor core part. Utilizing finite element simulation, we study the internal stress of assembling these two parts at the provided interference. Simulation results indicate the reasons for the delamination and buckling of the rotor core part and provide suggestions for improving the assembly.

Lin, Lianshan↗

DOE OSTI2022

Terahertz Circular Dichroism Spectroscopy of Molecular Assemblies and Nanostructures

Chemical, physical, biological and materials engineering disciplines use a variety of chiroptical spectroscopies to probe geometrical and optical asymmetry in molecules and particles. Electronic (ECD) and vibrational (VCD) circular dichroism are the most common of these techniques and collectively enable the studies of electronic and vibronic transitions with energies between 0.1 and 5.0 eV. The vibrational states with characteristic energies in the range of 0.001–0.01 eV carry valuable information about concerted intermolecular motions in molecules and crystals involving multiple atoms. These vibronic transitions located in the terahertz (THz) part of the spectrum become increasingly more important for the chemistry, physics, and biology of complex molecules and materials However, the methodology and hardware of THz circular dichroism (TCD) are much less developed than the chiroptical spectroscopies for ultraviolet, visible, near- and mid infrared photons. In this report we provide theoretical foundations, practical implementations, comparative assessments, and exemplary applications of TCD spectroscopy. We show that the sign, intensity, and position of TCD peaks are highly sensitive to the three-dimensional structure and long-range organization of molecular crystals, which offer unique capabilities to study (bio) molecules, their crystals, and nanoscale assemblies and apply the novel data processing methodologies. TCD also offers a convenient toolbox to identify new physical phenomena, such as chiral phonons and their propagation in nanostructured matter. We also discuss the major challenges, emerging opportunities and promising research directions, including broad investigation of chiral phonons observed in chiral (nano) crystals and emerging machine learning methodologies for TCD in biological and nanoscale structures. Ubiquity of low-frequency vibrations with rotational components in biomolecular structures, combined with sharpness of peaks in TCD spectra, enables a variety of technological translations.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Bottom-Up Soft Magnetic Composites (FY 2022 Annual Progress Report)

The project objective is to develop high-magnetization, low-loss iron nitride based soft magnetic composites for electrical machines. These new SMCs will enable low eddy current losses and therefore highly efficient motor operation at rotational speeds up to 20,000 rpm. Additionally, iron nitride and epoxy composites will be capable of operating at temperatures of 150 °C or greater over a lifetime of 300,000 miles or 15 years.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Bottom-Up Soft Magnetic Composites

36 MATERIALS SCIENCE↗