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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Distributed strain sensing using Bi-metallic coated fiber optic sensors embedded in stainless steel

Silica fiber optic sensors are resistant to corrosive environments and high temperatures, making them attractive candidates for harsh conditions found in nuclear and aerospace industries. Moreover, fibers can be deployed remotely for continuous measuring of spatially distributed temperatures and strains. Here, this study investigated embedding a Ni/Cu bi-metallic coated fiber in a stainless-steel 316 (SS316) matrix using laser powder bed fusion towards functionalizing metal components for site-specific health monitoring. The embedded fiber was continuously interrogated during controlled heating to 1000°C. The measured fiber strains were similar to the expected differential thermal strains between the fiber and the SS316 matrix, until divergent behavior was observed at temperatures >500°C. No debonding at the matrix–coating–fiber interfaces was observed during microscopy, but significant interactions between the coatings and matrix resulted in diffusion-driven chemistry variations and Kirkendall void formation. Applying the strain-lag theory revealed plastic behavior in the Ni coating at temperatures >500°C, limiting the strain transfer to the fiber at higher temperatures. It was estimated that the elastic modulus in the Ni coating had decreased from ~200 GPa at room temperature to below 40 GPa, starting at 600°C. The low elastic modulus above 600°C is within the margin of what the tangent modulus would be in the case of bilinear isotropic hardening. Regardless of the divergent strain transfer at higher temperatures, the fiber was exposed to the equivalent of 1.9 % engineering strain at 1000°C, but measured only a 0.7 % engineering strain due to the poor strain transfer. Although compensating for the plastic behavior of Ni proved challenging, the bonding of a brittle silica fiber to a metal matrix surviving to 1000°C invites potential iterations on coating material for future application. For example, the embedded fiber is sufficient for acoustic energy transfer, realizing high temperature distributed acoustic sensing.

36 MATERIALS SCIENCE↗
DOE OSTI2026

LDRD FY25 Program Overview

As Lawrence Livermore National Laboratory’s (LLNL’s) Laboratory Directed Research and Development (LDRD) program enters its fifth decade of leading-edge research and development, its impact and importance have never been stronger. The program continues to advance strategic investments in pioneering science, technology, and engineering, ensuring LLNL will be ready to deliver on our mission as it evolves over the coming decades. Investing in LDRD research, and the people who perform this critical work, gives LLNL the ability to sustain our role as a leader in the Department of Energy and National Nuclear Security Administration enterprise. The LDRD program enables high-risk, high-payoff research that anticipates emerging threats and future mission needs. By nurturing the ingenuity of the Lab’s greatest asset, its people, LDRD funding advances not only our research but also grows and nurtures our workforce: engaging future innovators with student mentoring, challenging postdoctoral researchers to apply their skills to support national security, and strengthening the leadership skills of early career staff. This annual report documents how LDRD investments advance LLNL’s science, technology, and engineering across our mission space. To assess LDRD’s impact we track both short and long-term metrics such as peer-reviewed publications, number of students, or professional fellows. In addition to reviewing these metrics, I encourage you to delve deeper into the breadth of science and technology that illustrate the strategic value of this research portfolio. For instance, a recent exploratory research project used advanced manufacturing to construct miniaturized three-dimensional ion traps for a quantum computer with reduced quantum error rates to enable applications that address national security missions and support basic science. Another project has delved into studying detonation by examining deflagration to enhance the safety and security of the nuclear weapons stockpile. LDRD researchers are also deploying AI agents on two of the world’s most powerful supercomputers to automate and accelerate inertial confinement fusion experiments. Other teams are delivering more accurate optical constants to enable improved validation for aluminum to advance atomic and molecular physics models. LDRD-driven discoveries of how metals deform under extreme conditions strengthen our ability to model and design materials for demanding national security environments. National security challenges are increasingly complex and continuously evolving. LDRD focuses our most innovative science and technology on these challenges, ensuring the Laboratory is developing creative, forward-leaning solutions for our nation and the world. The following pages feature highlights of published scientific advances, patents, and honors that stem from LDRD investments. As you read this report, I hope you will understand how these investments position the Laboratory, and our partners, to meet the demands of the decades ahead.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Accelerating nuclear-integrated data center pursuits in the USA: SWOT analysis, power-thermal management strategies and demonstration plan

Here, this study explores the increasing interest in leveraging nuclear power to meet the escalating energy demands of data centers in the United States (U.S.) by focusing on key factors that contribute to accelerated deployment. The study highlights the importance of N+1/N+2 power supplies (where N is the required number of units), outlines research and innovations in nuclear-integrated data center thermal management and demonstration plan. It also provides updates about status and costing of various reactor system designs. A summarized strengths, weaknesses, opportunities, and threats (SWOT) analysis shows the potential options for grid connectivity, reactors, and site selection. Suitable site discussions consider land and water availability, grid access, and optical fiber connectivity, and the study presents graded prospects for Department of Energy (DOE) sites with a specific example. Community engagement and partnerships are emphasized, particularly the roles of local government, federal agencies, utilities, and data center industry partners, which are crucial for accelerating deployment, business outreach, and approvals. The study provides actionable insights for stakeholders to accelerate the deployment of nuclear-powered data centers.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2026

Toward an AI-Powered Software Pipeline for Real-Time Tracking and Analysis of Wildfire and Smoke

Real-time tracking of wildfires and smoke is crucial for effective response, minimizing damage, protecting lives, and efficiently managing resources during fire emergencies. We develop a web-based AI-powered pipeline that detects wildfires in aerial video and estimates deployment-relevant behavior metrics, including cumulative burned area, burned-area growth rate, fire spread direction, and smoke dispersion. The system combines a YOLO-based detector with YCbCr-based fire segmentation, HSV-based smoke segmentation, Farneback optical flow, and centroid-based spatiotemporal tracking. Using ground sampling distance (GSD), pixel-level fire masks are converted to physical burned-area measurements by correlating fire pixel counts with camera altitude and tilt angle. We benchmark YOLO variants and non-YOLO baselines (GoogLeNet, CNN, DBN, Autoencoder, U-Net, and AlexNet) on the IEEE FLAME dataset and a newly created aerial frame dataset, Wildfire-DB. Cross-dataset evaluation uses a strict threshold-transfer protocol: decision thresholds are selected on FLAME validation and transferred unchanged to Wildfire-DB to quantify generalization under domain shift. YOLOv6 achieves the strongest cross-dataset frame-level fire detection on Wildfire-DB (ROC-AUC 0.8200, PR-AUC 0.8044, and transferred-threshold F1 0.7596). For tracking-oriented deployment requiring oriented localization, YOLO11-OBB provides the most reliable cross-dataset behavior among OBB-capable models while remaining computationally feasible. To analyze the feasibility of UAV deployment, we further measure inference efficiency using synchronized GPU and CPU power logs on a fixed workload of 1569 frames. YOLO-family models process the video in 5.73–12.47 seconds with net energy of 1247.28–1775.39 J, substantially lower latency and energy than heavier classification and reconstruction baselines. Overall, model optimality depends on operational objectives: YOLOv6 is best for cross-dataset detection robustness, whereas YOL...

Color segmentation↗
DOE OSTI2026

Characterizing Defect Dynamics in Silicon Carbide Using Symmetry-Adapted Collective Variables and Machine Learning Interatomic Potentials

Silicon carbide (SiC) divacancies are attractive candidates for spin-defect qubits possessing long coherence times and optical addressability. The high activation barriers associated with SiC defect formation and motion pose challenges for their study by first-principles molecular dynamics. In this work, we develop and deploy machine learning interatomic potentials (MLIPs) to accelerate defect dynamics simulations while retaining ab initio accuracy. We employ an active learning strategy comprising symmetry-adapted collective variable discovery and enhanced sampling to compile configurationally diverse training data, calculation of energies and forces using density functional theory (DFT), and training of an E(3)-equivariant MLIP based on the Allegro model. Here, the trained MLIP reproduces DFT-level accuracy in defect transition activation free energy barriers, enables the efficient and stable simulation of multidefect 216-atom supercells, and permits an analysis of the temperature dependence of defect thermodynamic stability and formation/annihilation kinetics to propose an optimal annealing temperature to maximally stabilize VV divacancies.

Computer simulations↗
DOE OSTI2026

CROCUS Tipping Bucket Rain Gauge Data from Argonne Deployable Mast Deployed at Argonne National Laboratory During Urban Flooding Campaign

The Tipping Bucket Rain Gauge (TBRG) dataset contains data from a non-heated Met One 12-inch tipping bucket rain gauge that was mounted on the Argonne Deployable Mast (ADM). The ADM is a rapid deployable meteorological trailer that can be outfitted with instrumentation to measure urban heat island effects, urban flooding or urban flux measurements. During the urban flooding field campaign, the ADM was outfitted with multiple precipitation measurement systems, including the TBRG. This dataset contains one minute measurements for precipitation accumulation during the ADM's deployment at the Argonne Testbed for Multiscale Observational Science (ATMOS) site. These data are helpful for identifying periods of precipitation, leading to potential flooding. TBRGs can be used to validate optical rain gauge data and disdrometer data collected during the CROCUS urban flooding campaign. Data were collected at ATMOS, a 20-acre prairie site at Argonne National Laboratory in Lemont, Illinois. The data is presented as daily NetCDF (.nc) files, each containing approximately 24 hours of observations. Files follow the naming convention of: the project (CROCUS), location (ADM-atmos), instrument name (tbrg), data level (raw, a1), and date (year, month, day). The NetCDF format can be accessed using common scientific software such as Python using xarray, netCDF4 or act-doe.

1-min Precipitation Accumulation↗
DOE OSTI2026

Multi-GeV FFA beam transport test at CEBAF

Jefferson National Lab plans an upgrade project to reach 22 GeV high polarization electron beam by using Fixed Field Alternating-gradient (FFA) magnets. The utilization of the FFA magnets for 10-22 GeV beam energy range is unexampled, therefore those magnets need an experimental validation before their full installation to form an arc in the Continuous Electron Beam Accelerator Facility (CEBAF). For this reason, JLAB is also considering the design of an FFA magnet test bench, i.e. a half or full FFA cell, that would be deployed in the current CEBAF in order to serve as the highest energy demonstration for the FFA field uniformity, permanent magnet resiliency with the beam as well as enabling beam optics measurements with the 5-11 GeV range highly polarized beams which closely resembles the full energy range of the 22 GeV upgrade. In this report, we present the status of the planned beamline for the FFA beam transport test at CEBAF.

Accelerator Physics↗
DOE OSTI2024

Millimeter-wave high-wavenumber scattering diagnostic developments on EAST and NSTX-U

A pioneering 4-channel, high-k poloidal, millimeter-wave collective scattering system has been successfully developed for the Experimental Advanced Superconducting Tokamak (EAST). Engineered to explore high-k electron density fluctuations, this innovative system deploys a 270 GHz mm-wave probe beam launched from Port K and directed toward Port P (both ports lie on the midplane and are 110° part), where large aperture optics capture radiation across four simultaneous scattering angles. Tailored to measure density fluctuations with a poloidal wavenumber of up to 20 cm -1 , this high-k scattering system underwent rigorous laboratory testing in 2023, and the installation is currently being carried out on EAST. Its primary purpose lies in scrutinizing ion and electron-scale instabilities, such as the electron temperature gradient (ETG) mode, by furnishing measurements of the k θ (poloidal wavenumber) spectrum. This advancement significantly bolsters the capacity to probe high-k electron density fluctuations within the framework of EAST. Finally, beam tracing and data interpretation modules developed for both EAST and NSTX-U high-k scattering diagnostics are described.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Overview of On-Line Optical Measurements at High Pressure for Flue Gases, Particulates and Acid-dew Point of Pressurized Oxy-Combustion

Optical flow cells are critical measurement interfaces, yet sampling under harsh conditions — high pressure, high temperature, particles, moisture, or corrosive gases — makes it difficult to maintain optical quality without perturbing the measurement. To address this challenge, a new flow cell was developed using a laminar coaxial flow field that separates the purge and sample flows. A dedicated test system was built to evaluate particle size distribution (PSD) measurements using a Malvern Panalytical Insitec analyzer. Results demonstrated that the sample flow alone defines the measurement zone, while the purge flow effectively shields the optical windows from deposition, eliminating sampling bias. The flow cell enables reliable PSD measurement under high pressure and temperature in moist, corrosive environments. As a key demonstration, the instrument was successfully deployed for on-line PSD measurement of flue gas from a 100 kWth pressurized oxy-coal combustor at 15 bara.

Cheng, Mao↗
DOE OSTI2024

Hydrogen Detection Strategies to Support H2@SCALE - The NREL Sensor Laboratory

Hydrogen represents a major pathway to decarbonize and stabilize the national and international energy industry and select manufacturing markets. To facilitate the development of hydrogen markets, the US Department of Energy initiated H2@Scale to bring together stakeholders to advance affordable hydrogen production, transport, storage, and utilization to increase revenue opportunities in multiple energy sectors. One major impediment to hydrogen implementation is cost. To expedite the use of hydrogen in energy and other markets, the United States announced in 2021 the Hydrogen Shot, which seeks to reduce the cost of clean hydrogen by 80% to $1 per 1 kilogram in 1 decade ("1 1 1"). As the cost of hydrogen drops, new applications will emerge that will require unique configurations of existing equipment and infrastructure, and eventually lead to advances in the generation and utilization of hydrogen. As the hydrogen economy expands, sensors and detection methods will need to adapt to changing infrastructure demands to address the primary targets of health & safety, emissions monitoring, and process control. The NREL Sensor Laboratory is playing a pivotal role in advancing the use of hydrogen sensors and detection methodologies in each of these categories to support DOE's mission for safe and efficient utilization in emerging markets. Health & safety monitors are required to ensure that operators and facilities can react to unintended hydrogen releases, either as GH2, LH2, or as a constituent of blends (e.g., natural gas or ammonia). Current detection methodologies focus on safety applications to detect near its lower flammable limit (4 vol %), and typically include point sensors in applications such as fixed or mobile detectors (e.g., personal gas monitors). Methodologies amenable for area detection include acoustic, emerging optical imaging methods, and flame detectors. Comparable detection strategies can be utilized for emissions monitoring and quantization, however few methods can simultaneously cover both low (emissions) and high (health & safety) levels. Deployment of emission level detectors will be required to 1) reduce product loss through small but potentially significant leaks from an environmental or cost perspective, 2) reduce downtime of high demand systems by early identification of eminent system failures (leaks through pump or compressor seals indicative of impending failure), and 3) address potential emission monitoring requirements that may be set by regulating bodies. The first two points should be adopted by industry to reduce the cost-of-goods-sold. The third main category for hydrogen detection relates to process control and may be advantageous for many existing applications. Two main applications are emerging. For example, the purity requirements for hydrogen that is dispensed from refueling systems for hydrogen fuel cell electric vehicles (FCEV) is rigorously regulated by the Standard SAE J2719, which prescribes maximum allowable levels of multiple impurities in the hydrogen fuel and must be verified by a regulatory body. Hydrogen contaminant detectors (HCD) integrated to the fueling station can assure this compliance. HCDs must be able operate in 100% H2 backgrounds and be able to distinguish between multiple contaminants at low ppm to low ppb levels. Secondly, as a strategy to decarbonize the natural gas grid, there are proposals to blend hydrogen with natural gas. This blending will affect transport applications (pipeline infrastructure), stationary combustion systems (turbines), and consumer and commercial appliances. In the short-term, hydrogen levels up to 20% are proposed. Variations in the hydrogen level can have dramatic impact on the combustion process and on the potential response of safety sensors. These mixtures may be regulated so that the concentration at a delivery point must be monitored with high precision. However, routine maintenance may introduce background gases such as ambient air (with water) or maintenance gases (introduced with welding processes or adhesive outgassing.) Therefore, the detection methodology must be robust enough to recover or respond to various contaminants. Several reviews can be found in literature addressing sensing and detection technologies, including their limitations and applications. However, for most applications, limitations can be alleviated by combining various detection techniques either through system integration or implementation of machine learning methods (artificial intelligence). In this presentation, we will discuss several applications, highlight their current approach for hydrogen detection, and suggest detection strategies to supplement their limitations.

ENERGY STORAGE,HYDROGEN↗
DOE OSTI2024

A Hermetic Package Technique for Multi-Functional Fiber Sensors through Pressure Boundary of Energy Systems Based on Glass Sealants

This paper presents a hermitic fiber sensor packaging technique that enables fiber sensors to be embedded in energy systems for performing multi-parameter measurements in high-temperature and strong radiation environments. A high-temperature stable Intrinsic Fabry–Perot interferometer (IFPI) array, inscribed by a femtosecond laser direct writing scheme, is used to measure both temperature and pressure induced strain changes. To address the large disparity in thermo-expansion coefficients (TECs) between silica fibers and metal parts, glass sealants with TEC between silica optical fibers and metals were used to hermetically seal optical fiber sensors inside stainless steel metal tubes. The hermetically sealed package is validated for helium leakages between 1 MPa and 10 MPa using a helium leak detector. An IFPI sensor embedded in glass sealant was used to measure pressure. The paper demonstrates an effective technique to deploy fiber sensors to perform multi-parameter measurements in a wide range of energy systems that utilize high temperatures and strong radiation environments to achieve efficient energy production.

Optics↗
DOE OSTI2026

Lunar accelerometer network gravitational observatory (LANGO)

With ground-based interferometers detecting hundreds of gravitational-wave (GW) events, GW astronomy has continued to blossom. U.S. and European scientists are developing plans to construct third-generation ground-based interferometers. ESA has proceeded through the mission formulation phase of space-based interferometer in a lower-frequency band, 10 –4 –0.1 Hz. Despite all these exciting developments, there is still a missing frequency band, 0.1–10 Hz. This mid-frequency band is rich with interesting astrophysical events. Coalescence and merger of intermediate-mass black holes (IMBHs) will occur in this frequency band. Coalescing stellar-mass BHs will pass through this frequency band days before they reach the frequency band of LIGO and Virgo. Detection of such signals would enable a mid-frequency detector to issue an advance notice to the high-frequency GW detectors, as well as to optical, x-ray and γ-ray telescopes. We propose Lunar Accelerometer Network Gravitational Observatory (LANGO) to detect GWs in this frequency band. In the first phase (LANGO 1), we propose to deploy four ambient-temperature (250 K) accelerometers in the tetrahedral or in a square configuration on the hemisphere facing the Earth. After successful operation at 250 K, LANGO would be upgraded to a cryogenic (4 K) version with over two orders of magnitude increased sensitivity (LANGO 2), with coherent rejection of seismic noise implemented. LANGO is a full-tensor detector, capable of determining the source direction and wave polarization. Each test mass (TM) is suspended as a pendulum with resonance frequency ∼ 0.01 Hz, thus is only weakly coupled to the lunar surface horizontally. LANGO is designed to detect the relative motion of globally separated, nearly free, TMs by using the Moon as a large quiet platform. LANGO 1 and 2 accelerometers aim at sensitivities ⩽ 10 –11 m s –2 Hz –1/2 and ⩽ 10 –13 m s –2 Hz –1/2 in the horizontal axes over the frequency band of 1 mHz–10 Hz, which yield GW sensitivities 1.1 x 10 -21 Hz -1/2 and 3.8 x 10 -24 Hz -1/2 at 1 Hz, respectively. The LANGO accelerometers will be 10 3 –10 5 times more sensitive than Apollo seismometers. With such sensitivity, LANGO will also make great contribution to the advancement of lunar geophysics.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Measurements of attenuation and scattering properties of water-based liquid scintillator

Water-based liquid scintillator (WbLS) is a hybrid detector medium which has been proposed as a fill material for future large-volume rare event searches, including ν − detectors. This family of scintillating suspensions promises waterlike attenuation and scattering behavior, while offering scintillation light yield for sub-Cherenkov-threshold events. These features may allow for improved vertex and energy resolution, and concomitant improvements in background rejection and particle identification. While subscale measurements of light yield, timing and pulse-shape have been performed in several WbLS formulations, detailed measurements of the attenuation and scattering properties of WbLS remain a critical, unresolved step along the pathway to deployment. In pursuit of a better understanding of these parameters, a “long-arm” attenuation and scattering instrument has been developed at Lawrence Livermore National Laboratory, dubbed LASE (Livermore Attenuation and Scattering Experiment). Optical property measurements have been performed using LASE in DI water, Gd-water, WbLS and Gd-WbLS. Measurements of the optical properties of WbLS (1% LAB-PPO scintillator) provided by Brookhaven National Laboratory demonstrate an attenuation minimum of 4.87 × 10 − 4 ± 1.42 × 10 − 4 cm − 1 at 450 nm, while Gd-loaded WbLS (1% LAB-PPO scintillator, 0.1% Gd) demonstrated a minimum attenuation coefficient of 4.77 × 10 − 4 ± 1.27 × 10 − 4 cm − 1 at the same wavelength. Measurements of scattering in WbLS show a scattering coefficient of 3.39 × 10 − 4 ± 1.98 × 10 − 5 cm − 1 at the 450 nm attenuation minimum, while Gd-WbLS has a scattering coefficient of 2.8 × 10 − 4 ± 1.63 × 10 − 5 cm − 1 at that wavelength. These scattering and attenuation coefficients are significantly larger than measured for DI water at similar wavelengths ( 8.8 × 10 − 5 cm − 1 ± 3.8 × 10 − 5 attenuation at 430 nm, 2.2 × 10 − 5 ± 1.28 × 10 − 6 cm − 1 scattering). Though the WbLS attenuation and scattering coefficients measured are lower than the corresponding values published for ultrapure oils and LAB-PPO liquid scintillator, the material tested attenuates significantly more than water across the blue and green portions of the visible spectrum. This attenuation is markedly stronger at wavelengths under 430 nm. Published by the American Physical Society 2025

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

CROCUS Tipping Bucket Rain Gauge Data from Argonne Deployable Mast Deployed at NEIU Carruthers Center for Inner City Studies (CCICS)

The Tipping Bucket Rain Gauge (TBRG) dataset contains data from a non-heated Met One 12-inch tipping bucket rain gauge that was mounted on the Argonne Deployable Mast (ADM). The ADM is a rapid deployable meteorological trailer that can be outfitted with instrumentation to measure urban heat island effects, urban flooding or urban flux measurements. During the urban flooding field campaign, the ADM was outfitted with multiple precipitation measurement systems, including the TBRG. This dataset contains one minute measurements for precipitation accumulation during the ADM's deployment at the Northeastern Illinois University (NEIU) Carruthers Center for Inner City Studies (CCICS) campus. These data are helpful for identifying periods of precipitation, leading to potential flooding. TBRGs can be used to validate optical rain gauge data and disdrometer data collected during the CROCUS urban flooding campaign. Data were collected at the CCICS building parking lot, located in the south side of Chicago, IL. The data is presented as daily NetCDF (.nc) files, each containing approximately 24 hours of observations. Files follow the naming convention of: the project (CROCUS), location (ADM-ccics), instrument name (tbrg), data level (raw, a1), and date (year, month, day). The NetCDF format can be accessed using common scientific software such as Python using xarray, netCDF4 or act-doe.

1-minute Precipitation Accumulation↗
DOE OSTI2026

Commercialization of Reflected Target Non-Intrusive Assessment (ReTNA) Tool, for Indoor Optical Analysis of Heliostats

Under HelioCon, NLR began developing a new optical measurement system, called Reflected Target Non-Intrusive Assessment (ReTNA). ReTNA has shown promise towards addressing metrology gaps for heliostat used in concentrated solar thermal (CST) plant. This project is focused on advancing this measurement system from the laboratory into industry, where it can provide valuable information for heliostat developers during research, development, and qualification of a heliostat design, and be used for quality assurance during heliostat manufacture. Over the course of this project, ReTNA was deployed at several commercial heliostat facilities. The system developed and deployed with the primary project partner, Solar Dynamics LLC, is described in detail. The report discusses each project Milestone, the ending status, the achieved value, and how these Milestones improve and qualify the ReTNA measurement tool. Finally, the final report covers the market advancements, path forward, commercial successes, and lessons learned. Final Technical report for TCF Base Technology-Specific project TCF-23-20118, Commercialization of Reflected Target Non-Intrusive Assessment (ReTNA) tool, for indoor optical analysis of Heliostats.

14 SOLAR ENERGY↗
DOE OSTI2026

Future foundries: A convergent manufacturing platform

This article introduces the Future Foundries platform developed at Oak Ridge National Laboratory, a first-generation research system designed to demonstrate convergent manufacturing. Convergent manufacturing brings together additive, subtractive, and transformative processes in a digitally interconnected environment to enable end-to-end production workflows. By linking traditionally discrete steps, convergent platforms accelerate production, improve repeatability, and support high-mix, low-volume manufacturing. The Future Foundries platform exemplifies this vision in practice by combining four modular, vendor-agnostic process cells that include robotic WAAM, induction heating, optical metrology, and machining, coordinated through an automated pallet handler and a ROS 2-based digital thread. This architecture provides the flexibility and scalability needed for agile production in small and medium-sized manufacturing enterprises and for field deployable manufacturing. Two case studies illustrate the platform’s capabilities. The first presents an integrated workflow for fabricating, transforming, and repairing critical replacement components, showing how consolidated thermal, additive, inspection, and machining operations reduce manual part handling and streamline process flow. The second case study highlights coordinated multi-part production enabled by automated pallet logistics and multi-cell scheduling. Together, these examples showcase convergent manufacturing as a practical and scalable strategy for strengthening domestic casting and forging capacity, improving supply-chain resilience, and enabling rapid, adaptable production of mission-critical components.

Convergent manufacturing↗
DOE OSTI2026

A compact in situ polarized 3He neutron spin filter for the diffractometer VULCAN at the Spallation Neutron Source

We have built and commissioned a compact in situ 3He polarizer based on spin-exchange optical pumping for the engineering materials diffractometer, named VULCAN, at the Spallation Neutron Source (SNS) at Oak Ridge National Laboratory. The system achieved 78% 3He polarization with a short pump-up time constant of 2.2 h. Its first deployment in an in situ half-polarized neutron diffraction experiment on a magnetic shape memory alloy, Ni–Mn–Ga, revealed changes in magnetization coupled to deformation twinning under compression. With this new capability, VULCAN has become the first diffractometer at SNS capable of performing polarized neutron experiments, opening new opportunities to study a wider range of magnetism-related material behaviors under varied thermal, mechanical, electrical, and/or magnetic fields.

Fu, Sichao [ORNL] (ORCID:0009000846771640)↗
DOE OSTI2026

Gravitational Lenses in UNIONS and Euclid (GLUE). I. A Search for Strong Gravitational Lenses in UNIONS with Subaru, CFHT, and Pan-STARRS Data

We present the results of our pipeline for discovering strong gravitational lenses in the ongoing Ultraviolet Near-Infrared Optical Northern Survey (UNIONS). We successfully train a deep residual convolutional neural network based on CMU-Deeplens architecture, which is designed to detect strong lenses in ground-based imaging surveys. We train on images of real strong lenses and deploy on a sample of 8 million galaxies in areas with full coverage in the g, r, and i filters—the first multiband search for strong gravitational lenses in UNIONS. Following human inspection and grading, we report the discovery of a total of 1346 new strong-lens candidates, of which 146 are Grade A, 199 are Grade B, and 1001 are Grade C. Of these candidates, 283 have lens galaxy spectroscopic redshifts from the Sloan Digital Sky Survey, and an additional 297 have them from the Dark Energy Spectroscopic Instrument Data Release 1. We find 15 of these systems display evidence of both lens and source galaxy redshifts in spectral superposition. We also report the spectroscopic confirmation of seven lensed sources in high-quality systems, all with z > 2.1, using the Keck Near Infrared Echellette Spectrograph and the Gemini Near-Infrared Spectrograph.

Storfer, Christopher J. [University of Hawaii, Hon↗