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Universal and versatile morphology engineering via hot fluorous solvent soaking for organic bulk heterojunction
After explosive growth of efficiency in organic solar cells (OSCs), achieving ideal morphology of bulk heterojunction remains crucial and challenging for advancing OSCs into consumer market. Herein, by utilizing the amphiphobic nature and temperature-dependent miscibility of fluorous solvent, hot fluorous solvent soaking method is developed to optimize the morphology with various donor/acceptor combinations including polymer/small-molecule, all-polymer and all-small-molecule systems. By immersing blend film into hot fluorous solvent which is utilized as liquid medium with better thermal conductivity, the molecular reorganization is accelerated. Furthermore, fluorous solvent can be miscible with the residue of chloroform and chloronaphthalene above upper critical solution temperature. This mixed solvent diffuses around inside the active layer and selectively promotes molecular reorganization, leading to optimized morphology. Compared to widely-used thermal annealing, this approach processed under mild conditions achieves superior photovoltaic performance, indicating the practicality and universality for morphological optimization in OSCs as well as other optoelectronic devices.
Toward large-scale simulation of residual stress and distortion in wire and arc additive manufacturing
In this study, we aim to advance the structural analysis of wire and arc additive manufacturing (WAAM) by considering the thermomechanical features inherent in direct energy deposition. Simulation approaches including the iterative substructure method (ISM), dynamic mesh refining method (DMRM), and graphics processing unit (GPU) based explicit finite element method (FEM) were developed for accelerating additive manufacturing stress analysis that is very time consuming by conventional numerical methods. ISM and DMRM take advantage of the strong nonlinearity phenomenon near the moving heat source by reducing the global iterations and refining the local mesh, respectively. In addition to the use of GPUs, the explicit FEM is accelerated by a time scaling technique based on the inherent strain concept. The residual stress and distortion of two large builds were analyzed, showing very consistent numerical results and good agreement with experiments. Compared with the commercial software Abaqus, the novel approaches reduced the computational cost substantially without compromising accuracy. The GPU code showed the highest computational efficiency (30~70×), while DMRM and ISM had acceleration factors of 9× and 3×, respectively. Finally, such high-fidelity modeling approaches will be very useful for building up a digital twin of WAAM to reduce development time and cost.
Effects of variable deceleration periods on Rayleigh-Taylor instability with acceleration reversals
The dynamics of an interfacial flow that is initially Rayleigh-Taylor unstable but becomes statically stable for some intermediate period due to the reversal of the externally imposed acceleration field is studied. We discuss scenarios that consider both single and double-acceleration reversals. The accel-decel (AD) case consists of a single reversal imposed at an instant after the constant acceleration instability has entered a self-similar regime. The layer of mixed fluid ceases to grow upon acceleration reversal, and the dominant mechanics are due to internal wave oscillations. Variation of mass flux and the Reynolds stress anisotropy is observed due to the action of the internal waves. Here, a second reversal of the AD case that is termed as accel-decel-accel, ADA is then explored; the response of the mixing layer is shown to depend strongly on the duration and the periodicity of the Reynolds stress anisotropy of the mixing layer during the deceleration period. We explore the effect of this variable deceleration period after the second acceleration reversal where the flow once again becomes Rayleigh-Taylor unstable based on metrics that include the integral mixing-layer width, bubble and spike amplitudes, mass flux, Reynolds stress anisotropy tensor, and the molecular mixing parameter.
DriveSense: A Noise-Resilient Framework for Driving Mode Identification
Accurate drive mode classification is essential for enhancing the reliability and predictive maintenance of heavy-duty electric trucks. This study proposes a novel fuzzy logic-based framework, DriveSense, for real-time drive mode classification, addressing key challenges such as sensor noise, transitional behaviors, and computational efficiency. The proposed approach integrates a two-stage filtering pipeline, combining adaptive outlier removal and a dynamic Kalman filter to enhance data quality. A fuzzy inference system with smoothened trapezoidal membership functions is then applied to classify driving modes into standstill, constant speed, acceleration, and deceleration while mitigating the effects of noise and edge cases. Performance evaluation using real-world and simulated drive cycles demonstrates significant improvements in classification accuracy (up to 97.8%), F1-score (up to 0.97), and robustness against noise, while reducing false positives. Comparative analysis against baseline models, demonstrates DriveSense’s superior accuracy and generalizability across diverse driving patterns. The framework’s lightweight and interpretable fuzzy inference engine operates with low computational latency, ensuring compatibility with real-time embedded systems typical of heavy-duty electric trucks. Moreover, DriveSense models transitional behaviors through overlapping fuzzy sets and adaptive borderline classification logic, enabling smooth identification of subtle shifts such as rolling stops or gradual deceleration. These results highlight DriveSense’s potential to enhance predictive maintenance strategies, reduce downtime, and support scalable, fleet-wide diagnostics.
Defining Threshold Values of Encapsulant and Backsheet Adhesion for PV Module Reliability
The width-tapered cantilever beam method is used to quantify the debond energy (adhesion) of encapsulant and backsheet structures of 32 modules collected from the field. The collected population of modules contains both those that have remained intact and those with instances of either or both encapsulant and backsheet delamination. From this survey, initial threshold values (an adhesion value above which a module should remain intact throughout its lifetime) for encapsulant and backsheet interfaces are proposed. For encapsulants this value is ~ 160J/m 2 and for backsheets ~ 10J/m 2 . Here, it is expected that these values will continue to be refined and evolve as the width-tapered cantilever beam method gets adopted by the PV industry, and that they may aid in the future improvement of accelerated lifetime tests and the development of new, low-cost materials.
Hierarchical Distributed Optimal Power Flow of HV and MV Distribution Networks With Continuous and Discrete Devices
With large-scale distributed photovoltaics (PVs) being integrated into distribution networks (DNs), coordinated optimal power flow (OPF) of high voltage (HV) and medium voltage (MV) DNs should be investigated to optimally dispatch the distributed PVs and other network devices. Here, this paper presents a hierarchical distributed OPF method for HV and MV DNs with on-load tap changers, reactive power compensators, feeder switches and distributed PVs. A hierarchical master-slave control architecture is applied to implement coordinated OPF of two-layer DNs. The HV master problem and MV subproblems are transformed into mixed-integer convex problems respectively with second order cone programming and LinDistFlow approximation. Since there is no efficient distributed algorithm to solve such OPF models with integer subproblems, a novel distributed algorithm is proposed in this paper to efficiently solve the hierarchical coordinated OPF model with integer subproblems in a distributed manner. In the proposed algorithm, the coordinated OPF model is solved in a branch-and-bound framework, where in each branch node generalized Benders decomposition (GBD) algorithm is applied to decompose the coordinated OPF model into a master problem and relaxed subproblems and solves them iteratively to get optimal solution. The GBD optimal and feasible cutting planes generated in a branch node are proved to be valid for its descendants. Moreover, three acceleration techniques are introduced into the proposed algorithm to improve computational efficiency. Finally, the effectiveness and accuracy of the proposed method are verified via simulation tests in Jinzhai DNs of China.
In Situ Transmission Electron Microscopy of High-Temperature Inconel-625 Corrosion by Molten Chloride Salts
This paper describes an approach to monitor high temperature molten chloride (MgCl 2 -NaCl-KCl) salt corrosion of Inconel-625 alloy in real time at high spatial resolution. The approach is based on a micro-environmental-cell assembly integrated into a transmission-electron-microscope goniometer to examine in situ the salt-alloy interface during corrosion, employing real time electron diffraction and imaging. It establishes procedures to minimize incorporation of H 2 O or O 2 from atmosphere in the chloride salts during sample fabrication and corrosion, which is critical to understanding the fundamental corrosion mechanisms. A clustering algorithm and a 2D Gaussian fit function are used to determine diffraction spot intensities in in situ diffraction patterns, to quantify alloy corrosion. This facilitates quantitative observation of the evolution of individual grains, in contrast to conventional macroscopic corrosion rate quantification. The isothermal corrosion rate of Inconel-625 in an anhydrous, unoxidized salt-stack is 220 ± 30 μm year -1 at 700 °C and 350 ± 20 μm year -1 at 800 °C. However, the corrosion rate at 700 °C increases five-fold to 1000 ± 170 μm year -1 when the salt stack is air-exposed, indicating the dominant effects of hydrated or oxidized impurities on corrosion acceleration. Furthermore, real time imaging of the microstructure evolution suggests that corrosion is initiated at grain boundaries.
Final Report: System Reliability Model for Solid-State Lighting (SSL) Luminaires
The primary objectives of this project was to develop and validate reliability models and accelerated stress testing (AST) methodologies for predicting the lifetime of integrated SSL luminaires. This study examined the likely failure modes for SSL luminaires including abrupt failure, excessive lumen depreciation, unacceptable color shifts, and increased power consumption. Data on the relative distribution of these failure modes were acquired through extensive accelerated stress tests and combined with industry data and other source of information on LED lighting. This data was compiled and utilized to build models of the aging behavior of key luminaire optical and electrical components.
An Authentication Vulnerability Assessment of Connected Lighting Systems
Emerging connected lighting systems (CLS) that incorporate distributed intelligence, network interfaces, and sensors can become data-collection platforms that enable a wide range of valuable new capabilities as well as greater energy savings in buildings and cities. However, CLS technology is currently at an early stage of development, and its increased connectivity introduces cybersecurity risks that are new to the lighting industry and that must be addressed for successful integration with other systems. While a number of existing frameworks, guidelines, and tests for evaluating cybersecurity vulnerability may apply to CLS in whole or in part, there is currently no mandatory requirement for cybersecurity testing or certification. The lighting industry, including technology developers and specification organizations, is currently evaluating the suitability of existing frameworks and guidelines for CLS. To support these efforts, Pacific Northwest National Laboratory (PNNL) is conducting a series of studies intended to educate lighting industry stakeholders on specific cybersecurity practices and characterize their implementation in commercially available CLS with varying system architectures, network-communication technologies, and degrees of maturity. This study demonstrates that tests for authentication vulnerabilities can be developed with objective pass/fail criteria, therby facilitating comparisons between CLS. Based on the limited results of this study, it appears that the CLS that are being brought to market have varying levels of authentication vulnerability. It is hoped that these evaluations will support and perhaps accelerate industry discussions on the risks of specific security vulnerabilities, what vulnerabilities should be addressed by in-development of future lighting-specific best practices, and whether any such practices should be included in voluntary lighting standards.
Trends in Field and Laboratory Performance of Photovoltaic Modules and Materials
This DuraMAT project intends to identify bill of materials (BOM) and/or process control measures for photovoltaic modules with representative failure modes as informed by accelerated and field tests to guide next steps in module and material design. We have begun work to identify correlation between module field performance and accelerated testing results by cross-comparing a module database of accelerated test results with a module database of fielded systems. We have identified fielded systems with degraded performance, and intend to compare this to the results observed in certification and qualification testing. We also intend to apply lessons and observations from accelerated tests to the field, where it may be possible to mitigate or avoid degradation in the field.
Interfacial microstructure and mechanical properties of rotary inertia friction welded dissimilar 422 martensitic stainless steel to 4140 low alloy steel joints
In this work, dissimilar rotary inertia friction welds between 422 martensitic stainless steel and 4140 martensitic low-alloy steel were made to fabricate prototype heavy-duty diesel engine pistons. The influence of the inertia friction welding process and post weld heat treatment (PWHT) temperature on the interfacial microstructure evolutions and corresponding effects on mechanical properties of the 422/4140 welds were evaluated in detail. Carbon diffused from the 4140 side to the 422 side during PWHT at 650 °C for 1.5 h, causing the formation of a hard carbide-rich layer on the 422 side, and a softer but discontinuous C-depleted layer the 4140 side. PWHT at 700 °C for 1.5 h greatly accelerated C diffusion across the interface relative to 650 °C, resulting in a thicker hard carbide-rich layer and a relatively thick and continuous layer of coarse C-depleted grains (ferrite) on the 4140 side. In addition, the PWHT temperature greatly influenced the tensile properties and fracture behavior of the welds, with the 650 °C PWHT-ed samples failing predominately in a ductile manner in the 4140 heat affected zone during tensile testing. Conversely, the 700 °C PWHT specimens exhibited a strength reduction compared with the 650 °C PWHT specimens because of additional coarsening of the interfacial ferrite layer and softening of the base materials during PWHT, with brittle fracture between the hard and soft layers the predominate failure mechanism. Based on the findings, a reduced PWHT temperature and/or time, minimizing the hardness differential of the base metals, and pre-heating the 422 steel prior to welding are the potential pathways to achieve a more optimal balance between desirable tempering and stress relief of the weld microstructure and undesirable C migration across the weld interface, and to reduce the strength mismatch across the weld.
Optimizing Perovskite Thin‐Film Parameter Spaces with Machine Learning‐Guided Robotic Platform for High‐Performance Perovskite Solar Cells
Abstract Simultaneously optimizing the processing parameters of functional thin films remains a challenge. The design and utilization of a fully automated platform called SPINBOT is presented for the engineering of solution‐processed functional thin films. The SPINBOT is capable of performing experiments with high sampling variability through the unsupervised processing of hundreds of substrates with exceptional experimental control. Through the iterative optimization process enabled by the Bayesian optimization (BO) algorithm, the SPINBOT explores an intricate parameter space, continuously improving the quality and reproducibility of the produced thin films. This machine learning (ML)‐guided reliable SPINBOT platform enables the acceleration of the optimization process of perovskite solar cells via a simple photoluminescence characterization of films. As a result, this study arrives at an optimal film that, when processed into a solar cell in an ambient atmosphere, immediately yields a champion power conversion efficiency (PCE) of 21.6% with satisfactory performance reproducibility. The unsealed devices retain 90% of their initial efficiency after 1100 h of continuous operation at 60–65 °C under metal‐halide lamps. It is anticipated that the integration of robotic platforms with the intelligent algorithm will facilitate the widespread adoption of effective autonomous experimentation to address the evolving needs and constraints within the materials science research community.
The putative center in NGC 1052
Context. Many active galaxies harbor powerful relativistic jets, however, the detailed mechanisms of their formation and acceleration remain poorly understood.Aims. To investigate the area of jet acceleration and collimation with the highest available angular resolution, we study the innermost region of the bipolar jet in the nearby low-ionization nuclear emission-line region (LINER) galaxy NGC 1052.Methods. We combined observations of NGC 1052 taken with VLBA, GMVA, and EHT over one week in the spring of 2017. Our study is focused on the size and continuum spectrum of the innermost region containing the central engine and the footpoints of both jets. We employed a synchrotron-self absorption model to fit the continuum radio spectrum and we combined the size measurements from close to the central engine out to ∼1 pc to study the jet collimation.Results. For the first time, NGC 1052 was detected with the EHT, providing a size of the central region in-between both jet bases of 43 μas perpendicular to the jet axes, corresponding to just around 250 RS (Schwarzschild radii). This size estimate supports previous studies of the jets expansion profile which suggest two breaks of the profile at around 3 × 103 RS and 1 × 104 RS distances to the core. Furthermore, we estimated the magnetic field to be 1.25 Gauss at a distance of 22 μas from the central engine by fitting a synchrotron-self absorption spectrum to the innermost emission feature, which shows a spectral turn-over at ∼130 GHz. Assuming a purely poloidal magnetic field, this implies an upper limit on the magnetic field strength at the event horizon of 2.6 × 104 Gauss, which is consistent with previous measurements.Conclusions. The complex, low-brightness, double-sided jet structure in NGC 1052 makes it a challenge to detect the source at millimeter (mm) wavelengths. However, our first EHT observations have demonstrated that detection is possible up to at least 230 GHz. This study offers a glimpse through the dense surrounding torus and into the innermost central region, where the jets are formed. This has enabled us to finally resolve this region and provide improved constraints on its expansion and magnetic field strength.Key words: methods: observational / techniques: high angular resolution / techniques: interferometric / galaxies: active / galaxies: jets / galaxies: Seyfert⋆⋆ NASA Hubble Fellowship Program, Einstein Fellow.
Generation Plant Cost of Operations and Cycling Optimization Model (Final Technical Report)
Modern coal plants are a masterpiece of engineering, having been refined and improved over more than a century. As they evolved, they have grown more efficient and cleaner. At the same time, they have grown much larger and increasingly designed to operate on very specific fuels at or near the maximum capacity, providing baseload power. In recent decades, however, they have been called on to operate at reduced capacity (cycled) at a loss of efficiency and possibly accelerated wear and tear. The purpose of this project was to develop a model to accurately estimate the cost of cycling large coal plants so that they can be operated efficiently as part of a comprehensive strategy for generation planning and dispatch. The final goal is a model which is commercial-ready that can be “tuned” to different plants for widespread use.
Data-Driven Buy Clean: Decarbonization and Beyond
This report was compiled to provide recommendations on the availability of public background data from the U.S. Federal life cycle assessment (LCA) Data Commons to be conformant with the Association for Life Cycle Assessment (ACLCA) 2022 Product Category Rule (PCR) Open Standard to build technical tools that can assist industry in creating more comparable Type II Environmental Product Declarations (EPDs) for Federal Buy Clean and sustainability initiatives. The Federal LCA Commons is not only a public data source but also a consistently structured, self-referencing mega-repository for data developed by federal agency experts (in agency repositories) and by academia, nonprofit organizations, and industry (via the US Life Cycle Inventory Database). The Federal LCA Commons Technical Working Group is continuously improving the standardization of data documentation, formatting, and nomenclature to ensure lossless data loading and accurate data representation. This report and appendixes include the following: 1) An introduction to data-driven Buy Clean and decarbonization initiatives at the federal level; 2) The current status and associated challenges with LCA data and EPD standards and comparability; 3) Opportunities for the Federal LCA Commons to support conformance with the ACLCA 2022 PCR Open Standard and provide resources to implement the Federal Sustainability Plan, Buy Clean Program, and Inflation Reduction Act (IRA) sustainability goals and objectives. To date, the Federal LCA Commons is the result of coordinated work by National Renewable Energy Laboratory (NREL), the U.S. Department of Agriculture (USDA), the Environmental Protection Agency (EPA), the National Energy Technology Laboratory (NETL), the Argonne National Laboratory (ANL), the U.S. Army Corps of Engineers (USACE), the Federal Highway Administration (FHWA), the U.S. Forest Service (USFS), the Federal Aviation Administration (FAA), the Department of Defense (DoD) and the National Institute of Standards and Technologies (NIST). The Federal LCA Commons will continue to combine databases from the collaborating agencies while remaining a public resource. There are several initiatives among the collaborating agencies to expand the Federal LCA Commons and dedicated federal funding and resources could accelerate and strengthen these initiatives.
Canadian Nuclear Laboratories Waste Management: Challenges and the Integrated Waste Strategy - 19160
Canadian Nuclear Laboratories (CNL) currently faces various waste management challenges and CNL's Integrated Waste Strategy is adapting to manage them. As Canada's premier nuclear science and technology organization, CNL is a global leader in developing peaceful and innovative applications from nuclear technology through its expertise in the scientific field, including physics, metallurgy, chemistry, biology and engineering. As demands change, CNL is shifting its focus to alpha therapies for cancer treatments and sustainable energy solutions. The next decade will see CNL decommission the sites it manages across Canada, whilst transforming Chalk River Laboratories (CRL) into a new, world-class facility which will have the capability to demonstrate the commercial viability of advanced reactor designs including Small Modular Reactors (SMRs). This is being enabled through an accelerated decommissioning program for all CNL operated sites, while renovating CRL, which includes revitalizing essential site infrastructure, and investment in new, world-class science facilities in a modern campus environment. With decommissioning and revitalization occurring simultaneously, the long-term strategy and vision for CNL presents some unique challenges to waste management. Therefore, integrated, collaborative and coordinated waste management is a vital component to ensuring a successful future. The Integrated Waste Strategy coordinates, and provides alignment of, waste management across CNL and: - Includes all CNL operated (Atomic Energy of Canada Limited (AECL) owned) sites; - Considers all CNL managed waste (including radioactive and non-radioactive operational, decommissioning, legacy and historic waste) for the planned lifetime of the sites; - Defines waste routes using a life cycle approach (from the generation of waste to final disposal) A baseline Integrated Waste Strategy and associated action plan to mitigate identified gaps and issues have been produced. A program of work is underway to close those gaps identified in a consistent, transparent, prioritized and justified manner. One of the key challenges is to ensure that waste management planning is completed effectively and in a timely manner. This will enable the provision of suitable and sufficient waste capability to meet CNL's long-term strategy. The Integrated Waste Strategy has been developed and maintained through engagement at all levels across CNL, ensuring buy-in of proposed solutions. Key process stakeholders include generators of CNL managed waste to ensure integrated consideration of legacy, current and future waste generation; waste management personnel to identify requirements, including processing, storage, transport and disposal; AECL as the client and waste liability owner; and the public to ensure they understand the 'big picture' regarding waste strategy. (author)
PACT Center: Perovskite PV Accelerator for Commercializing Technologies (Final Technical Report)
The Perovskite PV Accelerator for Commercializing Technologies (PACT) center was established in July 2021 as a national resource to accelerate the commercialization of perovskite photovoltaic (PV) technology in the United States. Since its inception, PACT has been led by Sandia National Laboratories (Sandia) in partnership with the National Laboratory of the Rockies (NLR), formerly known as NREL. From FY20-FY23, Los Alamos National Laboratory (LANL), CFV Labs, Black & Veatch (B&V), and the Electric Power Research Institute (EPRI) were part of the project team. LANL brought expertise in perovskite PV device designs and processing, CFV Labs (now GroundWork Renewables) provided initial indoor and outdoor measurement hardware technology, B&V led the initial effort on perovskite PV bankability, and EPRI worked on reviewing testing standards, identifying commercialization gaps, and helping to run PACT’s Industry Advisory Board, a group including representatives from commercial testing labs, independent engineering firms, insurance companies, state regulators, and electric utilities. To source perovskite PV module samples, PACT contracted with the University of North Carolina (UNC), the University of Toledo, the University of Washington, and SLAC/Stanford University to provide a steady stream of research-grade perovskite mini modules, enabling protocol development in advance of commercial module availability. The project period ran from July 1, 2021, through December 31, 2025, including a No Cost Extension. Starting in FY25, the project was continued as a Core Capability in the Lab Call portfolio and continues at a reduced budget with only Sandia and NLR as funded recipients. Notably, starting in FY25 PACT expanded its scope beyond MHP modules to accept all emerging PV mini module technologies for testing, including organic PV (OPV) and all-thin-film tandems, with the aim of supporting commercialization across the broader emerging PV ecosystem. With this change in scope the program was renamed the PV Accelerator for Commercializing Technologies, dropping perovskite from the name.