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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6

Spray System Documentation

The intent of this document is to provide background information on key design decisions for the Automatic Spray System, developed at LLNL. The document will overview mechanical, electrical, and toolpath critical decisions. The purpose of this design is to repeatably and uniformly spray parts with a variety of materials. The main aspects of the design are an atomizing air siphon spray nozzle and two rotary axes, C and B. Both axes are controlled by a NEMA17 stepper motor. The C axis is essentially a turntable that rotates the part to be sprayed. The B axis is where the atomizing spray nozzle is attached to the “crawler,” which is a stepper motor on an internal gear. Traditionally, spraying of hemispherical mandrels was done by a trained operator. Depending on the operator, there may be varying thickness in the spray coating. Moving towards an automated spraying system will reduce this variability and increase thickness consistency and uniformity.

42 ENGINEERING↗

SolarSTARTS: Solar-Assisted State-Aware and ResilienT infrastructure System

This final technical report provides a description and results of the design, development, testing, and validation of the Automated Resilience Management System (ARMS) solution, which integrates different systems to collect, store and process relevant information from the power distribution system to automatically manage the operation of multiple energy assets to enhance the resilience of the power grid against high-impact physical incidents (e.g., hurricanes) and cyber threats. The developed solution comprises a suite of novel AI-based algorithms designed to first detect, locate, and classify anomalies by collecting and analyzing data from multiple monitoring and control devices

14 SOLAR ENERGY↗

GRIDAPPSD/distopf (33583-E)

DistOPF is an open-source Python package providing a three-phase, asymmetric optimal power flow (OPF) tool specifically designed for distribution systems. The key inventive features include: - Asymmetrical 3-phase OPF modeling for distribution systems with unbalanced phases - Comprehensive control optimization supporting both active (P) and reactive (Q) power control variables - Built-in visualization and validation tools - Standard test system benchmarking platform for algorithm development and comparison - Modular CSV-based input system using Pandas DataFrames for flexible model specification - Standard power distribution model importer enabling direct conversion from CIM and OpenDSS format to optimization-ready models - Multiple solve interface compatibility (PYOMO, CVXPY, SciPy) with automatic solver selection based on problem type

Gray, Nathan [Pacific Northwest National Laborator↗

Continuous automatic polarization channel stabilization from heterodyne detection of coexisting dim reference signals

Quantum networking continues to encode information in polarization states due to ease and precision. The variable environmental polarization transformations induced by deployed fiber need correction for deployed quantum networking. Here, we present a method for automatic polarization compensation (APC) and demonstrate its performance on a metropolitan quantum network. Designing an APC involves many design decisions as indicated by the diversity of previous solutions in the literature. Our design leverages heterodyne detection of wavelength-multiplexed dim classical references for continuous high-bandwidth polarization measurements used by newly developed multi-axis (non-)linear control algorithm(s) for complete polarization channel stabilization with no downtime. This enables continuous relatively high-bandwidth correction without significant added noise from classical reference signals. We demonstrate the performance of our APC using a variety of classical and quantum characterizations. Finally, we use C-band and L-band APC versions to demonstrate continuous high-fidelity entanglement distribution on a metropolitan quantum network with an average relative fidelity of 0.94 ± 0.03 for over 30 hrs.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

MITgcm-AD v2: Open source tangent linear and adjoint modeling framework for the oceans and atmosphere enabled by the Automatic Differentiation tool Tapenade

The Massachusetts Institute of Technology General Circulation Model (MITgcm) is widely used by the climate science community to simulate planetary atmosphere and ocean circulations. A defining feature of the MITgcm is that it has been developed to be compatible with an algorithmic differentiation (AD) tool, TAF, enabling the generation of tangent-linear and adjoint models. These provide gradient information which enables dynamics-based sensitivity and attribution studies, state and parameter estimation, and rigorous uncertainty quantification. Importantly, gradient information is essential for computing comprehensive sensitivities and performing efficient large-scale data assimilation, ensuring that observations collected from satellites and in-situ measuring instruments can be effectively used to optimize a large uncertain control space. As a result, the MITgcm forms the dynamical core of a key data assimilation product employed by the physical oceanography research community: Estimating the Circulation and Climate of the Ocean (ECCO) state estimate. Although MITgcm and ECCO are used extensively within the research community, the AD tool TAF is proprietary and hence inaccessible to a large proportion of these users. The new version 2 (MITgcm-AD v2) framework introduced here is based on the source-to-source AD tool Tapenade, which has recently been open-sourced. Another feature of Tapenade is that it stores required variables by default (instead of recomputing them) which simplifies the implementation of efficient, AD-compatible code. The framework has been integrated with the MITgcm model’s main branch and is now freely available.

Adjoints↗

An automatic multi-precursor flow-type atomic layer deposition system

Designs for two automated atomic layer deposition (ALD) flow reactors are presented, and their capabilities for coating additively manufactured (AM) metal prints are described. One instrument allows the coating of several AM parts in batches, while the other is useful for single part experiments. To demonstrate reactor capabilities, alumina (Al 2 O 3 ) was deposited onto AM 316L stainless steel by dosing with water (H 2 O) vapor and trimethylaluminum (TMA) and purging with nitrogen gas (N 2 ). Both instruments are controlled by custom-programmed LabVIEW software that enables in situ logging of temperature, total pressure, and film thickness using a quartz crystal microbalance. An initial result shows that 150 ALD cycles led to a film thickness of ~55 nm, which was verified with Rutherford backscattering spectroscopy. This indicates that the reactors were indeed depositing single atomic layers of Al 2 O 3 per ALD cycle, as intended.

47 OTHER INSTRUMENTATION↗

Modeling Framework for Data Center

This chapter highlights the critical need for advanced modeling of data centers due to their rapidly increasing energy consumption and impact on grid reliability. Driven by the demand for AI applications, data centers are projected to consume a significant portion of US energy by 2028, putting stress on an already challenged power grid. The chapter emphasizes the importance of "fast" time-scale models to understand the dynamic interactions between data centers and the grid, especially given the rapid power fluctuations of AI workloads. It outlines a modeling framework that includes both offline and real-time EMT domain simulations, detailing the necessary representations for various components like utility interfaces, transformers, IT loads, UPS, cooling loads, Battery Energy Storage Systems (BESS), generators, protection systems, and higher-level control systems. While standard simulation tools like PSCAD offer basic models, custom development is often required to accurately capture the unique and fast-changing behaviors of modern data centers. The chapter also discusses key metrics and test cases for validating these models, focusing on transient load responses, protection relay coordination, and demand flexibility. Finally, it addresses the challenges of modeling large-scale data centers, such as computational complexity and the trade-off between model fidelity and practicality, suggesting hybrid modeling approaches as a solution. The overarching goal is to create a robust framework that helps assess data center impacts on grid stability, identify vulnerabilities, and inform the development of standards for reliable integration of these large loads into the bulk power system.

25 ENERGY STORAGE↗

Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications

Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.

Knapp, Gerald L. [Oak Ridge National Laboratory (O↗

Machine learning mathematical models for incidence estimation during pandemics

Accurate estimates of the incidence of infectious diseases are key for the control of epidemics. However, healthcare systems are often unable to test the population exhaustively, especially when asymptomatic and paucisymptomatic cases are widespread; this leads to significant and systematic under-reporting of the real incidence. Here, we propose a machine learning approach to estimate the incidence of a pandemic in real-time, using reported cases and the overall test rate. In particular, we use Bayesian symbolic regression to automatically learn the closed-form mathematical models that most parsimoniously describe incidence. We develop and validate our models using COVID-19 incidence values for nine different countries, confirming their ability to accurately predict daily incidence. Remarkably, despite the differences in epidemic trajectories and dynamics across countries, we find that a single model for all countries offers a more parsimonious description and is more predictive of actual incidence compared to separate models for each country. Our results show the potential to accurately model incidence in real-time using closed-form mathematical models, providing a valuable tool for public health decision-makers.

Fajardo-Fontiveros, Oscar (ORCID:0000000207058972)↗

Impact of Color Space and Color Resolution on Vehicle Recognition Models

In this study, we analyze both linear and nonlinear color mappings by training on versions of a curated dataset collected in a controlled campus environment. We experiment with color space and color resolution to assess model performance in vehicle recognition tasks. Color encodings can be designed in principle to highlight certain vehicle characteristics or compensate for lighting differences when assessing potential matches to previously encountered objects. The dataset used in this work includes imagery gathered under diverse environmental conditions, including daytime and nighttime lighting. Experimental results inform expectations for possible improvements with automatic color space selection through feature learning. Moreover, we find there is only a gradual decrease in model performance with degraded color resolution, which suggests the need for simplified data collection and processing. By focusing on the most critical features, we could see improved model generalization and robustness, as the model becomes less prone to overfitting to noise or irrelevant details in the data. Such a reduction in resolution will lower computational complexity, leading to quicker training and inference times.

47 OTHER INSTRUMENTATION↗

AutoEMX v1.

The invention consists in the full automation of compositional analysis of inorganic powder samples by scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS). The measurements and analysis are controlled via python-based software, Auto-SEMEDS. Auto-SEMEDS fully automates the SEM-EDS measurements, and analyses the collected data via the use of machine-learning (ML) algorithms, which have never been used before for such scope. Auto-SEMEDS enables the identification in fully-automated fashion of the individual material phases present in a powder sample. Similar technologies, such as commercial SEM-EDS software, can automatically classify particles based on their composition, but they have significant limitations. These solutions typically provide inaccurate composition measurements and struggle to identify single phases in lab samples, where phases are often closely intermixed. In contrast, Auto-SEMEDS achieves unprecedented accuracy in composition measurements of powder samples, and furthermore leverages machine learning algorithms to effectively discern intermixed phases. Notably, while previous studies have demonstrated accurate measurements on individual particles, Auto-SEMEDS stands out by successfully analyzing mixture of different phases, a capability that has not been reported in the literature until now.

Giunto, Andrea [Lawrence Berkeley National Laborat↗

Emulation and detection of physical faults and cyber-attacks on building energy systems through real-time hardware-in-the-loop experiments

The increasing use of remote or mobile access, integrated wearable technologies, data exchange, and cloud-based data analytics in modern smart buildings is steering the building industry towards open communication technologies. The increased connectivity and accessibility could lead to more cyber-attacks in smart buildings. On the other hand, physical faults (e.g., HVAC -heating, ventilation, and air-conditioning faults) may have similar adverse impacts as those from the cyber-attacks on building energy systems, such as occupant discomfort, energy wastage, and equipment downtime. However, current physical behavior-based anomaly detection methods fail to differentiate between cyber-attacks and physical faults in building energy systems. Moreover, the challenge in collecting real-world threat data with ground truth has led researchers to rely on numerical models with user-defined assumptions, which may not accurately reflect real-world conditions due to the lack of in-situ experimental datasets. To address these challenges and gaps, this paper presents a flexible hardware-in-the-loop (HIL) testbed for generating cyber-attack and physical fault datasets and demonstrating threat detection algorithms in a real building automation system (BAS) environment. This testbed combines hardware (i.e., real BAS with local HVAC controllers and a physical network) with software (i.e., high-fidelity models to represent behaviors of building envelope and HVAC energy systems), enabling emulations of realistic threats. Five HIL experiments, including one baseline without any threats, two with physical faults, and two with cyber-attacks, were conducted to generate datasets containing detailed network traffic and system states. A joint classification framework, incorporating a network analyzer and a physical HVAC fault detector, was proposed to automatically detect cyber-physical abnormalities on BAS at both the network and the physical HVAC levels. The network analyzer comprises a conditional random fields (CRF) based command validator and a statistics-based detection strategy. The fault detector employs a weather and schedule-based pattern matching and feature-based principal component analysis (WPM-FPCA) method. Evaluation of the classification using four metrics from the multi-class confusion matrix revealed an average accuracy of 90.2%, recall of 89.7%, precision of 88.5% and F1-score of 89.2%. Finally, these results demonstrate that the proposed joint classification framework can effectively differentiate between specific types of cyber-attacks (e.g., device reinitialization attack, network Denial-of-Service attack) and physical faults (e.g., air handling unit operational fault, cooling coil valve stuck) in real time for improved building energy management.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Income Verification Strategies for Income-Based Solar Programs

The Inflation Reduction Act has created substantial new programs that support adoption of solar power by low-income households, including the $7 billion Solar For All program and the Low-Income Communities Bonus Credit Program, which increases the investment tax credit for certain types of deployment. In addition, a growing number of states are using solar programs to reduce energy burdens and create energy justice opportunities for low-income households and disadvantaged communities. Verifying the income of participating customers is an important component of these programs. Program managers are seeking strategies to verify a large number of subscribing customers in an accurate, timely, and cost-efficient manner. To help inform program managers, Berkeley Lab investigated how a number of energy and non-energy programs manage income verification. The most common approach is to require proof through tax documents, pay stubs, or other formal income documentation, which can pose an impediment to enrolling eligible customers and create a paperwork burden for administrators. In order to reduce the burden for both the applicant and the program manager, some programs use alternative methods. We identify three common alternative verification methods: -Categorical eligibility: Customers enrolled in other, similar income-verified assistance programs are automatically eligible for enrollment in other income-qualified programs. -Geographic eligibility: Eligibility is based on the customer’s location within a specified area, typically a low-income or disadvantaged community or census tract, and; -“Self-attestation”: The participant claims eligibility with or without further documentation. We describe these options, their pros and cons, give examples of how they are used, and explore how some low-income programs address administrative issues, audits, or other quality control measures. Finally, we explore the risk of mistaken verifications (finding a participant eligible when they are not) in the different strategies. While this memo was initiated by a request relating to income-based community solar programs, the methods are applicable to any program with income eligibility requirements in the energy or non-energy sector. Funding was provided for this research by the Solar Energy Technologies Office of the US Department of Energy, through the National Community Solar Partnership.

14 SOLAR ENERGY↗

Multi-objective automatic discovery of optimized metamaterials for varying velocity impact protection

Mechanical metamaterials have demonstrated exceptional impact performance while remaining lightweight. Impact resistance has traditionally been investigated using quasi-static simulations, often with the assumption that performance will translate to high-velocity impact scenarios. However, critical crash protection parameters—such as peak stress and absorbed energy—are highly sensitive to impact velocity, leading to inconsistent performance under dynamic loading. To address this, we introduce a strain-rate-aware, active deep learning framework that enables multi-objective optimization of impact protection metrics across a wide range of impact velocities. Our framework captures the strain-rate sensitivity of architected lattices by learning to control spatial gradation in cellular metamaterials, resulting in over 200 % enhancement in impact protection relative to state-of-the-art designs such as Voronoi and re-entrant lattices. We demonstrate its practical utility by designing next-generation lattice structures for automotive bumper systems that satisfy multiple, velocity-specific safety criteria—capabilities beyond those of conventional designs. More than just a predictive tool, this framework marks the first step towards enabling adaptable impact-resistant structures across dynamic regimes.

Deep learning↗

Graph-based Reversible Evaluation and Tangents Library

GRETL is a C++ library for evaluation, re-evaluation and algorithmic differentiation of functional operations on an arbitrary computational graph with limited memory usage. Similar to popular machine learning frameworks in Python, like PyTorch and JAX, it tracks and stores both operations and output data as functions are evaluated. Once this composition of functions is built up, the entire chain of operations can be back propagated to compute sensitivities of the final result with respect to any number of inputs. In contrast to most machine learning applications, memory usage becomes the bottleneck for back propagation in many physics applications, especially for time-dependent PDEs. Dynamic check pointing becomes essential. An important distinguishing feature of GRETL is its ability to limit the maximum memory usage by automatically dynamic checkpointing the data output for each graph operation (see Wang, Moin, Iaccarino, 2009). During backpropagation, parts of the graph that are no longer in memory are automatically re-evaluated from upstream checkpointed states as needed for derivative sensitivity calculations (or more precisely, for vector-Jacobian products). GRETL is particularly beneficial for applications, such as coupled multi-physics, where deriving adjoint-based sensitivities and managing checkpoint memory across modules becomes onerous. Cases which can be readily handled by the GRETL library include: different time-integration algorithms per physics (e.g., coupled predictor-corrector algorithms, IMEX, etc.), sub-cycling, asynchronous integrators, state dependent timestep sizes, iterative solvers and coupling algorithms, controller algorithms, and more.

Tupek, MichaelR [Lawrence Livermore National Labor↗

Design considerations for a Digital Twin built to improve nitrification performance at a water resource recovery facility

A Digital Twin built around Activated Sludge Model No. 1 was deployed at a full-scale water resource recovery facility. Its design included a waste rate recommender system based on automatic scenario analyses, where influent loads and waste rates are varied to determine their impact on nitrification. At the same frequency as these scenario analyses, scheduled auto-calibrations allow for nitrifier maximum specific growth rate (μmax-NITO) soft sensing, the only kinetic parameter shown to require adjustment if the objective is aeration tank effluent ammonia forecasting accuracy. By integrating temperature forecasting over the next three sludge ages, this Digital Twin approach creates opportunities for advancing waste rate decisions in anticipation of seasonal temperature changes, optimizing ammonia control authority under varying influent loads, and furnishing valuable insights for future capital projects requiring nitrifier kinetic understanding and modelling.

54 ENVIRONMENTAL SCIENCES↗

Evaluating the Effectiveness of a Detection and Deterrent System in Reducing Golden Eagle Fatalities at Operational Wind Facilities

The Renewable Energy Wildlife Institute (REWI) was appointed as the prime awardee of DOE award number DE-EE0007883 to lead a team of scientists, wind developers, and technology manufacturers toward the overarching goal of evaluating the effectiveness of the current DTBird system in minimizing the risk of golden eagles (Aquila chrysaetos) and other large soaring raptors from approaching the rotor-swept zone (RSZ) of operating wind turbines. As part of this goal, the team set out to 1) quantify the expected reduction in collision risk for golden eagles from operation of the detection and deterrence modules in a manner that supports the approach used by the U.S. Fish and Wildlife Service (USFWS) to assess and credit facility operators for their efforts to minimize predicted collision fatalities and 2) provide information to help improve the technology to maximize its effectiveness. DTBird is an automated detection and audio deterrent system created by the Spanish company Liquen, designed to discourage birds from entering the RSZ of spinning wind turbines. The system uses cameras to automatically detect airborne targets of interest, records each such event in an online database, and triggers a warning signal (loud sound) if the tracked object has moved close to the turbine. If the object moves even closer to the RSZ, a more aggressive dissuasion signal is broadcast. To meet our objectives, the team conducted a two-year experiment at the Goodnoe Hills wind facility in Washington state, in which 14 turbines were outfitted with DTBird units. Daily, each DTBird-equipped turbine was randomly assigned to a control or treatment group. Treatment turbines operated with DTBird running as intended—broadcasting warning or deterrent signals when DTBird detected a target within range. On control turbines, no sound signals were broadcast if a moving target triggered the DTBird system. The team also flew unmanned aerial vehicles (UAVs) designed to coarsely mimic the general size, weight, and coloration of golden eagles in programmed flight transects across DTBird detection ranges to quantify DTBird’s ability to detect intended targets and to evaluate factors that influence the probability of detection and DTBird’s response distances. Additionally, the team evaluated the behavioral responses of in situ eagles exposed to spinning turbines alone (visual and sound influences) versus spinning turbines plus broadcasted DTBird audio deterrents, to estimate the effectiveness of deterrence by the DTBird system. The data and results from these investigations were combined with those from a pilot study conducted at the Manzana Wind Power Project in California to better evaluate DTBird’s effectiveness across different landscapes.

17 WIND ENERGY↗

Spectrally accurate, reverse-mode differentiable bounce-averaging algorithm and its applications

We present a fast, spectrally (exponentially) accurate, automatically differentiable bounce-averaging algorithm that is used to simplify kinetic models. Using this algorithm, implemented in the DESC stellarator optimisation suite, we can perform efficient optimisation of many objectives to improve stellarator performance, such as the effective ripple 𝜖 eff metric for the neoclassical transport coefficient in the low collisionality regime and proxies for energetic particle confinement. For the first time, we optimise a finite-beta stellarator to directly reduce neoclassical ripple transport using reverse-mode differentiation. This ensures the computational cost of differentiation is independent of the number of controllable parameters.

fusion plasma↗