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DOE OSTI2021

Computational Modeling Demonstrates the Joint Clearance Effect on the Tensile Strength of Solder Joints.

Soldered joints can be made with a wide range of base materials and filler metals that allow the assembly to meet its performance and reliability requirements. Structural solder joints have, as their foremost requirement, to provide mechanical attachment between base material structures. The joint is typically subjected to one, or a combination of, three loading configurations: (a) tensile or compressive force, (b) shear force, or (c) peel force. Solder filler metals and in particular, the so-called “soft solders” based on tin (Sn), lead (Pb), and indium (In), generally have a bulk strength that is less than that of the base materials. Finally, deformation occurs largely in the solder when the joint is subjected to an applied force.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Electronic structures and physical properties of Na 2 O doped silicate glass

Ab initio molecular dynamics has been applied to construct seven sodium silicate glass models with Na2O concentration ranging from 0 to 50 mol. %. The structures of the simulated (Na 2 O) x (SiO 2 ) 1-x glasses are critically analyzed and validated by comparing with available experimental data. Because the initial seed model is based on a near-perfect continuous random network model for amorphous SiO 2 with periodic boundaries, the structures of these silicate glasses are highly reliable. The electronic structure, interatomic bonding, and the mechanical and optical properties of seven models are calculated using the first-principles density functional method. In particular, a single quantum mechanical metric, the total bond order density (TBOD), is used to characterize the internal cohesion of sodium silicate glass. This is a significant step beyond the traditional analysis of glasses based purely on the geometric parameters. The TBOD value is found to decrease with increasing Na content, indicating the destruction of silica network connectivity. The calculated mass density and refractive index increase with x are in good agreement with experiment. The elastic coefficients and bulk mechanical properties exhibit a nonlinear variation in the series and depend greatly on the internal bonding and cohesion of the glass. The calculated Poisson's ratio indicates that the glass becomes more ductile with the addition of Na 2 O. Our results indicate that sodium silicate glass tends to be unstable for x greater than 0.4 due to the total destruction of the SiO 2 network.

36 MATERIALS SCIENCE↗

DOE OSTI2014

In Situ Diffraction from Levitated Solids Under Extreme Conditions—Structure and Thermal Expansion in the Eu 2 O 3 –ZrO 2 System

The accurate determination of structure and thermal expansion of refractory materials at temperatures above 1500°C is challenging. Here, for the first time, we demonstrate the ability to reliably refine the structure and thermal expansion coefficient of oxides at temperatures to 2200°C using in situ synchrotron diffraction coupled with aerodynamic levitation. Solid solutions in the Eu 2 O 3 –ZrO 2 binary system were investigated, including the high‐temperature order–disorder transformation in Eu 2 Zr 2 O 7 . The disordered fluorite phase is found to be stable above 1900°C, and a reversible phase transition to the pyrochlore phase is noticed during cooling. Site occupancies in Eu 2 Zr 2 O 7 show a gradual increase in disorder on both cation and anion sublattices with increasing temperature. The thermal expansion coefficients of all cubic solid solutions are relatively similar, falling in the range 8.6–12.0 × 10 −6 C −1 . These studies open new vistas for in situ exploration of complex structural changes in high‐temperature materials.

Maram, Pardha S.↗

DOE OSTI2024

Experimental and Analytical Verification of ASME Section IiII Division 5 Creep-Fatigue Design Rules

The continuous advancement of structural materials and the growing demands for more reliable and economical structural components in high-temperature reactor applications have necessitated the development of comprehensive design methodologies and design rules. Mechanical degradation of structural components at elevated temperatures subjected to cyclic deformation is controlled by the creep-fatigue damage. Over the past few decades, diligent research efforts have been dedicated to refining the development of elevated temperature design rules in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section III, Division 5 and to develop conservative design rules that can effectively guard against the risk of creep-fatigue failure. In ASME Section III, Division 5, for a design to pass the creep-fatigue acceptance criteria, creep damage and fatigue damage are evaluated separately, and these damages must not violate the bi-linear creep-fatigue interaction diagram, i.e., the so-called D-diagram. The creep-fatigue damage evaluation procedure assumes that the effects of the actual cyclic loading sequence can be bounded by assuming that the individual loading cycles are uniformly distributed throughout the component design life. In this study, creep-fatigue experiments with variable amplitudes and loading sequencies were designed and performed on Alloy 617 at high temperatures. The results were analyzed to evaluate the loading history effect on creep-fatigue damage accumulation and to verify the assumptions for the creep-fatigue evaluation design rules.

36 - MATERIALS SCIENCE↗

DOE OSTI2023

Effects of Encapsulant Properties on the Thermo-Mechanical Reliability of Double-Side Cooled Power Modules for Traction Inverters

Double-side cooled power modules are being developed for next-generation traction inverters due to their better heat extraction, lower profile, and lower parasitic inductances. However, due to their rigid structure, they cause reliability concerns arising from high thermo-mechanical stresses at the interconnection joints in the module. In this work, a materials-based approach using rigid encapsulants is presented for reducing thermo-mechanical fatigue. Finite-element thermo- mechanical simulations were performed to examine the effects of the elastic modulus and coefficient of thermal expansion of epoxy- based encapsulants on the bond deformation inside a double-side cooled power module. It was found that a rigid encapsulant with a high modulus of 6.0 GPa or above and a coefficient of thermal expansion around 20 ppm/oC would improve the thermo- mechanical reliability of double-side cooled power modules by decreasing the permanent bond deformation inside the modules by 50-60%.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2017

Understanding the reliability of solder joints used in advanced structural and electronics applications: Part 1 - Filler metal properties and the soldering process

Soldering technology has made tremendous strides in the past half-century. Whether structural or electronic, all solder joints must provide a level of reliability that is required by the application. This Part 1 report examines the effects of filler metal properties and soldering process on joint reliability. Solder alloy composition must have the appropriate melting and mechanical properties that suit the product's assembly process(es) and use environment. The filler metal must also optimize solderability (wetting-and-spreading) to realize the proper joint geometry. Here, the soldering process also affects joint reliability. The choice of flux and thermal profile support the solderability performance of the molten filler metal to successfully fill the gap and complete the fillet.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Design for reliability of BEoL and 3-D TSV structures – A joint effort of FEA and innovative experimental techniques

Copper-TSVs for 3D-IC-integration generate novel challenges for reliability analysis and prediction, e.g. the need to master multiple failure criteria for combined loading including residual stress, interface delamination, cracking and fatigue issues. So, the thermal expansion mismatch between copper and silicon leads to a stress situation in silicon surrounding the TSVs which is influencing the electron mobility and as a result the transient behavior of transistors. Furthermore, pumping and protrusion of copper is a challenge for Back-end of Line (BEoL) layers of advanced CMOS technologies already during manufacturing. These effects depend highly on the temperature dependent elastic-plastic behavior of the TSV-copper and the residual stresses determined by the electro deposition chemistry and annealing conditions. That’s why the authors pushed combined simulative/experimental approaches to extract the Young’s-modulus, initial yield stress and hardening coefficients in copper-TSVs from nanoindentation experiments, as well as the temperature dependent initial yield stress and hardening coefficients from bow measurements due to electroplated thin copper films on silicon under thermal cycling conditions. A FIB trench technique combined with digital image correlation is furthermore used to capture the residual stress state near the surface of TSVs. The extracted properties are discussed and used accordingly to investigate the pumping and protrusion of copper-TSVs during thermal cycling. Moreover, the cracking and delamination risks caused by the elevated temperature variation during BEoL ILD deposition are investigated with the help of fracture mechanics approaches.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2014

Experimental evaluation and numerical modelling of timber-framed walls

Timber-framed wall buildings are seen all over Europe, especially in seismic regions, given its adequacy to resist earthquakes. The pombaline buildings, developed after the big 1755 earthquake that destroyed Lisbon, constitute one of the best examples of ancient seismic-resistant structures based on timber-framed masonry walls. But in addition to suffering natural degradation and frequent inadequate interventions, these buildings were not prepared to resist the severe seismic actions envisaged by today’s structural codes. In this context, they increasingly have to undergo rehabilitation and reinforcing works. The success of these projects strongly depends on the accuracy of the structural modelling, which in turn depends on knowledge of the behaviour of the existing structure. Aiming at providing reliable data to be used in structural design, a series of tests was carried out on the base element that constitutes the timber-framed masonry walls: the Saint Andrew’s cross. The experimental tests were numerically simulated in order to determine the parameters that lead to the most accurate results when using linear-elastic models.

42 ENGINEERING↗

DOE OSTI2019

Experimental Study of Residual Stresses in Hybrid Laser Arc and Submerged Arc-Welded 10-mm-Thick Low-Carbon Steel Plates

Offshore structures are constantly exposed to a multihazard marine environment that threatens their structural integrity. This imposes a high risk for extensive structural failures while various deterioration mechanisms may degrade the available capacity of the structures. Thus, no reliable decisions can be reached regarding design, operation, and survivability of the structures unless a deep comprehension of their fatigue performance is available, including welding-induced residual stresses. In particular, the continuous increase in size of the weldments for the offshore wind industry needs special attention with regard to welding-induced residual stresses, as they can reduce fatigue life, promote distortion, and contribute to stress corrosion cracking. Thus, the current design methods and increased structural dimensions as well as new design and manufacturing methods need to be inspected, understood, and optimized. Related to this, there is a growing need for evaluation of the effect of welding methods with various heat input density distributions. This article deals with the influence of welding method on the welding-induced residual stresses in 10-mm-thick low-carbon structural steel plates. The residual stresses are investigated in hybrid laser-arc welded and submerged arc butt-welded steel plates by means of experimental temperature profile measurements and neutron diffraction measurements and in accordance with existing production procedures. The residual stresses were measured at three different depths in the plates. The goal of the analysis is to gain a comprehensive understanding of the distribution and development of residual stresses in relation to the welding method for better control of the residual stresses and distortion. Furthermore, the repeatability of the neutron diffraction measurements is also investigated and reported in this article.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Self-Sensing Composites via an Embedded 3D-Printed PVDF-MoS 2 Nanosensor for Structural Health Monitoring

Carbon fiber (CF)-reinforced epoxy composites are widely used in vehicle applications, where early damage detection is crucial for reliability and safety. To address this need, we developed a self-sensing epoxy/CF composite by embedding a PVDF-MoS 2 nanosensor via an embedded 3D printing method. By harnessing the intrinsic curing kinetics of epoxy, we tailored its rheological properties to optimize the embedded printing process, enabling precise and reliable support for sensor filaments without compromising the composite’s structural and functional integrity. Through comprehensive rheological and kinetic analysis, we established a quantitative relationship among curing temperature, conversion rate, and resulting yield modulus─defining a narrow processing window essential for successful sensor integration. Specifically, we identified that an epoxy yield modulus range of 180–294 Pa and a conversion rate below 10% are critical to support the PVDF-MoS 2 filament architecture. Here, this embedded 3D printing method produces complex and multimaterial PVDF-MoS 2 sensors within an epoxy matrix with minimal deformation and reduced postprocessing, which is scalable and adaptable for industrial applications. Under cyclic loading, the embedded sensors exhibited stable signals under constant loads and increased voltage signals in response to crack formation (17–35% higher) and catastrophic failure (1 order of magnitude higher), effectively capturing structural changes in real time. This study demonstrates the potential of PVDF-MoS 2 nanocomposite sensor materials for real-time structural health monitoring in epoxy–CF composite systems, enabling early detection of defects and stress anomalies, significantly reducing the risk of unexpected failures, and enhancing structural reliability.

PVDF-MoS2 sensor↗

DOE OSTI2024

Robust training of machine learning interatomic potentials with dimensionality reduction and stratified sampling

Abstract Machine learning interatomic potentials (MLIPs) enable accurate simulations of materials at scales beyond that accessible by ab initio methods and play an increasingly important role in the study and design of materials. However, MLIPs are only as accurate and robust as the data on which they are trained. Here, we present DImensionality-Reduced Encoded Clusters with sTratified (DIRECT) sampling as an approach to select a robust training set of structures from a large and complex configuration space. By applying DIRECT sampling on the Materials Project relaxation trajectories dataset with over one million structures and 89 elements, we develop an improved materials 3-body graph network (M3GNet) universal potential that extrapolates more reliably to unseen structures. We further show that molecular dynamics (MD) simulations with the M3GNet universal potential can be used instead of expensive ab initio MD to rapidly create a large configuration space for target systems. We combined this scheme with DIRECT sampling to develop a reliable moment tensor potential for titanium hydrides without the need for iterative augmentation of training structures. This work paves the way for robust high-throughput development of MLIPs across any compositional complexity.

Qi, Ji (ORCID:0000000158089931)↗

DOE OSTI2022

Machine Learning Models for Binary Molecular Classification using VUV Absorption Spectra

Machine learning methods were combined with differential absorption spectroscopy measurements in the vacuum-ultraviolet region (5.167 – 9.920 eV) in order to develop predictive capabilities for inferring molecular structure from the spectra. Several types of species were analyzed and, for modeling purposes, were defined using a single classification: (1) alkane, (2) conjugation with oxygen (e.g. diacetyl, ethyl vinyl ether), (3) non-conjugated alkene (e.g. 1-butene, 1,4-cyclohexadiene), (4) oxygen-containing (e.g. 1-butanol, tetrahydrofuran), or (5) cyclic (e.g. cyclopentane, cyclohexanone). The latter molecular classification excluded cyclic ethers. Several modeling methods were employed in the analysis of 102 absorption spectra, 24 of which were measured for the first time. The primary objective was to identify suitable methods that enable accurate predictions of molecular structure classifications with minimized statistical uncertainties. Rather than identifying a single, unifying method to reliably predict molecular structure contributions to VUV absorption spectra, coordination is required among a particular method, the type of molecular structure detail (e.g. conjugation), and absorption region of interest. The latter is accomplished using a binning approach, wherein absorption regions of ~0.5 eV were utilized rather than the entire ~4.8 eV range. Photon energy binning enabled analysis of region-specific predictions of accuracy, precision, and recall. The outcome from the binning approach is that, rather than utilizing the entire spectrum, optimal determination of molecular structure using machine learning methods depends on the absorption region. Furthermore, the present work provides separate machine learning models for each molecular classification, which enables the identification of multi-functional species relevant to atmospheric chemistry and combustion chemistry, where isomer-resolved speciation is critical to understanding complex reaction networks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

ON THE EFFECTIVENESS OF LLMS IN UNIT TEST GENERATION FOR STRUCTURED TEXT PROGRAMS

The reliability of industrial automation systems heavily depends on the correctness of Programmable Logic Controller (PLC) programs, which are often written in Structured Text (ST). While Large Language Models (LLMs) have shown promise in automating test generation for mainstream programming languages, their effectiveness for the syntactically strict ST language remains underexplored. This thesis presents a systematic empirical evaluation of three state-of-the-art LLMs—GPT-4o, Gemini 2.5 Pro, and Claude Sonnet 4.5—for generating ST unit tests. We examine three prompting strategies: Natural Language (NL), Code Language (CL), and Chain-of-Thought (CoT), across a curated set of 11 ST function blocks. The quality of the generated tests is assessed using Compilation Success Rate (CSR), Statement Coverage (SC), and Branch Coverage (BC). In the zero-shot setting, Claude Sonnet 4.5 achieves the highest CSR, while Gemini 2.5 Pro consistently delivers the best statement and branch coverage, particularly under CL prompts. By incorporating a one-shot CL prompt, all models exhibit substantial improvements—most notably GPT-4o, whose CSR increases from 45.45% to 90.91%, with substantial gains in both SC and BC. To further contextualize these findings, we compare GPT-4o’s one-shot results with PLCAutoTester, a state-ofthe- art ST unit test generation tool, on an additional benchmark dataset. While LLMgenerated tests approach competitive coverage levels, PLCAutoTester maintains significantly higher and more stable coverage across programs. This study provides the first comprehensive benchmark of modern LLMs for ST unit testing, highlighting their strengths, limitations, and improvements through one-shot prompting, and positioning their performance relative to specialized automated testing tools in industrial automation.

42 ENGINEERING↗

DOE OSTI2012

Effect of buffer structures on AlGaN/GaN high electron mobility transistor reliability

AlGaN/GaN high electron mobility transistors (HEMTs) with three different types of buffer layers, including a GaN/AlGaN composite layer, or 1 or 2 lm GaN thick layers, were fabricated and their reliability compared. The HEMTs with the thick GaN buffer layer showed the lowest critical voltage (Vcri) during off-state drain step-stress, but this was increased by around 50% and 100% for devices with the composite AlGaN/GaN buffer layers or thinner GaN buffers, respectively. The Voff - state for HEMTs with thin GaN and composite buffers were 100 V, however, this degraded to 50 60V for devices with thick GaN buffers due to the difference in peak electric field near the gate edge. A similar trend was observed in the isolation breakdown voltage measurements, with the highest Viso achieved based on thin GaN or composite buffer designs (600 700 V), while a much smaller Viso of 200V was measured on HEMTs with the thick GaN buffer layers. These results demonstrate the strong influence of buffer structure and defect density on AlGaN/GaN HEMT performance and reliability.

Liu, L.↗

DOE OSTI2023

Probabilistic Failure Criterion of SiC/SiC Composites Under Multiaxial Loading

Owing to its excellent mechanical properties and stability under high temperature and neutron irradiation conditions, SiC/SiC composites have emerged as a promising material for light water reactors (LWRs) in the development of accident-tolerant fuel (ATF) systems. Structural integrity and retention of hermeticity are two crucial requirements for SiC/SiC claddings during normal operations, and both of them are closely related to the proportional limit stress (PLS) of the material. Understanding the behavior of SiC/SiC composites under multiaxial stress states and developing a probabilistic approach for evaluating the structural vulnerability are of paramount importance for reliability-based analysis and design of SiC/SiC composite claddings. So far, there has been very limited effort towards experimental and analytical investigations of probabilistic failure of SiC/SiC claddings. This critical knowledge gap motivates this research. A probabilistic failure criterion for SiC/SiC composites under multi-axial loading is developed, and this criterion is incorporated into reliability analysis of the structural integrity of SiC/SiC fuel cladding. The research consists of two parts: 1) experimental investigation of multiaxial failure behavior of SiC/SiC composites, and 2) theoretical modeling of time-dependent probabilistic failure of SiC/SiC cladding. In the experimental investigation, the PLS is determined through the examination of stress-strain response, the acoustic emission measurement, as well as the X-ray computed tomography. The theoretical framework is derived by combin- ing the finite weakest-link statistical model and the subcritical damage growth model. This theoretical model captures the time-dependent failure mechanism of the material, which has a major consequence for predicting the lifetime distribution of the cladding. Meanwhile, the model also predicts that the failure statistics of the cladding depends strongly on the cladding length. The results of the multiaxial experiments reveal the level of statistical variation of the PLS of SiC/SiC materials under different stress states. The theoretical model provides a robust analytical tool for extrapolation of small-scale laboratory test results to the behavior of full-scale claddings. These findings establish a scientific foundation for the development of reliability-based design of SiC/SiC fuel claddings, which will play an essential role in improving the structural safety and integrity of LWRs.

42 ENGINEERING↗

DOE OSTI2017

Consideration of the Aluminum Distribution in Zeolites in Theoretical and Experimental Catalysis Research

Research efforts in zeolite catalysis have become increasingly cognizant of the diversity in structure and function resulting from the distribution of framework aluminum atoms, through emerging reports of catalytic phenomena that fall outside those recognizable as the shape-selective ones emblematic of its earlier history. Molecular-level descriptions of how active-site distributions affect catalysis are an aspirational goal articulated frequently in experimental and theoretical research, yet they are limited by imprecise knowledge of the structure and behavior of the zeolite materials under interrogation. In experimental research, higher precision can result from more reliable control of structure during synthesis and from more robust and quantitative structural and kinetic characterization probes. In theoretical research, construction of models with specific aluminum locations and distributions seldom capture the heterogeneity inherent to the materials studied by experiment. In this Perspective, we discuss research findings that appropriately frame the challenges in developing more predictive synthesis-structure-function relations for zeolites, highlighting studies on ZSM-5 zeolites that are among the most structurally complex molecular sieve frameworks and the most widely studied because of their versatility in commercial applications. We discuss research directions to address these challenges and forge stronger connections between zeolite structure, composition, and active sites to catalytic function. Such connections promise to aid in bridging the findings of theoretical and experimental catalysis research, and transforming zeolite active site design from an empirical endeavor into a more predictable science founded on validated models.

09 BIOMASS FUELS↗

DOE OSTI2021

Tailored computational approaches to interrogate heavy element chemistry and structure in condensed phase

In this chapter we are presenting a brief review of the challenges encountered in the study of 4f and 5f block elements in the condensed phase. Their recovery, use in molten salt reactors and other interesting applications necessitate the use of molecular dynamics and large-scale models that take into account both the electronic structure and relativistic corrections. Sampling the multitude of electronic and atomic configurational states is at the heart of reliable predictions of structure, reactivity, dynamics and transport of heavy metals in complex environments. We present three examples that combine lanthanide elements with large scale models: i) our recent developments of a versatile adaptive learning method that enables global optimization in high dimensional spaces, ii) results of computed pKa values of lanthanide aqua complexes, and iii) structure and computed EXAFS of heavy elements in molten salts. The latter two employ our recently-optimized lanthanide pseudo-potentials and companion basis sets for condensed phase ab initio molecular dynamics.

Nguyen, Manh Thuong↗

DOE OSTI2019

Prediction of Safety Level of Low-Head and Ownerless Hydraulic Structures

Methods of systems reliability theory are applied to the results of an expert inspection of more than 1000 low-head hydraulic power systems in the Moscow region. The rates of failure of homogeneous earth dams are estimated. A state graph of a hydraulic structure, represented as a system that passes through discrete states from a normal to a dangerous level without maintenance or repair, is proposed. The constant failure rates for these states are calculated. The probabilistic characteristics of the safety level of low-head earth dams are predicted.

42 ENGINEERING↗