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DOE OSTI2026

Toward Fully Soft and Multifunctional Shape Sensing via Optical Waveguide Arrays

For soft bodies, surface deformation and pressure provide proprioceptive and exteroceptive information, including body configuration, body compliance, and external forces. We develop a sheet sensor with a fully soft sensing surface that provides surface shape reconstruction using optical waveguide arrays. The waveguides are fabricated to achieve a tunable linear response to bi‐directional bending curvature, and the waveguide arrays are configured to differentiate between ambiguous shapes. We characterize the waveguide performance, relating curvature sensitivity to the core's surface roughness. Synergy of waveguide responses reduces the number of sensing elements required and achieves damage resilience. Using waveguide sensitivity to pressure, we also demonstrate feasibility for exteroception. We demonstrate the multifunctional sensing capability by wrapping the sheet around an upper arm, showcasing joint motion and external force sensing. Integrated into or applied onto surfaces of robotic or living systems, this design can be implemented in applications such as virtual reality, teleoperation, physical therapy, and soft robotics.

Yu, Qifan [Department of Mechanical Engineering Ma↗

DOE OSTI2026

California Trees Seasonally Use Augmented Water Sources: Water Isotope Tracking in a Groundwater‐Dependent Ecosystem

Sustainable groundwater management must account for the needs of groundwater dependent ecosystems. To understand the relationship of ecosystems and seasonal water use, we studied the stable isotope composition (δ 18 O and δ 2 H) of water in streamside trees in a semi-arid streamside environment (Livermore, California, USA). We sampled seven trees at two sites every other month from April 2024 through April 2025 for tree xylem stable water isotope signatures. These data were compared to potential source waters: precipitation, imported surface water, soil water and regional groundwaters. Large daily precipitation events were found to be isotopically similar to regional groundwater and were thus treated as one water source. A Bayesian mixing model using stable water isotopes was used to determine the ratios of these three potential source waters (small daily precipitation events, groundwater/large daily precipitation events and imported water) present in tree xylem water. On average, tree water sources include 32% imported water (SD = 9%), 35% small daily precipitation events (SD = 10%) and 33% groundwater (SD = 3%), with significant seasonal variation (t summer-winter = 30.8, p < 0.01), particularly drawing more imported water (more than 55%) in the summer. While small daily precipitation events contribute only 10% of the total precipitation in our dataset, it represents a third of water used by trees. In addition, while these ecosystems are designated as groundwater dependent ecosystems, the trees use approximately one third imported water and even more during dry summer months. This approach provides water managers with a practical tool for quantifying ecosystem water needs, supporting data-driven decisions and regulatory compliance. While California's Sustainable Groundwater Management Act emphasizes supporting groundwater dependent ecosystems, it allows flexibility in demonstrating benefits. In conclusion, our methodology provides a way to document that management actions (such as managed aquifer recharge with imported water) deliver measurable co-benefits to GDEs.

Geosciences↗

DOE OSTI2024

Challenges for monitoring and data analytics in a leadership public data repository

The availability and disposition of data has assumed increasing importance in large-scale computational science. Data repositories are evolving to meet new classes of requirements: compliance with government access guidelines, support for reproducibility of experimental results, and long-term availability of data products. The Constellation public data repository at the Oak Ridge Leadership Computing Facility faces these issues while being situated in one of the most productive data centers in the world. While monitoring and operational data analysis are ingrained in the operation of the OLCF’s large-scale high performance computing platforms, data repositories do not have this history of support. Problems faced by Constellation range from data size (over 7 petabytes in current holdings) to analytic complexity (detailed curation is both absolutely necessary for many data sets and absolutely impossible for humans to accomplish in any practical manner) to deployment environment (OLCF storage resources are oriented toward the needs of the compute platforms). In this paper we describe some of the challenges for collecting monitoring and analytic data from a leadership public data repository. We also discuss various strategies we are pursuing in order to address these challenges, from manual data collection to plans for introducing machine learning-based curatorial techniques.

Widener, Patrick [ORNL] (ORCID:0000000258820816)↗

DOE OSTI2025

A simple introduction to the SiMPL method for density-based topology optimization

We introduce a novel method for solving density-based topology optimization problems: Sigmoidal Mirror descent with a Projected Latent variable (SiMPL). The SiMPL method (pronounced as “the simple method”) optimizes a design using only first-order derivative information of the objective function. The bound constraints on the density field are enforced with the help of the (negative) Fermi–Dirac entropy, which is also used to define a non-symmetric distance function called a Bregman divergence on the set of admissible designs. This Bregman divergence leads to a simple update rule that is further simplified with the help of a so-called latent variable. Because the SiMPL method involves discretizing the latent variable, it produces a sequence of pointwise-feasible iterates, even when high-order finite elements are used in the discretization. Numerical experiments demonstrate that the method outperforms other popular first-order optimization algorithms. In conclusion, to outline the general applicability of the technique, we include examples with (self-load) compliance minimization and compliant mechanism optimization problems.

Calculus of Variations and Optimization↗

DOE OSTI2024

The Influence of Residual Stress on Fatigue Crack Growth Rates in Stainless Steel Processed by Different Additive Manufacturing Methods

The properties and microstructure of Type 304L stainless steel produced by two additive manufacturing (AM) methods—directed energy deposition (DED) and powder bed fusion (PBF)—are evaluated and compared. Localized heating and steep temperature gradients of AM processes lead to significant residual stress and distinctive microstructures, which may be process-specific and influence mechanical behavior. Test data show that materials produced by DED and PDF have small differences in tensile strengths but clear differences in residual stress and microstructural features. Measured fatigue crack growth rates (FCGRs) for cracks propagating parallel to and perpendicular to the build directions differ between the two AM materials. To separate the influences of residual stress and microstructure, K-control test procedures with decreasing and constant stress intensity factor ranges are used to measure FCGRs in the near-threshold regime (crack growth rates ≤ 1 × 10 −8 m/cycle). Residual stress is quantified by the residual stress intensity factor, K res , measured by the online crack compliance method. Correcting the FCGR data for differences in K res brings results for specimens of the two AM materials into agreement with each other and with results for wrought specimens, when the latter are corrected for crack closure. Differences in microstructure and tensile strength have an insignificant influence on FCGRs in these tests.

additive manufacturing↗

DOE OSTI2025

Leveraging artificial intelligence and advanced food processing techniques for enhanced food safety, quality, and security: a comprehensive review

Artificial intelligence is emerging as a transformative force in addressing the multifaceted challenges of food safety, food quality, and food security. This review synthesizes advancements in AI-driven technologies, such as machine learning, deep learning, natural language processing, and computer vision, and their applications across the food supply chain, based on a comprehensive analysis of literature published from 1990 to 2024. AI enhances food safety through real-time contamination detection, predictive risk modeling, and compliance monitoring, reducing public health risks. It improves food quality by automating defect detection, optimizing shelf-life predictions, and ensuring consistency in taste, texture, and appearance. Furthermore, AI addresses food security by enabling resource-efficient agriculture, yield forecasting, and supply chain optimization to ensure the availability and accessibility of nutritious food resources. This review also highlights the integration of AI with advanced food processing techniques such as high-pressure processing, ultraviolet treatment, pulsed electric fields, cold plasma, and irradiation, which ensure microbial safety, extend shelf life, and enhance product quality. Additionally, the integration of AI with emerging technologies such as the Internet of Things, blockchain, and AI-powered sensors enables proactive risk management, predictive analytics, and automated quality control. By examining these innovations' potential to enhance transparency, efficiency, and decision-making within food systems, this review identifies current research gaps and proposes strategies to address barriers such as data limitations, model generalizability, and ethical concerns. These insights underscore the critical role of AI in advancing safer, higher-quality, and more secure food systems, guiding future research and fostering sustainable food systems that benefit public health and consumer trust.

AI↗

DOE OSTI2026

Revolutionizing thermal Management in Next-Generation AI data centers: Challenges and breakthrough innovations

Data centers (DCs) serve as critical infrastructure for powering the growth and evolution of AI. Next-generation AI DCs present unique challenges in thermal management driven by unprecedented computational demands. This paper provides a comprehensive summary of key stakeholder perspectives on technology gaps, infrastructure requirements, test bed needs, emerging opportunities, and preliminary solutions related to thermal management for AI DCs. It establishes six strategic pillars of thermal management for next generation AI DC: reliability, deployability, efficiency, resilience, measurability, and valorization. The discussion spans a range of critical topics, including advanced cooling technologies, thermal strategies for emerging modular and edge DCs, system-level optimization and control frameworks, infrastructure planning and grid integration designs, benchmarking approaches, and pathways for waste heat recovery and reuse. The proposed research, development, and demonstration efforts are aimed at accelerating the deployment of AI DCs while ensuring energy efficiency, reliability, safety, and regulatory compliance.

Wang, Pengtao [ORNL] (ORCID:0000000214713429)↗

DOE OSTI2026

Ten questions concerning Large Language Models (LLMs) for building applications

Large Language Models (LLMs) are emerging as powerful AI tools capable of transforming how building information is collected, processed, analyzed, and applied across diverse research areas. Their capabilities can help building operators, facility managers and other stakeholders such as designers, architects and engineers by providing actionable insights for decision-making across planning, construction, operations, and maintenance of buildings and facilities. This paper explores ten key questions concerning the role of LLMs in shaping sustainable, intelligent, and human-centric buildings. From fundamental definitions to advanced applications, we examine how LLMs facilitate decision-making across the life cycle of buildings and energy systems. LLMs can enhance life cycle assessments (LCA), building energy simulations, and real-time data integration, empowering more efficient and adaptive human-AI environments. They can also contribute to streamlining regulatory compliance, improving post-occupancy evaluations, and fostering more inclusive and participatory design processes. Additionally, this paper addresses the ethical challenges posed by LLMs, such as bias, data privacy, and environmental impacts, and explores their potentials in advancing intelligent digital twins (DT) for ongoing building operations and maintenance. Built upon our applied research using LLMs and the review of tools, datasets, and research gaps, we provide a forward-looking perspective on how LLMs can drive innovation, collaboration, and productivity in the built environment while supporting ethical and effective implementation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Reactivity of net-zero carbon alcohol fuels and their corresponding aldehyde intermediates on PGM-based commercial oxidation catalysts for lean-burn emissions control

Alcohol net-zero carbon fuels will play a significant role in decarbonization of the hard-to-electrify transportation sectors. However, the combustion process in alcohol-fueled engines generate toxic aldehydes. For commercialization of net-zero carbon fuels on engines, compliance with the stringent U.S. EPA regulations is necessary. Here, this contribution focuses on reactivity of alcohols and aldehydes on commercial diesel oxidation catalysts (DOC) to inform selection of future net-zero carbon fuels. Alcohol (and aldehyde) light-off temperatures were measured on aged DOCs under full synthetic engine-exhaust conditions. Methanol was the most reactive, while ethanol completely oxidized at higher temperatures. Alcohols typically formed less reactive aldehyde intermediates. DRIFTS revealed strongly adsorbing surface formates and acetates during methanol and ethanol oxidation, respectively, resulting in inhibition effects. Preliminary alcohol oxidation mechanisms combining flow reactor and DRIFTS observations are presented. Aldehydes inhibited CO oxidation. Minimal N 2 O formation was observed for the alcohols investigated.

Alcohol oxidation↗

DOE OSTI2025

Techno-economic evaluation of emission control configurations for AMP/PZ-based post-combustion CO 2 capture

Minimizing the environmental impacts of amine-based post-combustion carbon capture technologies is essential for regulatory compliance and public acceptance. Experimental campaigns at RWE's CO 2 capture pilot plant in Niederaussem using CESAR1 demonstrated that combining existing emission abatement technologies can substantially reduce the concentration of amines and degradation products in the CO 2 -depleted flue gas to below the detection limit of an infrared spectrometer. The campaign confirmed that a proprietary dry bed technology (OEASE aerozone™) or a second water wash can reduce AMP and PZ emissions to below 1 mg/Nm 3 . However, an acid or chemically active wash downstream of the water wash is necessary to reduce NH 3 emissions to very low levels (<2 mg/Nm 3 ). Combining a dry bed with an acid wash significantly reduces both the required acid solution and the resulting acid waste. The techno-economic analysis indicates that implementing emission mitigation technologies provides substantial environmental benefits for the CESAR1 process, with only a marginal increase (<1 €/tCO 2 ) in both the carbon capture cost (CCC) and CO 2 avoidance cost (CAC). The additional capital cost associated with extra column packing is offset by operational cost savings from reduced solvent losses. For stringent emission permits targeting NH 3 , a configuration combining a dry bed upstream of the water wash followed by an acid wash achieves the best balance between emission control and cost efficiency. This configuration results in a Levelized Cost of Electricity (LCOE) of 143 €/MWh, a CCC of 45.4 €/tCO 2 , and a CAC of 88.4 €/tCO 2 .

AMP↗

DOE OSTI2025

Physically constrained 3D diffusion for inverse design of fiber-reinforced polymer composite materials

Designing fiber-reinforced polymer composites (FRPCs) with a tailored nonlinear stress-strain response is crucial for applications such as energy absorption in crash structures, flexible robotics, and impact-resistant protective gear. However, the inherent complexities of composite materials and the multitude of parameters involved, render traditional design and optimization methods inadequate for achieving effective inverse design of composites. In this paper, we present an AI-based inverse design framework that effectively and efficiently generates FRPCs with targeted nonlinear stress-strain responses. We introduce a physically constrained diffusion model (PC3D_Diffusion) capable of managing the complexities of composite materials and producing detailed, high-quality designs. We propose a loss-guided, learning-free approach to generate physically feasible microstructure designs by explicitly enforcing physical constraints during the generation process. For training purposes, 1.35 million FRPC samples were created, and their corresponding stress-strain curves were computed using established physics-based computational models. The results show that PC3D_Diffusion consistently generates high-quality designs with tailored mechanical behaviors, while guaranteeing compliance with the physical constraints. PC3D_Diffusion advances FRPC inverse design and may facilitate the inverse design of other 3D materials, offering potential applications in industries reliant on materials with custom mechanical properties.

Xu, Pei [Clemson Univ., SC (United States)]↗

DOE OSTI2024

Optimal operation of multi-plant steam district heating systems for enhanced efficiency and sustainability

Despite their crucial role in supplying heat and power to universities, industries, and healthcare facilities, many steam-based district heating systems rely on outdated control methods. Among these, multi-central plant districts are particularly challenging due to the complexities of coordinating multiple plants, optimizing load distributions, and managing system downtime. In response, new operational strategies are developed to enhance the efficiency and sustainability of steam districts while utilizing existing resources. These strategies include reducing plant operational pressure without compromising the reliable supply to buildings and optimizing load allocation across multiple plants. The load allocation considers boiler part-load efficiency, runtime, network losses, and building pressure set points, and is compared with traditional multi-boiler controls. To support this exploration, new dynamic Modelica models are developed. In addition, methods to reduce modeling complexities are incorporated, enhancing their suitability for practical applications. A holistic district-wide analysis using a real university case study demonstrates a 4.7% fuel savings by lowering boiler operational pressure from 900 kPa to 600 kPa, along with a 13.3% reduction in condensation losses across the distribution network. Furthermore, the load allocation approach results in a 13.1% reduction in fuel consumption during peak winter periods and 15.3% during shoulder periods, with corresponding decreases in carbon emissions and fuel costs. This approach can also save maintenance costs by reducing the boiler runtime by 49.6%. In conclusion, this research underscores the benefits of retrofitting aging steam district heating systems, offering immediate operational improvements by enhancing efficiency, meeting regulatory compliance, and extending infrastructure lifespans while delaying costly overhauls.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Private, public, and bottled drinking water: Shared contaminant-mixture exposures and effects challenge

Background: Humans are primary drivers of environmental–contaminant exposures worldwide, including in drinking-water (DW). In the United States, point-of-use DW (POU–DW) is supplied via private tapwater (TW), public-supply TW, and bottled water (BW). Differences in management, monitoring, and messaging and lack of directly–intercomparable exposure data influence the actual and perceived quality and safety of different DW supplies and directly impact consumer decision–making. Objectives: The purpose of this paper is to provide a meta-analysis (quantitative synthesis) of POU–DW contaminant–mixture exposures and corresponding potential human–health effects of private-TW, public-TW, and BW by aggregating exposure results and harmonizing apical–health–benchmark–weighted and bioactivity–weighted effects predictions across previous studies by this research group. Discussion: Simultaneous exposures to multiple inorganic and organic contaminants of known or suspected human-health concern are common across all three DW supplies, with substantial variability observed in each and no systematic difference in predicted cumulative risk between supplies. Differences in contaminant or contaminant–class exposures, with important implications for DW–quality improvements, were observed and attributed to corresponding differences in regulation and compliance monitoring. Conclusion: The results indicate that human-health risks from contaminant exposures are common to and comparable in all three DW–supplies, including BW. Importantly, this study’s target analytical coverage, which exceeds that currently feasible for water purveyors or homeowners, nevertheless is a substantial underestimation of the breadth of contaminant mixtures in the environment and potentially present in DW. Thus, the results emphasize the need for improved understanding of the adverse human-health implications of long-term exposures to low–level inorganic–/organic–contaminant mixtures across all three distribution pipelines and do not support commercial messaging of BW as a systematically safer alternative to public-TW. Regardless of the supply, increased public engagement in source-water protection and drinking–water treatment is necessary to reduce risks associated with long-term DW–contaminant exposures, especially in vulnerable populations, and to reduce environmental waste and plastics contamination.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Evaluating methods to reduce duration of near-threshold fatigue crack growth rate measurements for low-alloy steels in hydrogen gas

Measurement of the near-threshold fatigue crack growth rate (da/dN) vs. stress-intensity factor range (∆K) relationship in hydrogen gas is essential for maximizing the calculated design fatigue life of high-pressure hydrogen storage vessels. However, such measurements are rarely performed, since the low cyclic loading frequencies applied in standard practice lead to prohibitively protracted test durations. The objective of this study was to demonstrate two means for reducing test durations when measuring near-threshold da/dN vs. ΔK relationships under decreasing ΔK for low-alloy pressure vessel steels in hydrogen gas: 1) imposing steeper K-gradients relative to the recommended limits in standards such as ASTM E647, and 2) increasing cyclic loading frequency relative to typical values applied during fatigue crack growth testing of low-alloy steels in hydrogen gas. Recognizing that steeper K-gradients could amplify loading-history effects, test methods employing this approach were designed to mitigate such effects by either maintaining constant K max or gradually increasing the K-gradient as the threshold was approached. Although the varying K-gradient method was vulnerable to loading-history effects in the form of plasticity-induced crack closure, particularly at lower stress ratio (R) and higher starting K max values, these effects could be compensated by applying the adjusted compliance ratio (ACR) method. Here, it was demonstrated that steeper K-gradients in concert with increased cyclic loading frequency reduced the duration of near-threshold fatigue crack growth tests in hydrogen gas by more than 99% relative to standard practices.

Fatigue threshold↗

DOE OSTI2026

Evolution of storage monitoring – update in response to commercial and regulatory drivers

Carbon Capture and Storage (CCS) is in transition from first-of-a kind projects and research-orientated pilots to commercially-motivated applications. Monitoring results from many newly developed and planned large scale commercial projects are limited; however, it is worthwhile to assess their evolution and consider new strategies as part of an effort to assess and document best practices. Commercial monitoring is targeted to activities that comply with regulatory drivers and de-risk investments. Commercial monitoring also supports accounting that storage has occurred and is tied to project financing. It deals with long time frames and large volumes injected into multiple wells and multiple projects in favorable areas. We see developing trends toward reproducible workflows that systematically reduce risks and clarify expectations for oversight and long-term surveillance. Monitoring techniques showing increasing trends include injection zone pressure as a history-matching and compliance tool. To reduce cost and environmental impact of time-lapse seismic data collection, deploying new approaches and tools, such as use of fibre and installed sources are increasingly applied. Concern over the risk of induced seismicity by regulatory bodies and the general public has increased, which has also resulted in increased monitoring. Some techniques used in the early research phases have been sidelined or used only in restricted applications. For example, geochemical analyses in the injection zone as well as the environment are now being deployed less than it was in research-oriented programs, except in the US where it is required by the permitting process. Expectations of frequent area-wide near surface monitoring have also decreased.

25 ENERGY STORAGE↗

DOE OSTI2025

Development and validation of a software for simulating γ-γ coincidence emission and detection probabilities

Gamma-gamma coincidence spectrometers have the potential to significantly enhance detection sensitivity for ultra-trace radionuclide measurements. The implementation of these spectrometers, however, is limited by the complexity of acquisition hardware, data processing and quantification. This work reports development of a novel radionuclide quantification software for γ-γ coincidence measurements. For any radionuclide, the software parses the Evaluated Nuclear Structure Data File (ENSDF) database, recursively simulating all possible γ-γ coincidence signatures and their respective emission and detection probabilities. Implemented using Python programming language, the software employs several strategies to boost overall computational performance. Since coincidence-based spectrometers are of notable interest in monitoring compliance for the Comprehensive Nuclear-Test-Ban Treaty (CTBT), the software’s execution was tested for 84 CTBT-relevant radionuclides. To date, the software has been experimentally validated for 15 radionuclides using the Advanced Radionuclide Gamma spectrOmeter (ARGO) at Pacific Northwest National Laboratory, USA (PNNL). Notably, the software can be operated in convergence mode, whereby coincidence detection efficiency’s convergence behavior can help avoid unreliable radionuclide activity estimates. With growing number of coincidence spectrometers worldwide, this paper aims to assist the radiation metrology community in developing similar software for their system.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Optimizing a detection system for fissile material in nuclear disarmament verification

In arms control treaties, verification plays a crucial role in detecting non-compliance, deterring future violations, and building trust between state parties. Neutron interrogation that induces fission reactions in fissile isotopes and measures the resulting fission neutrons, could be employed for this purpose. This study aims to develop a system which can determine the presence of fissile material while intrinsically protecting information. In this paper, we focus on optimizing the system for discriminating between an enriched uranium block from a depleted uranium (DU) block. The system was built and we report on benchmark measurements with DU and 16% enriched uranium blocks. Furthermore, the Excalibur (Experiment for Calibration with Uranium) neutron source, a neutron spectrometer (redBubble Technology Industries (BTI) N-Probe), and superheated droplet detectors were used for these measurements. MCNP simulations provided insights into detector responses to fissile materials with varying isotopic compositions, confirming that the system functioned as designed.

Active neutron interrogation↗

DOE OSTI2026

Innovative laser-based methods for monitoring fuel retention in ITER

This paper addresses the challenge of tritium inventory management in ITER and future fusion reactors, highlighting the importance of accurate tritium measurement and its spatial distribution within the vacuum vessel. Given ITER’s operational constraints, especially the limit on tritium retention, precise measurement is essential for both safety and regulatory compliance. To tackle these questions, the paper presents the T-monitor diagnostic system developed by Forschungszentrum Jülich, which uses Laser-Induced Desorption (LID) in combination with Diagnostic Residual Gas Analysis (DRGA) to measure hydrogen isotope concentrations on the surface of divertor tiles. The system integrates a high-power laser, advanced optical components, and a Fast Scanning Mirror Unit (FSMU) for accurate laser spot positioning with rapid response. Designed to measure in situ tritium retention, the diagnostic provides high-resolution spatial mapping, vital for evaluating detritiation strategies. The laser heating process increases the divertor surface temperature to 1600 K within the laser spot, promoting hydrogen isotope desorption. Accurate measurements require the precise control of laser parameters, including pulse duration and spot size, with a target relative accuracy of 20%. The optical design includes both in-vessel and ex-vessel components, such as durable high-reflectivity mirrors made of gold and copper, selected not only for their infrared performance but also for their transmission of visible wavelengths for observation purposes. To protect optical components from contamination, a pneumatic shutter is used.

Hydrogen isotopes↗