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DOE OSTI2022

Physics-Informed and Data-Driven Prediction of Residual Stress in Three-Dimensional Machining

Efficient and reliable prediction of machining-induced residual stress (RS) is a key requirement for truly integrated computational materials engineering (ICME). Currently available process modeling approaches, including empirical, analytical, and numerical methodologies lack predictive power and require substantial calibration and validation data. Moreover, most model-based approaches consider only two-dimensional (2D) (i.e., orthogonal), cutting processes. Meanwhile, industrial processes such as milling, turning, and drilling are inherently three-dimensional (3D). The present work attempts to bridge the gap between 2D and 3D through careful consideration of the process physics, including geometric, kinematic, and size-effect constraints to realize robust prediction of how RS develops in 3D machining. Using a novel in-situ experimental technique and digital image correlation (DIC) to determine equivalent Hertzian contact widths, contact pressures, and friction coefficients, the proposed methodology leverages a discretized conversion algorithm that includes multi-pass shakedown effects. This paper presents a semi-analytical model to predict machining-induced RS in 3D turning operations, which are used representatively for 3D processes more generally. Rather than follow a ‘brute force’ 3D FEM approach or conduct countless experiments to train a purely data-driven machine learning algorithm, the proposed approach builds on previous 2D modeling work. Through careful consideration of the process physics, including complex geometry/kinematic considerations of 3D turning, the authors demonstrated an experimentally calibrated approach, as well as validation based on published RS data. Model predictions and previously published measurement data of RS depth profiles for turning of Inconel 718 were compared for a range of process parameters. Correlation between the proposed 3D model and validation data was found to be within the margin of experimental error for most conditions. The proposed model appears to capture the overall behavior of 3D RS depth profiles with acceptable accuracy, particularly the key metrics of near-surface stress, peak stress magnitude and location, as well as overall stress profile depth. This report presents a physics-informed, data-driven approach for efficient calibration of a 2D model for machining-induced RS through DIC analysis of in-situ characterized subsurface displacement fields.

42 ENGINEERING↗

DOE OSTI2025

The influence of V-defects, leakage, and random alloy fluctuations on the carrier transport in red InGaN MQW LEDs

Red InGaN-based light-emitting diodes (LEDs) exhibit lower internal quantum efficiencies than violet, blue, and green InGaN LEDs due to a reduction in radiative recombination rates relative to non-radiative recombination rates as the Indium composition increases. Additionally, the larger polarization and band offset barriers between high indium content InGaN quantum wells and GaN quantum barriers increase the forward voltage. In blue and green LEDs, random alloy fluctuations and V-defects play a key role in reducing the forward voltage. When V-defects are present, either naturally or intentionally introduced, they create an alternative path for carrier injection into the MQWs through the V-defect sidewalls. This injection mechanism explains the turn-on voltages of green LEDs. However, in InGaN red LEDs, these two phenomena do not reduce the forward voltage as effectively as in blue and green LEDs, and consequently, the computed forward voltage remains significantly higher than the measured one. Furthermore, currents are observed at low voltages before the turn-on voltage (V<ℏω/e=2.0 V) of red LEDs. To address this, we introduce dislocation-induced tail states in the modeling, suggesting that leakage current through these states may play a significant role both below and at turn-on voltages. The simulation also indicates that leakage carriers below turn-on accumulate, partially diffuse in the QWs, screen the polarization-induced barrier in the low injection regime, and further reduce the forward voltage. Despite these beneficial effects, a drawback of dislocation-induced tail states is the enhanced nonradiative recombination in the dislocation line region. This study provides a detailed analysis of device injection physics in InGaN QW red LEDs and outlines potential optimization strategies.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2022

Novel Quadratic High Gain Boost Converter With Adaptive Soft-Switching Scheme and Reduced Conduction Loss

In this article, an improved soft-switching quadratic boost converter is proposed. Instead of inserting an additional active clamp or auxiliary zero-voltage transition circuit at the switching node, the proposed topology connects the high-voltage switching node to the input diode node by replacing one of the input diodes with a low-rated switch. The proposed topology can attain soft-switching condition for all the switches and input diode turns- off under zero-current switching (ZCS). The operation of input-side switch not only aids zero-voltage switching (ZVS) turn- on for the main switch but also helps in reducing the conduction loss. Also, the input-side switch operates under ZCS turn- on and ZVS turn- off , making it a loss economical solution. An adaptive timing scheme for driving the input switch is proposed, which can ensure soft-switching condition under varying gain and load range. The detailed operational modes, analysis, and design considerations of the proposed topology are presented. A 250 W hardware prototype is built to validate the performance of the proposed converter operating at 100 kHz switching frequency. Results with adaptive soft-switching scheme shows that the converter is modulated to achieve its best efficiency condition under various system conditions. Furthermore, a peak efficiency of 96.1% at 155 W and efficiencies above 95.75% over a wide load range are achieved using all Si devices.

14 SOLAR ENERGY↗

DOE OSTI2022

Hybrid Voltage Balancing Approach for Series-Connected SiC MOSFETs for DC–AC Medium-Voltage Power Conversion Applications

Not provided.

Engineering↗

DOE OSTI2023

Grounding our Understanding of the Impacts of Boreal Forest Expansion on Shallow Cumulus Clouds with a Simple Modeling Framework

Abstract The expansion of the boreal forest poleward is a potentially important driver of feedbacks between the land surface and Arctic climate. A growing body of work has highlighted the importance of differences in evaporative resistance between different possible future Arctic land covers, which in turn alters humidity and cloudiness in the boundary layer, for these feedbacks. While thus far this problem has been studied primarily with complex Earth system models, we turn to a locally focused, idealized model capable of diagnosing and testing the sensitivity of first-order processes connecting vegetation, the atmospheric boundary layer, and low clouds in this critical region. This allows us to benchmark the mechanisms and results at the center of predictions from larger-scale simulations. A surface dominated by broadleaf trees, characterized by higher albedo and lower surface evaporative resistance, drives cooling and moistening of the boundary layer relative to a surface of needleleaf trees, characterized by lower albedo and higher surface evaporative resistance. Differences in evaporative resistance between these hypothetical Arctic vegetation covers are of equal importance to changes in albedo for the initial response of the boundary layer to boreal expansion, even with our idealized approach. However, compensation between the elevation of the lifting condensation level (LCL) and more rapid growth of the mixed layer over higher evaporative resistance surfaces can minimize changes in the favorability of shallow clouds over different land cover types under some conditions. We then perform two tests on the sensitivity of this compensating effect, to changes in water availability, represented first by a reduction in boundary layer humidity and then by both a reduction in humidity and soil moisture available to our vegetation surface. Finally, given the importance of this potential LCL–mixed-layer height compensation in our idealized modeling results, we look to determine its relevance in observational data from a field campaign in boreal Finland. These observations do confirm that such a coupling plays an important role in cumulus-topped boundary layers over a needleleaf forest surface. While our results confirm some underlying mechanisms at the center of prior work with Earth system models, they also provide motivation for future work to constrain the impact of boreal forest expansion. This will include both large eddy simulations to examine the impact of processes and feedbacks not resolved by a mixed-layer model, as well as a more systematic evaluation and comparison of relevant observations at the site in Finland and sites from prior boreal field campaigns. Significance Statement Clouds and vegetation are both important components of the climate system that interact across a range of scales. These interactions are central to understanding how changes at the land surface feedback on climate. For example, if a forest expands or recedes, diagnosing how that will impact clouds will determine whether you predict warming or cooling temperatures from that shift in the forest area. These predictions are often made with complex Earth system models, but we look to a more idealized representation of the land–atmosphere system to diagnose how shallow clouds should respond to changes in surface properties with different scenarios of boreal forest expansion at a more foundational level. This both grounds our understanding of previous analysis and provides helpful direction for future studies of this relevant and impactful land cover change.

Meteorology & Atmospheric Sciences↗

DOE OSTI2021

Multiplexer System for the SPEAR3 Booster BPM Upgrade

BPM measurements in booster synchrotrons are often only critical during accelerator commissioning or when a problem occurs. As a result, many facilities do not make large investments in booster BPM signal processors; they either have very few BPMs and/or use older generation processors. The SPEAR3 booster BPM processor system, for instance, has operated since 1990 with commercial multiplexers to switch between BPM button signals into a single dated analog BPM processor that was developed at SLAC*. This system has reached its end-of-life so we are in the process of upgrading to modern multiplexers that feed a pair of turn-by-turn Libera SPARK-ERXR processors. This low-cost solution gives us the ability to arbitrarily multiplex between BPM signals during the energy ramp with modern BPM processors. The system can either measure 2 BPMs turn-by-turn in parallel during the entire energy ramp, or sequentially measure all BPMs (2 at a time) at different time slices within the ramp. Here we show measurements of the MiniCircuits switch we chose as well as our architecture for the upgrade.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2023

Modeling of standing wave RF cavities for tracking through multi-pass energy recovery linac

Short bunches, high current and multiple linac pass are all characteristics of Energy Recovery Linacs (ERLs), which may result in collective effects. They in turn, may affect the beam, degrading its quality, or even yield to instabilities causing a beam loss. To study and mitigate these effects one needs a numerical simulation code, that can take into account both the collective effects, as well as, particular ERL features, such as a multi-turn design that does not reach a steady state or the multiple passages of the beam through Radio-Frequency (RF) cavities at different energies. CODAL [1], a code developed by SOLEIL in collaboration with IJCLab, enables such studies. It is a 6 dimensional (6D) tracking code applying 'kicks' based on the integration of the local Hamiltonian for each element of the lattice. It is also capable of simulating space charge, wakefields and coherent synchrotron radiation. However, to correctly take into account the ERL dynamics, an upgrade had to be made to include the effect of a standing wave RF cavity in 6D. In this paper, we will concentrate on the implementation and benchmarking (with DESY’s tracking code ASTRA [2]) of both the longitudinal and the transverse models (by J.B. Rosenzweig and L. Serafini [3]), which we use to carry out tracking of fully analytical 6D RF cavity.

Bogacz, A.↗

DOE OSTI2025

An extraction scheme for future CEBAF FFA based energy upgrade

Jefferson lab is considering an energy increase from current 12 GeV to 22 GeV for its CEBAF accelerator. This will be accomplished by recirculating 5-6 additional turns through two parallel CEBAF LINACs using an FFA arc at each end of the racetrack. The total recirculation turns would be 10 times, the first four turns use present conventional arcs to make the 180-degree bends from one LINAC to the other. However, the last 5-6 turns will all share a single beam line inside two FFA arcs. This reduces the footprint and the cost of the project significantly. On the other hand, having the trajectories of last 5-6 recirculating beams close to each other makes it challenging to extract beams from different passes with different energies. In this paper we will explain our present extraction system for 12 GeV, our challenges and limitations, and a possible extraction solution for the 22 GeV upgrade with the goal of extracting beam at different turns/energies to different experimental halls.

Accelerator Physics↗

DOE OSTI2024

Extraction scheme for future CEBAF FFA based energy upgrade

Kazimi, Reza↗

DOE OSTI2025

Design and Fabrication of a Thyristor Using Ion Implantation of Anode and Cathode

A thyristor is a solid-state semiconductor switch made up of four alternating p and n type layers. When the switch is turned on by a small pulse, current can flow as long as the device stays on. When the voltage drops below the turn on level or the current reverses, the switch will turn off. Thyristors only allow current to flow in one direction. One of the benefits of a thyristor device is in its capacity to conduct large voltages with a small device and a small turn-on pulse requirement. Another distinguishing feature of thyristors compared to other semiconductor devices is that it can only be in the on or off state, there’s no in-between state for the device to exist within. These properties make thyristors very useful as switch devices, especially in applications where current flow is only needed in one direction and could potentially be damaging in the opposite direction. Currently, thyristors are most commonly used to control very high power loads and they are available commercially in many designs to control different amounts of current.

42 ENGINEERING↗

DOE OSTI2025

Evaluating Variable-Impedance Magnetically-Insulated Transmission Lines as a Risk-Mitigation Measure for Next-Generation Pulsed Power

This project has produced the first detailed characterizations of power flow resulting from applying the “variable-impedance MITL” concept to real-life systems in Sandia’s pulsed power program (Z and next-generation pulsed power (NGPP)). We present simulation results and analyses for constant-impedance versions of both Z and NGPP and survey the operational viability of several variable-impedance re-designs in the parameter space of linear tapers. Circuit modeling (SCREAMER/Bertha) was used to pinpoint promising candidate designs, and EM-PIC (Empire) simulations were used to evaluate these candidates more rigorously. This approach was particularly successful in the Z regime which resulted in the identification of several viable variable-impedance MITL designs for each level. The approach was more challenged in the operating space NGPP occupies, producing data points that speak to a more restrictive design space due to anode plasma turn-on. In the end, we were able to converge on one viable variable-impedance design for the highest inductance line (level “F”) and one for the highest current line (level “A”). Altogether, the body of simulation evidence presented in this report suggest there does exist flexibility in operating space for magnetically-insulated transmission lines (MITLs) having variable geometric impedance to be a potential enabling technology for safely increasing current delivery (and potentially lowering stack voltage) in pulsed-power drivers by manipulating electron losses; however, operating points for a particular design must be carefully screened. Circuit and EM-PIC modeling provided consistent verdicts in safe operating regimes for operational viability, but additional physics such as anode plasma turn-on which is included in Empire but not in SCREAMER/Bertha was found to be a critical factor affecting power flow that lead to different assessments between the codes. It is not always the case that the occurrence of anode plasma caused a design to fail (some designs turned on anode plasma yet still delivered load currents meeting design targets); the details matter such as how early in the pulse anode surfaces break down (and how large a region). However, in every case that it did fail it was found that the feedback from anode plasma was the cause (i.e., turning off the anode plasma model in Empire restored agreement with the circuit model prediction). As circuit simulations represent an efficient and practical means of surveying design space compared to more computationally-expensive approaches such as EM-PIC, it could be prudent to invest in the research and development of models to include the effects of anode plasma such as ion emission in circuit codes. The variable-impedance MITL design is a new concept that enables controlled manipulation of the initial electron losses in the outer MITL and can be tested on Z today. We encourage follow-on work to explore further optimization (including alternative variable-impedance profiles, e.g., having constant dZ/dR), and to confirm the major findings presented in this report by fielding test hardware on actual Z shots.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Changing-look Active Galactic Nuclei from the Dark Energy Spectroscopic Instrument. I. Sample from the Early Data

Changing-look active galactic nuclei (CL AGNs) can be generally confirmed by the emergence (turn-on) or disappearance (turn-off) of broad emission lines (BELs), associated with a transient timescale (about 100 ~ 5000 days) that is much shorter than predicted by traditional accretion disk models. We carry out a systematic CL AGN search by crossmatching the spectra coming from the Dark Energy Spectroscopic Instrument and the Sloan Digital Sky Survey. Following previous studies, we identify CL AGNs based on Hα, Hβ, and Mg ii at z ≤ 0.75 and Mg ii, C iii], and C iv at z > 0.75. We present 56 CL AGNs based on visual inspection and three selection criteria, including 2 Hα, 34 Hβ, 9 Mg ii, 18 C iii], and 1 C iv CL AGN. Eight cases show simultaneous appearances/disappearances of two BELs. We also present 44 CL AGN candidates with significant flux variation of BELs, but remaining strong broad components. In the confirmed CL AGNs, 10 cases show additional CL candidate features for different lines. In this paper, we find: (1) a 24:32 ratio of turn-on to turn-off CL AGNs; (2) an upper-limit transition timescale ranging from 330 to 5762 days in the rest frame; and (3) the majority of CL AGNs follow the bluer-when-brighter trend. Our results greatly increase the current CL census (~30%) and would be conducive to exploring the underlying physical mechanism.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2021

Rolled-up electromagnetic component for on-chip applications and method of making a rolled-up electromagnetic component

A rolled-up electromagnetic component for on-chip applications comprises: a multilayer sheet in a rolled configuration comprising at least one turn about a longitudinal axis; a core defined by a first turn of the rolled configuration; and a soft magnetic material disposed within the core, where the multilayer sheet comprises a conductive pattern layer on a strain-relieved layer. A method of making a rolled-up electromagnetic component for on-chip applications includes forming a rolled-up device comprising: a multilayer sheet in a rolled configuration having at least one turn about a longitudinal axis, where the multilayer sheet comprises a conductive pattern layer on a strain-relieved layer; and a core defined by a first turn of the rolled configuration. The method further includes introducing a soft magnetic material into the core.

Li, Xiuling↗

DOE OSTI2019

Diverse Antibody Responses to Conserved Structural Motifs in Plasmodium falciparum Circumsporozoite Protein

Malaria vaccine candidate RTS,S/AS01 is based on the central and C-terminal regions of the circumsporozoite protein (CSP) of P. falciparum. mAb397 was isolated from a volunteer in an RTS,S/AS01 clinical trial, and it protects mice from infection by malaria sporozoites. However, mAb397 originates from the less commonly used VH3-15 germline gene compared to the VH3-30/33 antibodies generally elicited by RTS,S to the central NANP repeat region of CSP. The crystal structure of mAb397 with an NPNA4 peptide shows that the central NPNA forms a type I β-turn and is the main recognition motif. In most anti-NANP antibodies studied to date, a germline-encoded Trp is used to engage the Pro in NPNA β-turns, but here the Trp interacts with the first Asn. This “conserved” Trp, however, can arise from different germline genes and be located in the heavy or the light chain. Variation in the terminal ψ angles of the NPNA β-turns results in different dispositions of the subsequent NPNA and, hence, different stoichiometries and modes of antibody binding to rsCSP. Diverse protective antibodies against NANP repeats are therefore not limited to a single germline gene response or mode of binding.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

Macrocyclic β‐Sheets Stabilized by Hydrogen Bond Surrogates

Abstract Mimics of protein secondary and tertiary structure offer rationally‐designed inhibitors of biomolecular interactions. β‐Sheet mimics have a storied history in bioorganic chemistry and are typically designed with synthetic or natural turn segments. We hypothesized that replacement of terminal inter‐β‐strand hydrogen bonds with hydrogen bond surrogates (HBS) may lead to conformationally‐defined macrocyclic β‐sheets without the requirement for natural or synthetic β‐turns, thereby providing a minimal mimic of a protein β‐sheet. To access turn‐less antiparallel β‐sheet mimics, we developed a facile solid phase synthesis protocol. We surveyed a dataset of protein β‐sheets for naturally observed interstrand side chain interactions. This bioinformatics survey highlighted an over‐abundance of aromatic–aromatic, cation‐π and ionic interactions in β‐sheets. In correspondence with natural β‐sheets, we find that minimal HBS mimics show robust β‐sheet formation when specific amino acid residue pairings are incorporated. In isolated β‐sheets, aromatic interactions endow superior conformational stability over ionic or cation‐π interactions. Circular dichroism and NMR spectroscopies, along with high‐resolution X‐ray crystallography, support our design principles.

Chemistry↗

DOE OSTI2023

Understanding the Breakdown Behavior of Ultrawide-Bandgap Boron Nitride Power Diodes Using Device Modeling

Herein, a device study using technology computer-aided design simulation to theoretically analyze the electrical performance of ultrawide-bandgap boron nitride (BN)-based vertical junction devices is performed, including h-BN Schottky diode, h-BN pn diode, and h-BN/AlN pn diode; this is also the first demonstration of the BN power devices in simulation. The material properties of BN are defined with recently reported data, and the physical mechanisms of the device performance are systematically investigated. Additionally, the h-BN junctions in this simulation shows excellent performance, especially for breakdown behaviors. Schottky diode shows a turn-on voltage of 0.6 V for Pt Schottky contact and breakdown voltages over 450 V for 5 μm, 6 × 10 15 cm –3 p-type-doped drift layer; The h-BN pn diode shows a turn-on voltage of 6 V and breakdown voltages over 3 kV with a critical electric field of 13.6 MV cm –1 for 2.5 μm, 2 × 10 16 cm –3 p-type-doped drift layer. The h-BN/AlN heterojunction pn diode shows a turn-on voltage of 5.8 V and breakdown voltage over 2 kV for 2.5 μm, 2 × 10 16 cm –3 n-type-doped AlN drift layer. Herein, an understanding of the device principles of vertical BN junctions is provided, which can serve as a reference for the future development of robust BN power electronics.

36 MATERIALS SCIENCE↗

DOE OSTI2022

The Rule of Thirds: Controlling Junction Chirality and Polarity in 3D DNA Tiles

The successful self-assembly of tensegrity triangle DNA crystals heralded the ability to programmably construct macroscopic crystalline nanomaterials from rationally-designed, nanoscale components. This 3D DNA tile owes its “tensegrity” nature to its three rotationally-stacked double helices locked together by the tensile winding of a center strand segmented into 7 base pair (bp) inter-junction regions, corresponding to two thirds of a helical turn of DNA. All reported tensegrity triangles to date have employed [Z + 2/3] turn inter-junction segments, yielding right-handed, antiparallel, “J1” junctions. Here, we report here a minimal DNA triangle motif consisting of 3-bp inter-junction segments, or one third of a helical turn. Here, we find that the minimal motif exhibits a reversed morphology with a left-handed tertiary structure mediated by a locally-parallel Holliday junction—the L1 junction. This parallel junction yields a predicted helical groove matching pattern that breaks the pseudosymmetry between tile faces, and the junction morphology further suggests a folding mechanism. We identify a Rule of Thirds by which supramolecular chirality can be programmed through inter-junction DNA segment length. These results underscore the role that global topological forces play in determining local DNA architecture and ultimately point to an under-explored class of self-assembling, chiral nanomaterials for topological processes in biological systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

A new tubular ironless linear induction motor using non-interrupted winding method

The ironless linear induction motor device can be used for any application which requires a large motion span or rotation restrictedly by the ironless feature due to the strong magnetic field environment. One of the possible applications is ITER diagnostics shutters. The tokamak reactor systems have a severe radiation issue during the operation. The traditional Kapton-insulated wires have significantly lower radiation resistance than an expected large radiation dose at ITER Motion Stark Effect (MSE) shutter location. Furthermore, the traditional single-sided linear induction motor winds the wire to make the N-turn pitch coils independently and then connect them in series to make a one-phase winding. Therefore, it is a big challenge to make so many radiation-protection connectors in such a limited space as inside the vacuum vessel of fusion reactors. The approved mineral-insulated kinds of cables need a large bend radius for the end turns, so the traditional single-sided linear motor with two-layer three-phase windings need to be upgraded to the tubular linear motors. The new proposed tubular ironless linear induction motor can not only overcome the large bend radius issue with the mineral-insulated cables but also allow the motor coils wound continuously around the tubular-shaped stator, forward and backward N times to make a N-turn winding for each phase, in order to resolve the radiation protection issue with the winding connection. The 3D transient Maxwell electromagnetic model with a tubular three-phase linear induction motor has been analyzed. Furthermore, this paper will present the detailed design and winding method of ironless linear induction motor actuators, and results of the 3D transient numerical simulation of the actuator performance.

Ironless↗