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DOE OSTI2023

Deformation mechanisms in an additively manufactured dual-phase eutectic high-entropy alloy

Nanostructured metals and alloys often exhibit high strengths but at the expense of reduced ductility. Through harnessing the far-from-equilibrium processing conditions of laser powder-bed fusion (L-PBF) additive manufacturing, we develop a dual-phase nanolamellar structure comprised of FCC/L1 2 and BCC/B2 phases in a Ni 40 Co 20 Fe 10 Cr 10 Al 18 W 2 eutectic high-entropy alloy (EHEA), which exhibits a combination of ultrahigh yield strength (>1.4 GPa) and large tensile ductility (~17%). The deformation mechanisms of the additively manufactured EHEA are studied via in-situ synchrotron X-ray diffraction and high-resolution transmission electron microscopy. The high yield strength mainly results from effective blockage of dislocation motion by the high density of lamellar interfaces. The refined nanolamellar structures and low stacking fault energy (SFE) promote stacking fault (SF)-mediated deformation in FCC/L1 2 nanolamellae. The accumulation of abundant dislocations and SFs at lamellar interfaces can effectively elevate local stresses to promote dislocation multiplication and martensitic transformation in BCC/B2 nanolamellae. The cooperative deformation of the dual phases, assisted by the semi-coherent lamellar interfaces, gives rise to the large ductility of the as-printed EHEA. In addition, here we also demonstrate that post-printing heat treatment allows us to tune the non-equilibrium microstructures and deformation mechanisms. After annealing, the significantly reduced SFE and thicknesses of the FCC nanolamellae facilitate the formation of massive SFs. The dissolution of nano-precipitates in the BCC/B2 nanolamellae reduces spatial confinement and further promotes martensitic transformation to enhance work hardening. Our work provides fundamental insights into the rich variety of deformation mechanisms underlying the exceptional mechanical properties of the additively manufactured dual-phase nanolamellar EHEAs.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Design, Deployment, and Characterization of the World’s First Flexible Large Power Transformer

As we know, power transformers are the most critical asset of the transmission network. Although highly reliable, they still can fail prematurely or ultimately retire at the end of their service life. In today’s design practices, transformers are tailored to their specific application and therefore cannot replace each other unless identical. Additionally, they provide minimal support to the grid operation and therefore limit the grid flexibility and resiliency when facing severe conditions. In this presentation, we will introduce the concept of flexible power transformer and demonstrate how one single unit can serve as a spare to multiple units in a given fleet, allow to control the power flow between transformers or lines operating in parallel and ultimately be used to limit subsequent faults in transmission lines. We will also introduce the world’s first prototype in operation, a 60MVA, 165kV flexible autotransformer.

flexible power transformer, autotransformer, varia↗

DOE OSTI2024

Property Variations in Modern REBCO Coated Conductors from Multiple Manufacturers

The complex, multilayer structure of REBCO Coated Conductor (CC) poses significant challenges in the fabrication of high magnetic field devices where large stresses may initiate various forms of damage. Our goal is to peer below the cartoon representations of CC so that, amongst other things, we might better understand whether a CC from one manufacturer is interchangeable with that from another. This involves knowledge of a broad range of electromagnetic, geometric, microstructural, and J c (θ,B,T) properties, and their variations that collectively pose challenges for the fault tolerance of REBCO CC devices. Accordingly, comparative measurements of J c , visualization of flux penetration with Magneto-Optical Imaging (MOI), tape geometry from Scanning Electron Microscopy (SEM) of polished cross-sections, and extensive optical microscopy was performed on recently purchased samples from multiple manufacturers. Our analyses reveal many deviations from or characteristics absent from manufacturers’ specifications, while a comparison of different manufacturers’ mechanically and laser slit tapes shows a diverse array of slitting characteristics amongst the manufacturers and variation in properties those made to the same specification. Laser slit tapes from several manufacturers reveal ablated edges with damaged regions extending up to 50 μm, comparable to the damaged region found in the mechanically slit CC of this study. Overall, the aim of this study is to flesh out appropriate ways to understand the real conductor below the manufacturers’ cartoons to avoid surprises in our REBCO CC coil development program. The goal of this work was to perform a broad array of characterizations of the type needed for validation of purpose for making high field magnets: to our surprise we found a wide range of properties which greatly impact the mechanical strength and electromagnetic performance of solenoids composed of these conductors and reinforced the need for a broad characterization program for each conductor prior to its implementation.

Bradford, G.↗

DOE OSTI2024

Analyzing Prospects for Quantum Advantage in Topological Data Analysis

Lloyd [Nat. Commun. , 10138 (2016)] were first to demonstrate the promise of quantum algorithms for computing Betti numbers, a way to characterize topological features of data sets. Here, we propose, analyze, and optimize an improved quantum algorithm for topological data analysis (TDA) with reduced scaling, including a method for preparing Dicke states based on inequality testing, a more efficient amplitude estimation algorithm using Kaiser windows, and an optimal implementation of eigenvalue projectors based on Chebyshev polynomials. We compile our approach to a fault-tolerant gate set and estimate constant factors in the Toffoli complexity. Our analysis reveals that superquadratic quantum speedups are only possible for this problem when targeting a multiplicative error approximation and the Betti number grows asymptotically. Further, we propose a dequantization of the quantum TDA algorithm that shows that having exponentially large dimension and Betti number are necessary, but insufficient conditions, for superpolynomial advantage. We then introduce and analyze specific problem examples which have parameters in the regime where superpolynomial advantages may be achieved, and argue that quantum circuits with tens of billions of Toffoli gates can solve seemingly classically intractable instances. Published by the American Physical Society 2024

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Scalable Circuit Cutting and Scheduling in a Resource-constrained and Distributed Quantum System

Despite quantum computing's rapid development, current systems remain limited in practical applications due to their limited qubit count and quality. Various technologies, such as superconducting, trapped ions, and neutral atom quantum computing technologies are progressing towards a fault tolerant era, however they all face a diverse set of challenges in scalability and control. Recent efforts have focused on multi-node quantum systems that connect multiple smaller quantum devices to execute larger circuits. Future demonstrations hope to use quantum channels to couple systems, however current demonstrations can leverage classical communication with circuit cutting techniques. This involves cutting large circuits into smaller subcircuits and reconstructing them post-execution. However, existing cutting methods are hindered by lengthy search times as the number of qubits and gates increases. Additionally, they often fail to effectively utilize the resources of various worker configurations in a multi-node system. To address these challenges, we introduce FitCut, a novel approach that transforms quantum circuits into weighted graphs and utilizes a community-based, bottom-up approach to cut circuits according to resource constraints, e.g., qubit counts, on each worker. FitCut also includes a scheduling algorithm that optimizes resource utilization across workers. Implemented with Qiskit and evaluated extensively, FitCut significantly outperforms the Qiskit Circuit Knitting Toolbox, reducing time costs by factors ranging from 3 to 2000 and improving resource utilization rates by up to 3.88 times on the worker side, achieving a system-wide improvement of 2.86 times.

Kan, Shuwen [Fordham University]↗

DOE OSTI2021

Adapting Secure MultiParty Computation to Support Machine Learning in Radio Frequency Sensor Networks

In this project we developed and validated algorithms for privacy-preserving linear regression using a new variant of Secure Multiparty Computation (MPC) we call "Hybrid MPC" (hMPC). Our variant is intended to support low-power, unreliable networks of sensors with low-communication, fault-tolerant algorithms. In hMPC we do not share training data, even via secret sharing. Thus, agents are responsible for protecting their own local data. Only the machine learning (ML) model is protected with information-theoretic security guarantees against honest-but-curious agents. There are three primary advantages to this approach: (1) after setup, hMPC supports a communication-efficient matrix multiplication primitive, (2) organizations prevented by policy or technology from sharing any of their data can participate as agents in hMPC, and (3) large numbers of low-power agents can participate in hMPC. We have also created an open-source software library named "Cicada" to support hMPC applications with fault-tolerance. The fault-tolerance is important in our applications because the agents are vulnerable to failure or capture. We have demonstrated this capability at Sandia's Autonomy New Mexico laboratory through a simple machine-learning exercise with Raspberry Pi devices capturing and classifying images while flying on four drones.

42 ENGINEERING↗

DOE OSTI2022

Assessment of the Electrical Substation-Grid Testbed with Inside/Outside Devices and Distributed Ledger Technology

The electrical substation-grid testbed was created to integrate the GOOSE and/or DNP (Distributed Network Protocol) messages with time synchronized sources and Distributed Ledger Technology (DLT). The objective was to study the impact of faults and cyber-events at an electrical substation with inside (protective relays) and outside (power meters) substation devices. The electrical substation-grid testbed was based on the design of a 34.5/ 12.47 kV electrical substation (sectionalized bus configuration) with two power transformers, connected to radial power lines and load feeders. The electrical substation-grid testbed was installed at 252 lab space (Advanced Power System Protection), Grid Research Integration and Deployment Center (GRID-C), Oak Ridge National Laboratory. This testbed was created for Task 5, DarkNet project. The electrical substation-grid testbed was created to simulate fault and/or cyber events that could potentially result in damage to the electrical infrastructure. In addition, tests were run that are usually not allowed to be performed in an operational electrical power grid, because these test scenarios could trip breakers and/or generate fault situations that could potentially damage equipment. The number of tests performed in the electrical substation-grid testbed were executed in a better way than in a real electrical substation and/or power grid, because multiple tests could be run in a short period of time, and complex permits, and safety/ schedule restrictions like in a real electrical substation environment were not needed. The electrical substation-grid testbed was created using real measurement, communication, and protection devices that are used by electrical utilities, to have same conditions that we could observe in a real power grid or electrical substation. The electrical substation-grid testbed was based on using a real time simulator and expansion box with amplifiers that were wired to electrical substation-grid devices. This hardware-in-the-loop (HIL) was provided by protective relays, power meters, ethernet switches, remote terminal units, synchronized timing network clock, DLT devices, workstations, and servers. This report includes the design, installation, and assessment of the electrical substation-grid testbed that was similar to an operational electrical substation, integrating the power system protection, communication, and control systems. The results for the electrical substation-grid testbed were based on:• verifying the analog signals for protective relays and power meters, • observing the synchronized time source frame at devices, • authenticating the GOOSE (IEC 61850) and DNP messages from power meters and protective relays, and • verifying the trip conditions of protective relays at fault tests with the power system fault event detection, using DLT devices. For future work, the electrical substation-grid testbed with protective relays and power meters, using DLT and synchronized time source from DarkNet, will be used to study the impact of cyber-events at inside and outside substation devices. Advanced algorithms for detecting cyber-events produced by non-desired protective relay settings will be studied, to improve the detection and reliability of protection, control, and communication systems at power grids.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Performance and power modeling and prediction using MuMMI and 10 machine learning methods

Energy-efficient scientific applications require insight into how high performance computing system features impact the applications' power and performance. This insight can result from the development of performance and power models. Here, in this article, we use the modeling and prediction tool MuMMI (Multiple Metrics Modeling Infrastructure) and 10 machine learning methods to model and predict performance and power consumption and compare their prediction error rates. We use an algorithm-based fault-tolerant linear algebra code and a multilevel checkpointing fault-tolerant heat distribution code to conduct our modeling and prediction study on the Cray XC40 Theta and IBM BG/Q Mira at Argonne National Laboratory and the Intel Haswell cluster Shepard at Sandia National Laboratories. Our experimental results show that the prediction error rates in performance and power using MuMMI are less than 10% for most cases. By utilizing the models for runtime, node power, CPU power, and memory power, we identify the most significant performance counters for potential application optimizations, and we predict theoretical outcomes of the optimizations. Based on two collected datasets, we analyze and compare the prediction accuracy in performance and power consumption using MuMMI and 10 machine learning methods.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Multi phenomena melt pool sensor data fusion for enhanced process monitoring of laser powder bed fusion additive manufacturing

Finding actionable trends in laser-based metal additive manufacturing process monitoring data is challenging owing to the diversity and complexity of the underlying physical interactions. A single monitoring solution that captures a particular process phenomenon, such as a photodiode that tracks melt pool intensity, is not alone capable of evaluating process stability or detecting flaw formation with sufficient precision for routine application in industry. In this work, to improve flaw detection performance, we adopted a data fusion approach that captures multiple process phenomena. To demonstrate this, we acquired data from laser powder bed fusion (LPBF) builds of cylindrical specimens produced with different laser spot sizes, emulating defocusing due to process faults such as thermal lensing. The resulting specimens had porosity of varying types and severity, quantified by post-build non-destructive X-ray computed tomography, Archimedes density measurements, and destructive metallographic characterization. During the build, the melt pool state was monitored with two coaxial high-speed video cameras and a temperature field imaging system. Physically intuitive low-level melt pool signatures, such as melt pool temperature, shape and size, and spatter intensity were extracted from this high-dimensional, image-based sensor data. These process signatures were subsequently used as input features in relatively simple machine learning models, such as a support vector machine, which were trained to detect laser defocusing, and in addition, predict porosity type and severity. The results show that the data fusion approach significantly enhanced system performance by reducing the overall false positive rate from ~ 0.1 to ~ 0.001 without sacrificing the true positive rate (~0.90). These results were at par with a black-box, deep machine learning approach (convolutional neural network).

36 MATERIALS SCIENCE↗

DOE OSTI2023

Grid Strength Assessment for High Levels of Inverter-based Resources in the Puerto Rico Power

A system-wide assessment of the Puerto Rico power system grid strength is studied when considering high levels of inverter-based resource penetration. This study is carried out in PSSE and assesses the impact of inverter-based resource (IBR) contributions in response to three-phase ground faults. A hypothetical 100% inverter-based generation scenario is created to assess the extreme impact on short circuit levels and a realistic scenario is considered to assess the impact to short circuit ratios. The overall conclusion is that short circuit capacity and current will drastically decrease in a high IBR scenario, an effect that is quantified in this paper. The short circuit ratio metric is typically used to assess the impact of IBR but generally overestimates grid strength due to not accounting for the impact from multiple IBRs. Other methods such as equivalent circuit based short circuit ratio and weighted short circuit ratio offer a more comprehensive consideration for multiple IBRs and can better account for their mutual interactions. The work presented in this paper is part of the PR100 study.

inverter based resources, PR100, grid strength↗

DOE OSTI2025

Precursory Locking Precedes Slip Events on Laboratory Fault

Earthquakes occur through repeated cycles of locking and slip. What is the relationship between transiently locked patches and the size, location, and timing of the subsequent slip events? Here we use an experimental fault made of transparent rubber to image the slip history of over 18,000 events. The soft elastic system allows for contained ruptures and thus a natural evolution of stress heterogeneity over multiple earthquake cycles. We observe a precursory locking phase preceding slip nucleation for events of all sizes. The integrated locking distance increases linearly with the moment of the eventual event. The most intense (largest slip deficit) locking events are spatially and temporally correlated with the hypocenters of the largest rupture events. These results show that the transient locking is statistically, but not deterministically, predictive of the location, timing, and size of the eventual slip event.

earthquakes↗

DOE OSTI2026

A Cryogenic Muon Tagging System Integrated with a Superconducting Qubit Device for Radiation-Induced Error Mitigation

Superconducting qubits are highly sensitive to ionizing radiation, which can induce correlated errors and limit scalable fault-tolerant quantum computing. In particular, cosmic-ray muons can deposit energy in the substrate, generating phonon bursts that break Cooper pairs and produce quasiparticles, leading to correlated decoherence events across multiple qubits. We present the development of a cryogenic muon tagging system based on Kinetic Inductance Detectors (KIDs) and its integration with superconducting quantum hardware. Originally developed within the ACE-SuperQ project and validated as a standalone detector, the system demonstrated a muon tagging efficiency of approximately 90% and excellent agreement with Monte Carlo simulations. Building on this validation, the tagging system has been integrated with a multi-qubit superconducting chip operated in a dilution refrigerator. The detector configuration consists of a multi-layer KID stack arranged above and below the quantum device, enabling time-coincident identification of muon-induced events within the same cryogenic environment. The integrated setup has been successfully commissioned, enabling simultaneous operation of the qubit chip and the muon tagging system. A first measurement campaign has been carried out, and preliminary data show time-correlated events between the muon tagging detectors and the qubit readout. A quantitative analysis of radiation-induced effects on qubit performance is currently ongoing. This work represents a step toward the implementation of event-level radiation tagging as a tool for characterizing and potentially mitigating correlated errors in superconducting quantum processors, while establishing a modular platform for future studies at the interface between particle physics and quantum information science.

Roy, Tanay [Fermilab] (ORCID:000000019442862X)↗

DOE OSTI2023

Blockchain for Fault-Tolerant Grid Operations Version 2.0

This report explores the potential of distributed ledger technology (DLT) as a transformative tool to enhance fault-tolerant operations in electrical distribution systems. Leveraging DLT's core attributes, including an immutable decentralized ledger, distributed consensus mechanisms, and state replication capabilities, this study focuses on three critical use cases. A central aspect of this research centers on the utilization of a consensus-driven ledger, providing actors within the system, such as distributed resources, with access to a reliable data repository. This empowers these actors to collaborate effectively and make informed decisions, all securely recorded on the blockchain. The first use case concentrates on data configuration, utilizing mathematical criteria---particularly, the chi-squared test for gross error detection---to identify trustworthy sensors for advanced decision-making. Building upon this foundation of trust, the second use case, topology identification, accurately determines circuit breaker states, unveiling the distribution network's topology. Ultimately, the third use case leverages this trust to execute switching actions, reconfiguring feeders and restoring power to disconnected customers after fault events. The concept of trust serves as a cornerstone in this approach, marking a departure from traditional fault location, isolation, and service restoration (FLISR) methods. Additionally, the blockchain-based architecture introduces decentralization, empowering disconnected areas to make autonomous decisions, even when communication with a central control center is disrupted. The primary contributions of this report are twofold: (1) a novel approach for evaluating distribution system voltage areas while preserving data ownership and (2) the implementation of interactions between distribution network areas using the actor model. Unlike the previous sequential approach for evaluating the area connection voltages, which required a radial network topology, this study's area model reduction enables a more versatile approach. The area model reduction addresses issues of prolonged data waiting times and multiple points of failure within the previous approach. Notably, the presented evaluation for the reduced network model area connection reveals a significant increase in the differences in voltage magnitudes. Simulation and evaluation of area agents across four distinct cases elucidate the area-level interaction behavior during a fault event. Simulations demonstrate that the proposed distributed FLISR (DFLISR) approach can successfully restore service to an affected area. Varying message delays and message loss probabilities in each simulation case underscore their impacts on restoration times, ranging from 3 min and 32 s to 6 min and 19 s. In contrast, power is not restored in an area in one of our simulation cases.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

EMT Models to Evaluate Traveling Wave-Based Protection in Distribution System

The distribution system is going through significant changes. One of them is the high penetration of inverter-based distributed energy resources in the distribution system. Due to this high penetration, there is a need for a better protection system. Multiple organizations are working on creating novel protection techniques for distribution systems with high penetration of inverter-based DERs. One such innovative method is the use of traveling waves to detect and locate faults. Transmission system protection utilizes this approach, and commercial solutions exist for the transmission system. Using this approach in the distribution system is not straightforward and presents some challenges for implementation. This presentation will discuss the need for using wide-band models to model the traveling wave phenomenon in the distribution system.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2020

Semantic Interoperability to Enable Smart, Grid-Interactive Efficient Buildings

Achieving a widespread transition to grid-interactive, efficient buildings (GEBs) depends critically on there being sufficient interoperability among connected building systems. While many critical elements already exist at the technical interoperability level (TCP/IP, BACnet, etc.), a lack of interoperability in the semantic level hinders streamlined integration of interdependent applications. Semantics refers to expressing information about “things” in a way that can be consistently understood by applications. Key components of formalized semantics include identifying what a “thing” is (its “type”), defining general information about that “thing” (its characteristics or properties), and defining the appropriate relationships of that “thing” to other “things” (its function or role in a larger system). Although this might seem initially trivial, the success of smart building applications is highly dependent on maintaining consistent self-descriptive notions of the “things”. Without semantic interoperability, it is technically difficult, labor-intensive, and cost-prohibitive to enable three key objectives of GEBs: optimizing performance, automatically identifying and diagnosing faults, and delivering grid services. Industry, academia, and standards bodies have invested effort in developing information models to facilitate semantic interoperability, however, they have not been widely adopted across the U.S. commercial building portfolio. This paper will present a pathway to drive semantic interoperability through a three-pronged approach to be led by the DOE Building Technologies Office in partnership with NIST and multiple national laboratories comprising: 1) industry engagement and coordination across existing efforts; 2) a semantic interoperability standard that empowers building owners to identify and require interoperable attributes when procuring equipment and applications; 3) tools to assist in implementation and a test framework to verify compliance of products with semantic interoperability specifications. This approach is designed to accelerate the timeline for adoption of semantic interoperability specifications. The intent is to reduce soft costs associated with implementing advanced controls, fault detection and diagnostics, and other smart building technologies and use cases as a necessary step in achieving an energy efficient smart grid future.

Bergmann, Harry↗

DOE OSTI2020

Semantic Interoperability to Enable Smart, Grid-Interactive Efficient Buildings

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2025

A Two-Stage Current Limiting Control Strategy for Direct-Droop-Controlled Grid-Forming Inverters

This paper presents a two-stage current limiting control strategy with fault ride-through capability for the direct-droop-controlled grid-forming (GFM) inverters. The proposed approach comprises Stage 1 and Stage 2 current limiting controls. During faults, Stage 1 current limiting control instantly clamps the inverter output current magnitude to its maximum transient limit by blocking the switching pulses to the insulated-gate bipolar transistors (IGBTs) with the help of a hysteresis loop control, and Stage 2 current limiting control limits the inverter output current magnitude to its steady-state limit by regulating the amplitude and frequency of the modulating waveform utilizing the active and reactive current limiting control loops. By implementing the current limiting actions in two stages, this approach can effectively limit the over-current within a few cycles after the fault occurrence and ensure synchronism to the grid after long-term fault events. The efficacy of the proposed control approach is validated through electromagnetic transient (EMT) simulation results conducted on a single GFM inverter-based test system and the IEEE 39-bus test system with multiple GFM inverters in the PSCAD platform.

Mohiuddin, Sheik Mohammad↗

DOE OSTI2026

ML–Enabled FPGA Framework for Fast Quantum State Discrimination in Mid-Circuit Measurement Regimes

Accurate and low-latency quantum state discrimination is essential for protocols involving mid-circuit measurement (MCM) and conditional feed-forward. In superconducting quantum systems, conventional readout pipelines transfer measurement data to host processors for post-processing, introducing millisecond-scale delays that far exceed qubit coherence times. To overcome this bottleneck, we present an in-situ machine learning (ML) inference engine implemented on an FPGA for real-time quantum state discrimination. Our design performs inference directly on digitized readout signals with 40 ns latency, supports both qubit and qutrit readout, and enables conditional operations without host-side intervention. This capability is critical for MCM and for feedback-driven protocols such as quantum error correction. We validate the system on superconducting transmon hardware, demonstrating robust discrimination fidelity across multiple qubit and qutrit channels. We further demonstrate conditional qutrit logic driven by FPGA-resident classification, highlighting the potential of low-latency ML-on-FPGA control for NISQ applications and scalable fault-tolerant quantum computing.

Vora, Neel [Lawrence Berkeley National Laboratory ↗