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DOE OSTI2025

Post-build stress-relief optimization for laser powder bed fusion 316H stainless steel

Nuclear energy remains a critical component of a diversified and efficient energy portfolio, offering reliable, high-capacity, and low-carbon power. However, in the U.S., aging infrastructure and the slow qualification and deployment of advanced materials and manufacturing techniques hinder progress in next-generation reactor technologies. This study explores the application of laser powder bed fusion (LPBF) additive manufacturing for stainless steel 316H, with a focus on optimizing post-build heat treatments to enhance material properties for high-temperature nuclear applications. The research targets the optimization of stress-relief temperatures to alleviate postbuild residual stresses, ensuring improvements in the microstructural corelated properties. A series of microstructural and mechanical evaluations were performed on LPBF-printed SS-316H samples which were subjected to annealing at temperatures varying between 650 °C and 850 °C. X-ray diffraction, scanning electron microscopy, and transmission electron microscopy analyses revealed that increasing the heattreatment temperature accelerated dislocation recovery. Vickers microhardness measurements showed an initial reduction in values, followed by stabilization over extended durations at all the temperatures. While higher temperatures facilitated faster recovery, they also promoted carbide precipitation along grain and solidification cell boundaries, narrowing the safe processing window. In contrast, heat treatment at 650°C preserved the cellular substructure and enabled controlled carbide precipitation over time. In conclusion, these findings highlight the importance of time–temperature optimization and suggest that 650°C for up to 2 h provides the most favorable balance between recovery and carbide control for a stress-relief treatment.

316 stainless steel↗

DOE OSTI2026

Sequence-Structure–Property Relationships in Short-Chain Polyesters: How Primary Structure Governs Macroscopic Performance

While polymer properties are fundamentally linked to their nanostructure, the influence of monomer sequence remains less understood than stereochemical factors like tacticity. This study examines how sequence distribution affects the thermal behavior and morphology of homo- and copolyesters, specifically comparing polymers derived from constitutionally identical monomers but with varying degrees of sequence regularity depending on monomer structure or polymerization selectivity. Our findings show that increasing sequence defects progressively diminish thermal stability, crystallinity, melting temperatures, and morphological order. As new materials become more compositionally complex, this work underscores the importance of sequence control in the design of advanced polymers for emerging applications.

Bocharova, Vera [Oak Ridge National Laboratory (OR↗

DOE OSTI2025

Room-temperature multiferroicity in sliding van der Waals semiconductors with sub-0.3 V switching

The search for van der Waals (vdW) multiferroic materials has been challenging but also holds great potential for the next-generation multifunctional nanoelectronics. The group-IV monochalcogenide, with an anisotropic puckered structure and an intrinsic in-plane polarization at room temperature, manifests itself as a promising candidate with coupled ferroelectric and ferroelastic order as the basis for multiferroic behavior. Unlike the intrinsic centrosymmetric AB stacking, we demonstrate a multiferroic phase of tin selenide (SnSe), where the inversion symmetry breaking is maintained in AA-stacked multilayers over a wide range of thicknesses. We observe that an interlayer-sliding-induced out-of-plane (OOP) ferroelectric polarization couples with the in-plane (IP) one, making it possible to control out-of-plane polarization via in-plane electric field and vice versa. Notably, thickness scaling yields a sub-0.3 V ferroelectric switching, which promises future low-power-consumption applications. Furthermore, coexisting armchair- and zigzag-like structural domains are imaged under electron microscopy, providing experimental evidence for the degenerate ferroelastic ground states theoretically predicted. Non-centrosymmetric SnSe, as the first layered multiferroic at room temperature, provides a novel platform not only to explore the interactions between elementary excitations with controlled symmetries, but also to efficiently tune the device performance via external electric and mechanical stress.

Chen, Rui [University of California, Berkeley, CA ↗

DOE OSTI2026

Influence of the drive design on ablation front hydrodynamic instability growth in a capsule implosion at the National Ignition Facility

A critical aspect of inertial confinement fusion experiments lies in the control of ablation front instabilities during the implosion process. The growth of Rayleigh–Taylor and Richtmyer–Meshkov instabilities, seeded by target defects, can significantly degrade the performance of the implosion. Here, this study explores the influence of drive design on ablation front stability using the hydro-growth radiography platform at the National Ignition Facility. This platform allows the measurement of the ablation front hydrodynamic instability growth. Because these measurements are restricted to early convergence, their primary role is to constrain the initial instability growth and benchmark the simulations used to infer shell integrity and performance at peak velocity and ignition. Three ignition designs, Hybrid-E (HyE), SQ-n (“S” for scaling and “Q” for quality), and High temperature, High thickness (HiT) were analyzed. The results demonstrated a high dependence of the growth factor on the choice of design, capsule scale as well as the hohlraum conditions, mainly the radiative temperature and the gold M-band emission. HyE and SQ-n display a similar growth factor range, but their evolution is different due to the design differences in hohlraum conditions. HiT has the lowest growth factor of the studied designs, which is a result of a higher radiative temperature. These results highlight the importance of design choices in controlling instability dynamics. These insights inform future drive design strategies to enhance stability and efficiency in fusion ignition experiments.

Physics↗

DOE OSTI2020

Synthesis of Tunable SnS-TaS 2 Nanoscale Superlattices

Nanoscale superlattices represent a compelling platform for designed materials as the specific identity and spatial arrangement of constituent layers can lead to tunable properties. A number of kinetically stabilized, nonepitaxial superlattices with almost limitless structural tunability have been reported in telluride and selenide chemistries but have not yet been extended to sulfides. Here, we present SnS-TaS 2 nanoscale superlattices with tunable layer architecture. Layered amorphous precursors are prepared as thin films programmed to mimic the targeted superlattice; subsequent low temperature annealing activates self-assembly into crystalline nanocomposites. We investigate structure and composition of superlattices comprised of monolayers of TaS 2 and 3–7 monolayers of SnS per repeating unit. Furthermore, a graded precursor preparation approach is introduced, allowing stabilization of superlattices with multiple stacking sequences in a single preparation. Controlled synthesis of the architecture of nanoscale superlattices is a critical path toward tuning their exotic properties and enabling integration with electronic, optical, or quantum devices.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Trajectory-independent speed limits for controlled open quantum systems

Existing quantum speed limits for controlled open quantum systems depend on the specified trajectory. For example, lower bounds on quantum annealing times in the presence of dissipation depend explicitly on the chosen annealing schedule. Recently, schedule-independent speed limits have been derived for annealing in the closed quantum system setting [L. P. García-Pintos et al ., SciPost Phys. 18 , 159 (2025)]. In this work, we generalize these results to open quantum systems, deriving schedule-independent lower bounds for quantum annealing times in systems described by a Lindblad master equation. We analyze the interplay between coherent control and dissipation in single- and two-qubit examples, demonstrating that the derived lower bounds capture key scaling behavior with respect to the strength of the dissipator. Finally, we apply the bound to thermal state preparation and show that the bound matches the expected asymptotic behavior for an Ising model in the high-temperature limit.

open quantum systems & decoherence↗

DOE OSTI2025

Effect of homogenization heat treatment on the evolution of carbonitrides in powder bed fusion processed INCONEL 718

Inconel 718 fabricated using laser powder-bed fusion, contains precipitates in the as-built condition that can be coarsened by high-temperature heat treatments. In this study, two homogenization heat treatment regimens were applied to discern the impact of heat treatment conditions on the growth of complex M(C, N) carbonitrides. In the first heat treatment, the samples underwent heat treatment between 1050 °C and 1200 °C for 0.5 h. In the second heat treatment, the samples were held at a constant temperature of 1150 °C, with varied holding times from 0.5 h to 8 h. Heat treatments dissolved the unstable Laves phase, but the carbonitrides persisted in the structure regardless of temperature and duration. Changes in the compositions, lattice parameters, and sizes of M(C, N) carbonitrides were measured using transmission electron microscopy and high-energy synchrotron X-ray diffraction. The results show an Nb enrichment at carbonitrides while Nb loss at the matrix with increased homogenization temperature. The findings suggest the optimum heat treatment conditions to achieve a homogeneous structure and controlled carbonitride size are between 1000 and 1050 °C for up to 2 h.

IN178↗

DOE OSTI2025

High dopant activation in arsenic doped single-crystal CdTe thin films: Insights from MBE growth and rapid thermal processing

Single-crystal model systems are valuable tools to investigate fundamental material properties. In this work, we use molecular beam epitaxy to deposit in situ arsenic (As) doped single-crystal CdTe films on large area Si substrates to better understand As doping for photovoltaic applications. We found that As incorporation is highly temperature dependent: a substrate temperature difference of 50 °C can lead to several orders of magnitude difference in As concentration. Cd overpressure during in situ doping may limit out-diffusion of As but decrease As incorporation, especially at lower growth temperatures. Carrier concentrations greater than 10 16 cm −3 can be achieved with or without Cd overpressure when annealed at temperatures above 500 °C. However, unlike the low (∼1% to 5%) dopant activation commonly observed in polycrystalline CdTe, our films achieve significantly higher activation ratios—exceeding 50%, and in some cases approaching 80%. These values are consistent with or exceed prior reports in single-crystal CdTe systems. In addition to as-deposited arsenic concentrations, we also consider arsenic distribution after different rapid thermal processing temperatures. We propose a detailed definition and description of how arsenic incorporation is considered and calculated. Due to carrier concentration saturation, As incorporation also needs to be controlled to average levels of 10 17 cm −3 to achieve high activation. These findings suggest that higher annealing temperature regimes may be beneficial to polycrystalline CdTe based PV devices.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Harnessing Chemical Short‐Range Disorder to Improve Lithium Retention in Epitaxial LLTO Solid‐Electrolyte Thin Films

Lithium lanthanum titanate Li 3x La 2/3-x TiO 3 (LLTO) is a promising perovskite-based solid-state electrolyte for next-generation lithium-ion batteries, but controlling crystallinity and Li stoichiometry in thin-film form is challenging because high growth temperatures are required to achieve good crystallinity while Li remains strongly volatile. Here, we systematically investigate the effect of substrate temperature on epitaxial LLTO thin films grown by pulsed laser deposition. We identify a narrow growth window (750–800°C) in which LLTO films grow as c-axis oriented with atomically flat surfaces. Lower growth temperatures (<750°C) stabilize laterally extended, chemically disordered stripe domains that coexist with ordered LLTO regions, whereas higher temperatures (≥825°C) suppress these defects but promote island morphologies and Al/Ti interdiffusion. While spectroscopy measurements show that Ti remains in the 4+ oxidation state and Li is globally deficient for all films, our depth-resolved time-of-flight secondary ion mass spectrometry studies reveal that the 700°C film retains the highest Li content across its thickness. These results clarify how growth temperature controls crystallinity, chemical short-range disorder, and Li retention, and highlight moderate growth temperatures (∼700°C) as a route to mitigate Li loss in epitaxial solid-electrolyte films.

chemical short-range disorder↗

DOE OSTI2025

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

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

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

An encoder–decoder LSTM-based EMPC framework applied to a building HVAC system

Numerous studies have demonstrated the benefit of economic model predictive control (EMPC) applied to building heating, ventilation, and air conditioning (HVAC) systems. However, the construction and training of predictive models for building HVAC systems are widely recognized as a key technological barrier preventing large-scale adoption of EMPC for buildings. In this work, an encoder–decoder long short-term memory-based EMPC framework is developed. The key advantage of the approach is that a model may be automatically generated from a list of inputs and outputs. From the definition of inputs and outputs, the constructed model may be trained and automatically embedded into the EMPC framework for real-time estimation and control. The overall end-to-end EMPC framework from model training to on-line estimation and control are described. To this end, the encoder–decoder model provides a natural framework for state estimation (encoder), which is required to provide an initial condition for the predictive model of EMPC (decoder). Closed-loop simulations using EnergyPlus are performed to demonstrate the approach. The simulated closed-loop system consists of a building zone from a multi-zone building, which is served by an air handling unit-variable air volume HVAC system. For the HVAC example considered, the trained encoder–decoder model can predict the indoor air temperature and HVAC sensible cooling rate of a building zone over a two-day horizon with high accuracy. Overall, we find that considering a time-of-use electric rate structure, the EMPC, which manipulates the zone temperature setpoint, can reduce the HVAC power consumption cost relative to keeping the zone temperature setpoint at its maximum value (i.e., minimum energy approach).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Spatially correlated incommensurate lattice modulations in an atomically thin high-temperature Bi 2.1 Sr 1.9 CaCu 2.0 O 8+y superconductor

Strong variations in superconducting critical temperatures in different families of the cuprate perovskites, even with similar hole doping in their copper-oxygen planes, suggest the importance of lattice modulation effects. The one-dimensional incommensurate lattice modulation (ILM) of Bi 2 Sr 2 CaCu 2 O 8+y , with the average atomic positions perturbed beyond the unit cell6, offer s an ideal test ground for studying the interplay between superconductivity and the long-range incommensurate lattice fluctuations. Here we report Scanning nano X-ray Diffraction (SnXRD) imaging of incommensurate lattice modulations in Bi 2 Sr 2 CaCu 2 O 8+y Van der Waals heterostructures of thicknesses down to two-unit cells. Using SnXRD, we probe that the long-range and short-range incommensurate lattice modulations in bulk sample surface with spatial resolution below 100 nm. We find that puddle-like domains of ILM of size uniformly evolving with dimensionality. In the 2-unit cell thin sample, it is observed that the wavevectors of the long- and short-range orders become anticorrelated with emerging spatial patterns having a directional gradient. The emerging patterns, originated by tiny tuning of lattice strain, induce static mesoscopic charge density waves. Finally, our findings thus demonstrate that the strain can be used to tune and control the electromagnetic properties of two-dimensional high-temperature superconductors.

36 MATERIALS SCIENCE↗

DOE OSTI2025

High Power Density, Carbon Neutral Electrical Power Generation for Air Vehicles

The synergistic integration of a Solid Oxide Fuel Cell-Combustor (SOFC-C) with a turbogenerator (TG) will provide a very high fuel-to-electricity conversion efficiency while maintaining high power-to-weight ratio during high-altitude flight. The proposed SOFC-C-TG power generation technology exceeds the REEACH technical performance targets (TPT). This unique concept addresses many of the challenges faced in all electric propulsion-based aviation. The system has high part-load efficiency (more than 65% lower heating value (LHV)) during long cruise times, load following capability, high-power capacity at high altitudes adapting to low temperatures and pressures, rapid startup time of less than 30 minutes (proven with current SOFC technology), high power density (more than 3.2 kW/kg), efficient thermal management, and a foundation for a compact, efficient electrical storage and power generation system (ESPG). The SOFC-C concept achieves the technology targets by reducing the complexity of traditional fuel cell-gas turbine hybrid systems (FC-GT). The SOFC-C does not require heat exchangers and dramatically reduces the balance of plant increasing power density and performance in efficiency. The reduction in mass through elimination of heat exchangers, external reformer, and other components dramatically decreases the overall thermal dampening of the system which enables rapid startup and load following capability. Direct control of the cathode inlet temperature of the SOFC-C enables rapid warm-up of the SOFC tubes with the ability to reach operating temperature and full power in less than 30 minutes.

03 NATURAL GAS↗

DOE OSTI2025

Stability of aqueous neodymium complexes in carbonate-bearing solutions from 100–600 °C

Rare earth element exploration requires a quantitative understanding of factors governing their mobilization and economic concentration. However, the behavior of rare earth elements in carbonate- bearing hydrothermal fluids associated with carbonatite-hosted deposits is poorly understood, and conflicting mechanisms of rare earth transport by anionic ligands and alkali behavior have been described. Here, we report quantitative data to characterize the role of carbonate-bearing solutions in the hydrothermal mobilization of neodymium. Solubility studies of neodymium phosphate were performed at temperatures ranging from 100 to 600 °C in carbonate-bearing solutions. The thermodynamic data determined for the predominant complex were used to model the separation of neodymium from thorium in a simple flow-through system based on fluid and mineral compositions characteristic of carbonatite deposits. Our data suggest that neodymium transport is controlled by the stability of the carbonate species NdCO 3 OH o , and at temperatures of 500–600 °C, the concentrations of neodymium in solutions can reach ~1000 ppm.

58 GEOSCIENCES↗

DOE OSTI2023

Integrate FARM with PID controllers: IES Simulation Ecosystem Control System Development

The FARM (Feasible Actuator Range Modifier) software module is a component of the RAVEN-based FORCE framework for analysis of Integrated Energy Systems (IES). FARM was designed to support the HERON software module in the solution of the optimal dispatch problem for IES units. As the result of HERON-FARM dispatch simulation, the set-point trajectories are optimized to meet constraints on both the production variables (i.e., the variables to be optimized such as the electrical power, the hydrogen production rate, etc.) and the process variables tied to the service life of equipment (e.g., steam flowrate, vessel pressure, turbine firing temperature, etc.) at a coarse time resolution (every 10 or 100 seconds) over long time horizons (several days or weeks). In case the operational constraints need to be met at finer time resolution, the computational burden of HERON-FARM would linearly increase with the sampling rate, and sub-optimal solutions might be obtained. System responses characterized by overshoots and damped oscillations temporarily violating the imposed constraints might occur during abrupt power transients. In this report, a hierarchical control system architecture for the operation of the Dynamic Energy Technology and Integration Laboratory (DETAIL) facility constructed at INL was proposed. First, the preliminary studies on the proposed control strategy for operating the facility and the designed PI controllers were reviewed. In particular, the current approach for generating the set-point trajectories was studied, and its limits were identified. To this aim, the inclusion of a Supervisory Control layer embedding a modified version of the FARM algorithm for preserving the system safe operation over both long and real-time horizons was proposed. In this way, FARM would be applied twice, i.e., the original version (“FARM Validator”) aiding the solution of the power dispatch problem, and the modified version (“FARM Supervisory” coordinating the PI controllers to address the real-time control tasks. Despite the kernel of the two modules is the same algorithm, their roles, tasks, and capabilities are quite different. A detailed description of the role of FARM at addressing low-level control tasks is provided, along with tentative operational procedures for training the models embedded into the algorithm by using the collected experimental data.

42 ENGINEERING↗

DOE OSTI2022

Performance Assessment of High-Efficiency Refrigerated Display Cases with Low-GWP Refrigerants: Preprint

As California policy makers enforce new regulations such as SB 1383 to achieve state greenhouse gas (GHG) reduction goals, it will be critical to understand the energy efficiency implications of low global warming potential (GWP) refrigerants in commercial refrigeration applications. The goal of this research project, funded by Commonwealth Edison was to assess the energy performance of two high efficiency medium-temperature, self-contained, reach-in display cases that utilized natural refrigerant propane (R-290), and hydrofluorocarbon (HFC) drop-in hydrofluoroolefin R-513a, respectively. Performance of these display cases were compared to a baseline fixture using HFC (R-134a) under equal conditions in a controlled environment chamber. These display cases were selected due to their widespread use in convenience stores, and small supermarkets. The high efficiency cases were equipped with energy efficient lighting, improved panel insulation, high efficiency evaporator and condenser fan motors, and high effectiveness heat exchangers. The test method used in this project was foundationally inspired by the ANSI/ASHRAE 72-2018 standard method to evaluate each case under equivalent conditions. However, minor modifications to this methodology were implemented to better represent more realistic operation of the units. While maintaining target product temperature, the energy efficient fixtures containing R-290 and R-513a consumed 61.8% to 32.6% less energy, respectively, than a baseline case using R-134a refrigerant. The daily energy consumption of the R-290, R-513a, and baseline display cases at the upper limit of environmental conditions was 4.30, 7.59, and 11.26 kWh/day, respectively.

alternative refrigerants↗

DOE OSTI2024

Ash Fouling Free Regenerative Air Preheater for Deep Cyclic Operation

The University of Kentucky (UKy) project titled “Ash Fouling Free Regenerative Air Preheater for Deep Cyclic Operation”, DE-FE0031757, was conducted from 8/15/2019 to 8/14/2024 in two Budget Periods. Other participants included PPL Corporation and Black Dragon Double Boiler. The overall goal was to investigate the proposed self-cleaning technology to achieve ash fouling free air preheater operation in a coal-fired power plant, especially during deep cycling. All project deliverables, milestones, and success criteria were met. UKy obtained the following scientific findings. • Temporary and periodic high temperature of heating elements (450 ~ 500 °F) can prevent ash accumulation and maintain air preheater free of clogging. • The ash samples analysis and unit operation provide solid evidence of ABS formed during low load with SCR ammonia slip being the major cause of ash accumulation, and air preheater clogging can be prevented by raising the heating element temperature up to 450 °F~ 500 °F at which ABS is decomposed. • In-situ self-cleaning can be controlled by monitoring temperature and/or presetting fixed number of cleanings per day. Both approaches in pilot testing show positive results for maintaining an ash free state for the air preheater. • Temperature criteria (cold end or gas outlet temperature) for entering self-cleaning service is critical to balance the number of cleaning cycles with maintaining the ash level. • Temperature criteria (cold end or gas outlet temperature) for exiting self-cleaning service is critical to balance the duration of the cleaning cycles with maintaining the ash level.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2026

Structural Phase Transitions in the van der Waals Ferromagnets Fe x Pd y Te 2

Two-dimensional van der Waals (vdW) magnets are attracting significant attention, both as platforms for studying fundamental magnetic interactions and for the exciting possibility of utilizing them as building blocks in devices and heterostructures, which may lead to new physical phenomena and functionalities. Here, we provide a detailed study of the crystal structure and physical properties of the recently discovered vdW ferromagnet FePd 2 Te 2 . We find this compound has a relatively wide width of formation, and grow single crystals with compositions Fe x Pd y Te 2 where x ranges from 0.9 to 1.1 and y from 1.8 to 2.5, respectively. Temperature-dependent X-ray diffraction and transport measurements reveal that a first-order structural transition occurs in the range of T = 360–420 K, where the critical temperature, modulation wave vector, and corresponding room-temperature crystal structures all depend on chemical composition. Above the transition, the compounds with Pd fraction y > 2 adopt a disordered derivative of the tetragonal FeTe structure, with the Fe layer showing mixed Fe/Pd occupancy and the extra Pd atoms partially occupying interstitial sites. Below 370 K, the structure is incommensurately modulated, likely associated with the complex ordering of Pd/Fe atoms in the metal layers or the interstitial Pd in the vdW gaps. For y < 2, the composition Fe 1.1 Pd 1.8 Te 2 has monoclinic symmetry at room temperature that is consistent with the reported structure of FePd 2 Te 2 . This phase undergoes a structural transition at 420 K for which the high temperature structure is yet to be determined; however, based on the similarities with the y > 2 compounds, we speculate that its T > 420 K structure is also tetragonal. Importantly, the high temperature, symmetry-breaking structural transition observed here provides a likely explanation for the origin of the structural domains previously observed in FePd 2 Te 2 . All compounds investigated in the Fe x Pd y Te 2 series show metallic behavior, with magnetic characterization indicating that they are easy-plane, hard, ferromagnets with T C spanning 98–180 K. Both the critical temperature for the structural transition and the Curie temperature are moderately suppressed with increasing Pd fraction y and corresponding decreasing Fe fraction x, indicating that synthetic control over x and y paves way for the further exploration of these compounds.

crystal structure↗