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At least 19 records

All sources NASA NTRS DOE OSTI

DOE OSTI2024

Propulsion Electrification Architecture Selection Process and Cost of Carbon Abatement Analysis for Heavy-Duty Off-Road Material Handler

The heavy-duty off-road industry continues to expand efforts to reduce fuel consumption and CO 2 e (carbon dioxide equivalent) emissions. Many manufacturers are pursuing electrification to decrease fuel consumption and emissions. Future policies will likely require electrification for CO2e savings, as seen in light-duty on-road vehicles. Electrified architectures vary widely in the heavy-duty off-road space, with parallel hybrids in some applications and series hybrids in others. The diverse applications for different types of equipment mean different electrified configurations are required. Companies must also determine the value in pursuing electrified architectures; this work analyzes a range of electrified architectures, from micro hybrids to parallel hybrids to series hybrids to a BEV, looking at the total cost, total CO 2 e, and cost per CO 2 e (cost of carbon abatement, or cost of carbon reduction) using data for the year 2021. This study is focused on a heavy-duty off-road material handler, the Pettibone Cary-Lift 204i. This machine’s specialty application, including events like unloading large oil pipes from a railcar, requires a unique electrified architecture that suits its specific needs. However, the results from this study may be extrapolated to similar machinery to inform fuel savings options across the heavy-duty off-road industry. In this study, a unique electrified architecture is determined for the Cary-Lift. This architecture is informed by multiple rounds of a Pugh matrix decision analysis to select a shortened list of desirable electrified architectures. The shortened list is modeled and simulated to determine CO 2 e, cost, and cost per CO 2 e. A final architecture is determined as a plug-in series hybrid that reduces fuel consumption by 65%, targeting the large fuel and CO 2 e savings that are likely to be required for the future of the heavy-duty off-road industry.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

ARM Lead Mentor Selection Process

The Atmospheric Radiation Measurement (ARM) Program was created in 1989 with funding from the U.S. Department of Energy (DOE) to develop several highly instrumented ground stations to study cloud-formation processes and their influence on radiative transfer. This scientific infrastructure provides for fixed sites, mobile facilities, an aerial facility, and a data archive available for use by scientists worldwide through the ARM Climate Research Facility—a scientific user facility. The ARM Climate Research Facility currently operates more than 300 instrument systems that provide ground-based observations of the atmospheric column. To keep ARM at the forefront of climate observations, the ARM infrastructure depends heavily on instrument scientists and engineers, known as Mentors. Mentors must have an excellent understanding of instrumentation theory and operation for their instrument areas and have comprehensive knowledge of critical scale-dependent atmospheric processes. They must also possess the technical and analytical skills to develop new data retrievals that provide innovative approaches for creating research-quality data sets. The ARM Facility seeks the best overall qualified candidate, or team when appropriate, that can fulfill Mentor requirements in a timely manner. The roles and responsibilities of the ARM Instrument Operations Manager are provided in Appendix A. The key role and responsibilities and detailed responsibilities of ARM Lead Mentors are provided in Appendix B and Appendix C, respectively.

47 OTHER INSTRUMENTATION↗

DOE OSTI2025

Site-specific surface reactivity on SnO 2 : Evaluating selective atomic layer deposition processes

Area selective atomic layer deposition (AS-ALD) is a bottom-up synthesis approach with potential for deposition with molecular level precision. Here, the site-specific hydration of metal oxide substrates, combined with surface H 2 O-selective ALD processes, provides a potentially powerful path to targeted synthesis. Density functional theory (DFT) calculations are used to predict the thermodynamics of ALD precursor reactivity and hydration for (001), (101), (110), and (100) rutile SnO 2 facets as a function of temperature. Trimethylaluminum (TMA) and dimethyl aluminum isopropoxide (DMAI) dimers are predicted to react with both dehydrated and hydrated SnO 2 (001), (101), and (110) facets at ALD-relevant temperatures, while the SnO 2 (100) facet is predicted to be uniquely unreactive with TMA and DMAI monomers as well as dehydrate near 177 °C making this facet more amenable to targeted ALD. In situ ellipsometric studies of Al 2 O 3 ALD on polycrystalline SnO 2 at 150 °C are consistent with the computational predictions of rapid and unselective nucleation, in stark contrast to inhibited and selective ALD on isostructural rutile TiO 2 .

Atomic Layer Deposition↗

DOE OSTI2026

Transition Metal Dichalcogenide MoS 2 : Oxygen and Fluorine Functionalization for Selective Plasma Processing

Low-temperature plasma processing is a promising technique for tailoring transition metal dichalcogenides (TMDs). For chalcogen substitution processing, a key challenge is to identify the ion energy window that enables selective chalcogen removal while preserving the metal lattice. Using ab initio molecular dynamics (AIMD), we demonstrate that oxygen and fluorine functionalization widen the processing window by significantly lowering the sulfur sputtering energy threshold (E sputt,S ) of MoS 2 from ∼30 to ∼10 eV via formation of sputtering products such as SO 2 and SF n . Additionally, we show that experimentally relevant cryogenic temperatures strongly affect E sputt,S (T). The dependence is confirmed via AIMD and also predicted by a mechanistic parameter-free theory, suggesting that E sputt (T) generalizes to other TMDs, functionalizations, and surface impact conditions. Our results highlight oxygen/fluorine functionalization, ionic impact angle, and material temperature to be key control parameters for selective, damage-controlled chalcogen removal in TMD processing.

Polyachenko, Yury [Princeton Plasma Physics Labora↗

DOE OSTI2024

Data Visualization and Analytics for Optimal Process Parameter Selection in Turning

The objective of this project is to research physics-guided machine learning methods to recommend optimal tools and machining process parameters for turning applications using the MSC test database. For a given turning application, the MSC metalworking specialist needs to make decisions on tools and the associated process parameters for the MSC customer. For a given material, there are many alternatives for tools and a wide range of process parameters to consider. MSC has built a database of tools and parameters for different applications from the historical turning tests completed at various customer sites. The research project aims to use machine learning methods to predict optimal tools and process parameters for the MSC metalworking specialists using the MSC test database. This enables continuous learning of optimal tool and process parameters for different applications as new information is collected from testing. Through MSC, this information can be shared with machining shops across the US leading to improved productivity and efficiency.

42 ENGINEERING↗

DOE OSTI2025

SITCOMTN-161: PSF assessment in the field of Abell 360 and shapeHSM shear profile using LSSTComCam data

The Rubin LSSTComCam on-sky campaign performed at the end of 2024 provided observations of the Abell 360 galaxy cluster; these data allow a preliminary study of cluster weak lensing analysis using Rubin Data Preview 1 (DP1) data. Among all the steps required for such analyses, accurate modeling of the PSF is essential. This work uses several diagnostics, mostly based on the residuals between the second moments of stars and the PSF model, to characterize the accuracy of the PSF modeling in the A360 field. We find the level of the residuals to be sufficiently low not to hinder the measurement of the tangential shear profile around A360. With a simple source selection process, we demonstrate that outputs of the LSST Science Pipelines can be used to detect the tangential shear profile in Abell 360 at the 3.6σ level, and our analysis indicates that contamination from PSF modeling systematics is negligible.

Dell'Antonio, Ian [Brown University]↗

DOE OSTI2024

Predictive analytics of selections of russet potatoes

We explore the application of machine learning algorithms specifically to enhance the selection process of Russet potato (Solanum tuberosum L.) clones in breeding trials by predicting their suitability for advancement. This study addresses the challenge of efficiently identifying high-yield, disease-resistant, and climate-resilient potato varieties that meet processing industry standards. Leveraging manually collected data from trials in the state of Oregon, we investigate the potential of a wide variety of state-of-the-art binary classification models. The dataset includes 1086 clones, with data on 38 attributes recorded for each clone, focusing on yield, size, appearance, and frying characteristics, with several control varieties planted consistently across four Oregon regions from 2013 to 2021. We conduct a comprehensive analysis of the dataset that includes preprocessing, feature engineering, and imputation to address missing values. We focus on several key metrics such as accuracy, F1-score, and Matthews correlation coefficient (MCC) for model evaluation. The top-performing models, namely a feedforward neural network classifier (Neural Net), a histogram-based gradient boosting classifier (HGBC), and a support vector machine classifier (SVM), demonstrate consistent and significant results. To further validate our findings, we conducted a simulation study using the aims, data-generating mechanisms, estimands, methods, and performance measures (ADEMP) framework, simulating different data-generating scenarios to assess model robustness and performance through true positive, true negative, false positive, and false negative distributions, area under the receiver operating characteristic curve (AUC-ROC) and MCC. The simulation results highlight that non-linear models like SVM and HGBC consistently show higher AUC-ROC and MCC than logistic regression, thus outperforming the traditional linear model across various distributions, and emphasizing the importance of model selection and tuning in agricultural trials. Variable selection further enhances model performance and identifies influential features in predicting trial outcomes. The findings emphasize the potential of machine learning in streamlining the selection process for potato varieties, offering benefits such as increased efficiency, substantial cost savings, and judicious resource utilization. Our study contributes insights into precision agriculture and showcases the relevance of advanced technologies for informed decision-making in breeding programs.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2025

MCPC Friction Stir Welding (FSW) Process Data

Processing parameters and machine log data for the MCPC LDRD Agile investment is collected material samples processed. This dataset captures the selected processing parameters, machine logs captured during material processing, and descriptions of how characterization samples were extracted from processed plates of material. The collect characterization data is captured in other datasets.

316 Stainless Steel↗

DOE OSTI2025

A quality-agnostic combinatoric cost estimation model for large-format directed energy deposition metal additive manufacturing

Directed energy deposition (DED) additive manufacturing (AM) processes are amenable to synergistic combination into multi-process AM systems due to similar requirements for automation and energy sources. This work analyzes the economic performance of such DED AM systems from a quality-agnostic combinatoric standpoint with a model that calculates lowest-cost system combinations based on part geometry and process performance metrics. Common DED AM systems research focuses on a single process and does not consider the process, system, and application in the context of all possible system combinations (e.g., the combined set of process selection(s), motion system(s), and process hardware), leading to limited applicability of the resulting DED AM systems to cost-sensitive components such as those found in energy generation applications. The model developed herein incorporates the capital, material, and energy costs associated with DED AM system combinations into a predictive tool for estimating part and system cost, the output of which is intended to guide deployment of finite research and development resources towards DED AM system combinations with the lowest costs and greatest likelihood of economic impact. The DED AM systems identified by this framework may enable domestic production of the large conventionally cast and forged components necessary for energy generation.

Shanafield, Alexandra [ORNL]↗

DOE OSTI2025

Laser Powder Bed Fusion Additive Manufacture Nb1Zr Development

Next generation fission and fusion nuclear reactors require materials that can withstand operating temperatures greater than 500 °C, neutron irradiation doses of up to 200 displacements per atom (dpa), and potentially corrosive coolants such as the alkali liquid metals sodium, lithium, and NaK (Na33K eutectic alloy). Refractory alloys, such as Nb1Zr (Nb-1wt%Zr) and Molybdenum alloy TZM (Mo-0.5wt%Ti-0.08wt%Zr) have been traditionally considered viable candidates for advanced fission and fusion reactor concepts. However, it is relatively difficult to generate complex geometries of interest from these alloys using traditional manufacturing methods. In addition, there needs to be a concentrated effort to address refractory metal challenges at elevated temperature operation. In order to generate complex geometries of interest, modern manufacturing techniques are considered to increase the technological readiness level (TRL), cost-effectiveness, and schedule savings. This work focused on the continued development of laser powder bed fusion (L-PBF) additive manufacturing (AM) to improve both design flexibility, evaluate microstructure and properties, and ultimately accelerate the TRL and qualification of these processes and alloys for components to potentially be put into service. Niobium alloy Nb1Zr was identified through a down-selection process outlined in previous reports as a candidate to develop in L-PBF AM. Historically, Nb1Zr had been explored for high temperature fast spectrum fission reactors for both terrestrial and space applications. Molybdenum alloy TZM has also been considered for these reactor concepts due to exceptional high-temperature strength, creep resistance, and stability under irradiation. L-PBF AM of TZM has previously been investigated at LANL under the Microreactor program, NASA, ORNL, and in academia. However, due to the crack prone nature of TZM, L-PBF AM of TZM resulted in significant microcracking and additional development is required to pursue viable maturation. Other AM methods have been found to be more successful in printing TZM, and those alternatives approaches are discussed in this effort. The efforts detailed in this report focused on continued development of Nb1Zr through L-PBF and development of TZM via L-PBF and electron powder bed fusion (E-PBF). The objective of this work was to further the development of these AM techniques for the chosen refractory alloys, elucidating and addressing associated challenges through characterization of several demonstration builds. At LANL, Nb1Zr builds were completed using an EOS M290 and M400 machines, and a refractory alloy-dedicated L-PBF system, the Xact Metal XM200G, was installed. The XM200G primary purpose was to do the Nb1Zr parameter development process; however, due to difficulties associated with the machine installation and qualification process, it was decided to pivot development to the larger M400 and M290 machines. Although the supply of Nb1Zr powder was limited, it was sufficient to generate sub-scale metallographic specimens for the purpose of parameter development. This was first accomplished on the EOS M400 then the M290 due to machine schedule availability. Further development of TZM has been initiated at the University of Texas El Paso (UTEP) under contract with LANL to use both a heated build envelope L-PBF machine and E-PBF machine that have been found in the literature to mitigate microcracking. UTEP was provided with TZM powder and build plates to support parallel TZM parameter development across both machines. As part of the contract, UTEP will also be conducting microstructural characterization once optimized process parameters have been identified. The optimized process parameters for each machine will be used to generate a series of metallographic, mechanical, and surface finish specimens for subsequent characterization and testing. In the next section, we provide a detailed discussion of the methodology used for investigating the feasibility of leveraging these alloys for use in advanced reactor applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Optimizing Bendability and Hardness of Age-Hardenable Aluminum Sheets through Local Thermo-Mechanical Processing

This paper introduces a novel thermo-mechanical process to modify the local mechanical properties of 6xxx aluminum (Al-Mg-Si-Cu) alloy sheets. In this process, two pairs of rollers travel along the length of a sheet while locally bending and unbending it so that the final shape and thickness of the sheet remains unchanged. Room temperature bending/unbending (B/U) produces a deformation gradient through thickness and local hardening in both T4 and T6 sheets (with 41% and 18% greater Vickers hardness, respectively). High temperature bending/unbending performed at ~ 500°C via induction heating, produces significant improvements in local formability as measured by bend testing. Formability levels equivalent to the as-received T4 temper are achieved within the processed zones of T6 sheets with bend angles of ~ 150°, without disturbing the T6 temper in the remainder of the sheet. Finite element simulations and characterization explained the mechanical property improvements and the heterogenous microstructure with weakened Cube texture. Due to its similarity with the roller hemming process, and its compact dimensions, the apparatus developed for B/U has the potential for seamless integration with roller hemming robots to selectively process high strength aluminum sheet materials within mass-production settings.

Efe, Mert [BATTELLE (PACIFIC NW LAB)]↗

DOE OSTI2026

Modeling and Calibration of Supplier Selection Problem in Freight Agent-Based Simulations

Freight transportation modeling often struggles with data limitations, especially in accurately representing complex supplier selection processes and their impact on network flows. This research addresses this critical gap by developing a large-scale, calibrated agent-based model for supplier selection, complemented by a probabilistic heuristic for international shipments. Our approach integrates trade relationships between industry sectors, transportation costs, and a supplier-rating model adapted from existing literature. The model’s core objective is to minimize the discrepancy between modeled and observed commodity flows while ensuring a close match to regional shipping distance distributions. Implemented and tested across four major U.S. metropolitan areas—Atlanta, Chicago, Dallas–Fort Worth, and Los Angeles—the model demonstrates high fidelity in replicating observed freight patterns. Key findings reveal consistent alignment with national shipping distance trends and highlight significant spatial variations in commodity trade assignments and demand across the study regions. This behaviorally informed and transport-sensitive framework is designed to approximate real-world decision making, providing a robust tool for policymakers and planners to evaluate targeted interventions, assess infrastructure investments, and enhance supply chain resilience in the face of disruptions.

Ismael, Abdelrahman (ORCID:0000000303712110)↗

DOE OSTI2025

Nanoscopic Plugs Block Hydrogen Crossover in Submicron Thick Proton-Conducting SiO 2 Membranes for Water Electrolysis

Zero-gap electrolyzers based on submicron thick proton-conducting oxide membranes (POMs) represent a promising approach to increasing the efficiency of H 2 production from water electrolysis while moving away from conventional perfluorosulfonic acid (PFSA) membranes. A critical barrier to the commercialization of such electrolyzers is that the ultrathin nature of POMs, which is necessary to achieve low cell resistance, makes them more susceptible to defects that can lead to unacceptably high rates of H 2 crossover. Herein, we demonstrate an approach to mitigate this problem through selective deposition of carbon-containing silicon oxide (SiO x C y ) “nanoplugs” into the defects of submicron thick SiO 2 membranes using a facile electrochemically mediated deposition process. Selective deposition of nanoplugs within the defects was verified by multiple characterization techniques, while scanning electrochemical microscopy (SECM) was used to confirm selective plugging of H 2 -crossover hotspots associated with defects at identical locations. Thanks to the use of nanoplugs, the H 2 permeance of 250 nm thick SiO 2 membranes was reduced by 5 to 6 orders of magnitude compared to the unmodified atomic layer deposition (ALD) SiO 2 membranes while having negligible impact on the ionic resistance of the membrane. These plug-modified membranes also enabled safe and stable operation of a zero-gap full cell electrolysis cell, in contrast to cells lacking nanoplugs that produced anode effluent streams having H 2 concentrations near or exceeding the lower flammability limit (LFL) of H 2 . Furthermore, beyond water electrolysis, this defect-sealing strategy has the potential to be broadly implemented in other applications, such as fuel cells and flow batteries, offering a versatile solution to mitigate crossover-related performance losses.

ALD SiO2↗

DOE OSTI2024

Predictive Control to Further Reduce DC-Link Capacitor Current Stress for Segmented Inverter

Two three-phase interleaved inverters have been used in traction drive applications to reduce the current stress in a DC link capacitor bank. In such applications, either carrier-based or space vector modulation is used to select the optimum switching sequences, and the results show 50% less capacitor current than that of a single three-phase inverter. The switching state selection process for this inverter is tedious, and there has been no research to find the optimal switching state. To overcome this challenge, this research employed a simple finite set model predictive control to select the optimum switching sequence for a dual three-phase interleaved topology, called a segmented inverter. The results show that the predictive control algorithm can provide a simple solution and can reduce the current stress by 27% compared with traditional modulation techniques for the segmented inverters.

Ribeiro, Pedro↗

DOE OSTI2025

A Robust Data-Driven Approach for Mechanical Serial Sectioning

Mechanical serial sectioning (MSS) provides detailed microstructural information across large length scales. By repeatedly removing thin layers of material and imaging the exposed surface, a 3D representation of a specimen’s internal structure can be constructed, enabling failure analysis and feature identification that are otherwise inaccessible via conventional 2D or nondestructive evaluation techniques. Achieving consistent and accurate material removal can be challenging due to system variability, requiring an experienced operator to manually adjust parameters, prolonging data collection times and necessitating post-processing routines to standardize the data. Here, to address these challenges, this paper presents the employment of a one-step model predictive control (MPC) framework tailored to a run-to-run (R2R) controller. The R2R-MPC controller automates the parameter selection process, improving the consistency of material removal through iterative feedback for disturbance rejection and accurate tracking of the target removal rate. Using a data-driven approach, the controller robustly adapts to changing material characteristics. The effectiveness of the R2R-MPC controller is demonstrated through simulation and experimental results and compared to previous data collection procedures.

3D Materials Science↗

DOE OSTI2024

Measuring Muon Antineutrino Charged-Current Interactions Without Mesons in the Final State, in the NOvA Near Detector

NOvA is a long-baseline neutrino experiment based at Fermilab in the US, with the primary aim of measuring neutrino and antineutrino oscillations. This will enhance our understanding of electroweak interactions by measuring the neutrino mixing angles, CP-violating phase and neutrino mass ordering. To measure these oscillations, we first need to have a deep understanding of how neutrinos and antineutrinos interact with matter. Antineutrino interaction cross sections are, at present, particularly poorly constrained, and processes such as meson exchange currents are not well understood in the antineutrino sector. This analysis will develop a cross-section measurement of muon antineutrino interactions without mesons (e.g. pions or kaons) in the final state, in the NOvA near detector. A high-statistics, high-purity sample is obtained through a cut-based selection process implementing machine learning techniques. The sample is dominated by quasi-elastic and meson exchange current interactions which are sensitive to nuclear effects such as Final-State Interactions. The cross section will be extracted as a function of the incoming neutrino energy and the kinematics of the outgoing particles.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Measuring Muon Antineutrino Charged-Current Interactions without Mesons in the Final State, in the NOvA Near Detector

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Mechanistic Insights into Adsorptive and Catalytic Reactions from Controllable Distributions of Metal Cations (Pd, Pt, Ni, Cr, Cu) as [M‐OH] +1 /1Al or M +2 /2Al in Zeolites

Anchoring divalent metal ions in the same zeolite framework with similar Si/Al ratio selectively as zeolite-bound M +2 or [M +2 -OH] +1 cationic species enables critical comparison of the species’ intrinsic reactivity for industrially and fundamentally relevant reactions. H-BEA zeolites with similar Si/Al ratios but differing framework Al siting were used to anchored multiple divalent metal cations (Ni, Pd, Pt, Cr, Cu) in the zeolite micropores. State-of-the-art infrared (IR) spectroscopy, electron paramagnetic resonance (EPR) measurements, including two-dimensional pulsed HYSCORE EPR, extended X-ray absorption fine structure (EXAFS), and density functional theory (DFT) calculations together provide unambiguous evidence for the selective formation of divalent metal cations as M +2 /2Al species (for H-BEA prepared in the conventional hydroxide media), and [M +2 OH] +1 /1Al species for H-BEA prepared in HF. Solid-state proton-decoupled triple-quantum magic-angle spinning (3Q MAS) NMR measurements confirmed contrasting Al distributions in the two H-BEA zeolites, which led to a contrasting divalent cation speciation. The reactivities of the two cationic species were explored for catalytic and adsorptive applications in both organometallic homogeneous and heterogeneous catalysis. This work demonstrates their divergent reactivity in ethylene dimerization, ethylene oxidation (Wacker process), selective catalytic reduction (SCR) of NO, NO adsorption, and methane oxidation. Both M +2 /2Al and [M +2 OH] +1 /1Al cations are both active for ethylene dimerization, but [M +2 OH] +1 /1Al species show higher reaction rates for each Pd, Ni, Pt. [M +2 OH] +1 /1Al is active for acetaldehyde formation in Wacker ethylene oxidation. A new active site for ethylene oligomerization is proposed that possesses a terminal OH group (Cr-OH) in Phillips catalysts evident by a nearly inactive isolated Cr +2 /2Al species that contrast an active Cr─OH motif.

Divalent metal cations in a zeolite↗