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DOE OSTI2026

Cyclic moisture reactivation of calcium sorbents for long duration thermochemical energy storage

The transition to a flexible and reliable energy infrastructure, using electro-thermal energy generation technologies such as geothermal, concentrated solar power, and nuclear, usually demands simultaneous advancement of thermal energy storage (TES) to support on-demand electricity generation and industrial applications while mitigating the inherent intermittency of renewable energy sources and power outages from direct energy generation. Among TES technologies, thermochemical energy storage (TCES) based on calcium looping emerges as a compelling high-power energy storage candidate due to its high reaction enthalpy, compatibility with elevated operating temperatures, and abundance of low-cost materials. However, the long-term durability of calcium-based sorbents for TCES is hindered by surface sintering and particle aggregation, leading to performance degradation over repeated thermal cycles. This study explores a moisture hydration-based strategy to regenerate a degraded calcium sorbent and mitigate performance degradation for long duration TCES. The addition of moisture transforms calcium oxide into calcium hydroxide and produces intercalation water layers, associated with a regenerated surface area and reduced calcium oxide crystallite size. Both these effects are beneficial in restoring the sorbents' reactivity for carbonization. Additionally, an optimized hydration-assisted reactivation protocol balances the recovered energy storage capacity with heating penalty required for moisture removal from hydrated samples, resulting in an enhanced energy storage capacity up to 176% compared to benchmark sorbents that undergo cycling without reactivation after 60 cycles. In conclusion, these results highlight the potential of hydration-assisted reactivation to enhance the long-term performance of TCES, providing an effective pathway to advancing electro-thermal storage technologies.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Systems and methods for randomized, packet-based power management of conditionally-controlled loads and bi-directional distributed energy storage systems

The present disclosure provides a distributed and anonymous approach to demand response of an electricity system. The approach conceptualizes energy consumption and production of distributed-energy resources (DERs) via discrete energy packets that are coordinated by a cyber computing entity that grants or denies energy packet requests from the DERs. The approach leverages a condition of a DER, which is particularly useful for (1) thermostatically-controlled loads, (2) non-thermostatic conditionally-controlled loads, and (3) bi-directional distributed energy storage systems. In a first aspect of the present approach, each DER independently requests the authority to switch on for a fixed amount of time (i.e., packet duration). The coordinator determines whether to grant or deny each request based electric grid and/or energy or power market conditions. In a second aspect, bi-directional DERs, such as distributed-energy storage systems (DESSs) are further able to request to supply energy to the grid.

Frolik, Jeff↗

DOE OSTI2025

Bulk synthesis of radiation resistant W – Ti – Cr – V compositionally complex alloys

Refractory compositionally complex alloys are candidate material systems for next generation advanced nuclear reactors. This work showcases the first successful bulk synthesis of low activation W–Ti based refractory compositionally complex alloys using arc melting and provides insights on using additive manufacturing for these compositions using directed energy deposition. Both techniques produce equiaxed grains composed of a tungsten matrix with Ti–V–Cr dendritic boundaries. The arc melted specimen possesses a multi-modal grain size distribution, while the directed energy deposition specimen possesses a more gaussian distribution of grain size. Both arc melted and directed energy deposition specimens demonstrate high thermal stability up to 900 °C, as well as promising radiation resistance with low loop formation and the presence of homogeneously distributed helium cavities maintaining small diameters at ≥10 dpa under simultaneous light (helium) and heavy (krypton) ion irradiation at 900 °C.

Arc melting (AM)↗

DOE OSTI2020

Assessing the Vulnerability of Unmanned Aircraft Systems to Directed Acoustic Energy

The increasingly large payloads of Unmanned Aircraft Systems (UASs) are exponentially increasing the threat to the nuclear enterprise. Current mitigation using RF interference is effective, but not feasible for fully autonomous systems and is prohibited in many areas. A new approach to UAS threat mitigation is needed that does not create radio interference but is effective against any type of vehicle. At the present time there is no commercial counter-UAS system that directly assaults the mems gyros and accelerometers in the Inertial Measurement Unit on the aircraft. But lab testing has revealed resonances in some IMUs that make them susceptible to moderate amplitude acoustic monotones. Sandia's energetic materials facility has enabled a quick and thorough exploration of UAS vulnerability to directed acoustic energy by using intense acoustic impulses to destabilize or down a UAS. We have: 1) detonated/deflagrated explosive charges of various sizes; 2) accurately measured impulse pressure and pulse duration; 3) determined what magnitude of acoustic insult to the IMU disrupts flight and for how long and; 4) determined if the air blast/shock wave on aircraft/propellers disrupts flight.

42 ENGINEERING↗

DOE OSTI2024

Towards Energy–Efficient Direct Air Capture with Photochemically–Driven CO 2 Release and Solvent Regeneration

The intensive energy demands associated with solvent regeneration and CO 2 release in current direct air capture (DAC) technologies makes their deployment at the massive scales (GtCO 2 /year) required to positively impact the climate economically unfeasible. This challenge underscores the critical need to develop new DAC processes with significantly reduced energy costs. Recently, we developed a new approach to photochemically drive efficient release of CO 2 through an intermolecular proton transfer reaction by exploiting the unique properties of an indazole metastable-state photoacid (mPAH), opening a new avenue towards energy efficient on-demand CO 2 release and solvent regeneration using abundant solar energy instead of heat. In this Concept Article, we will describe the principle of our photochemically-driven CO 2 release approach for solvent-based DAC systems, discuss the essential prerequisites and conditions to realize this cyclable CO 2 release chemistry under ambient conditions. We outline the key findings of our approach, discuss the latest developments from other research laboratories, detail approaches used to monitor DAC systems in situ, and highlight experimental procedures for validating its feasibility. Finally, we conclude with a summary and outlook into the immediate challenges that must be addressed in order to fully exploit this novel photochemically-driven approach to DAC solvent regeneration.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Photochemically‐Driven CO 2 Release Using a Metastable‐State Photoacid for Energy Efficient Direct Air Capture

Abstract One of the grand challenges underlying current direct air capture (DAC) technologies relates to the intensive energy cost for sorbent regeneration and CO 2 release, making the massive scale (GtCO 2 /year) deployment required to have a positive impact on climate change economically unfeasible. This challenge underscores the critical need to develop new DAC processes with substantially reduced regeneration energies. Here, we report a photochemically‐driven approach for CO 2 release by exploiting the unique properties of an indazole metastable‐state photoacid (mPAH). Our measurements on simulated and amino acid‐based DAC systems revealed the potential of mPAH to be used for CO 2 release cycles by regulating pH changes and associated isomers driven by light. Upon irradiating with moderate intensity light, a ≈55 % and ≈68 % to ≈78 % conversion of total inorganic carbon to CO 2 was found for the simulated and amino acid‐based DAC systems, respectively. Our results confirm the feasibility of on‐demand CO 2 release under ambient conditions using light instead of heat, thereby providing an energy efficient pathway for the regeneration of DAC sorbents.

Premadasa, Uvinduni I.↗

DOE OSTI2023

Photochemically-Driven CO 2 Release Using a Metastable-State Photoacid for Energy Efficient Direct Air Capture

One of the grand challenges underlying current direct air capture (DAC) technologies relates to the intensive energy cost for sorbent regeneration and CO 2 release, making the massive scale (GtCO 2 /year) deployment required to have a positive impact on climate change economically unfeasible. This challenge underscores the critical need to develop new DAC processes with substantially reduced regeneration energies. Here, in this work, we report a photochemically-driven approach for CO 2 release by exploiting the unique properties of an indazole metastable-state photoacid (mPAH). Our measurements on simulated and amino acid-based DAC systems revealed the potential of mPAH to be used for CO 2 release cycles by regulating pH changes and associated isomers driven by light. Upon irradiating with moderate intensity light, a ≈55 % and ≈68 % to ≈78 % conversion of total inorganic carbon to CO 2 was found for the simulated and amino acid-based DAC systems, respectively. Our results confirm the feasibility of on-demand CO 2 release under ambient conditions using light instead of heat, thereby providing an energy efficient pathway for the regeneration of DAC sorbents.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Nuclear Structural Component Relevant Properties of Nickel-Based Alloys Produced via Additive Manufacturing

Idaho National Laboratory initiated examination of nickel-based alloys manufactured via three different additive manufacturing methods for potential applications in nuclear, high temperature structural components. The three methods analyzed included laser powder bed fusion, blown powder laser directed energy deposition, and wire-fed gas metal arc directed energy deposition. With the rapid push towards additive manufacturing, codes do not exist that definitively define what is or is not tolerable for each process and application, such as with conventional, wrought products. This report contains the initial work to understand possible manufacturing methods for high temperature alloys, and specifically, void formation, microstructure evolution, corrosion, and mechanical properties. To generate mechanical test data, specimens were tested irrespective of voids and microstructures were analyzed to better understand how to negate/improve these issues. The preliminary results showed major decreases in mechanical performance for material tested. Test specimens will continue to be produced to further improve each additive manufacturing processes, quantify void acceptance, and better understand the most suitable high temperature alloys receptive to additive manufacturing and high temperature nuclear applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Design and performance validation of a high-temperature downhole permanent magnet generator used for an electro-pulse boring system in geothermal energy applications

Novel, direct-energy drilling technologies such as electro-pulse boring, have the potential to significantly increase the speed and depth of geothermal drilling but have not achieved widespread adoption due to several economic and technical barriers. One major challenge is that these drilling systems require electric power downhole. The current practice is to supply power to the drill string components by running electric cables down the geothermal well, but at the targeted well depths, this practice is cost-inhibitive, inefficient in terms of power consumption, and adds an additional failure point with the long cabling going through a highly corrosive, high-temperature environment. A solution to this problem is to develop high-temperature electric generator technology that can generate the required power downhole. Such a generator must also operate with high efficiency at the target downhole ambient temperature of 250 °C. In this paper, we investigate the various design considerations for this concept and subsequently design the downhole electric generator using a multi-objective design optimization approach. Through electromagnetic-, thermal- and short-circuit fault condition analysis, it is demonstrated that the optimized downhole electric generator concept presented in this paper can meet the performance requirements within this extreme drilling environment. Most remarkably, it is shown that a generator efficiency of 90% is achieved. In conclusion, to validate the results presented in this paper, a prototype generator is built and its performance is measured at 250 °C using a test bench uniquely developed for this application.

15 GEOTHERMAL ENERGY↗

DOE OSTI2025

InDEEP, DEEC-Tec, and Direct Generation Synergies for Ocean Wave Energy: Wave Energy Scotland's Direct Generation Programme Review

The presentation highlights: (i) how DEEC-Tec, advanced through the U.S. DOE's InDEEP Prize, holds the potential to redefine ocean wave energy conversion through modular, embedded energy conversion; (ii) a global scan that identified 158 participants and 35 promising concepts, showcasing strong international momentum; (iii) InDEEP's innovation-first approach and how it complements Wave Energy Scotland's structured Direct Generation research; and (iv) the ongoing and possible future collaborative pathways for co-funded trials, joint metric/standards developments, and maturation of these technologies toward and real-world deployment.

16 TIDAL AND WAVE POWER↗

DOE OSTI2026

Thermokinetic mixing compounding for polymer composites – a comprehensive review

High-speed thermokinetic mixers (K-mixers) represent an advanced compounding technology that employs intense shear and friction to convert kinetic energy directly into thermal energy. This mechanism enables rapid mixing cycles, often under one minute, facilitating exceptional filler dispersion while minimizing the material’s thermal history. This is particularly effective for compounding challenging materials, including heat-sensitive biopolymers, wet filler feedstocks, and nanofillers prone to agglomeration. As the first comprehensive review of this technology, this article synthesizes the fundamental principles of thermokinetic mixing (K-mixing) and surveys recent advances in polymer composite fabrication. We contrast the working principles of K-mixers with conventional twin-screw extrusion, highlighting distinct advantages in dispersing nanoscale fillers, exfoliating layered materials, and processing wet cellulosic feedstocks and ultra-high filler loadings (e.g., 85 wt%). Furthermore, strategies to optimize filler–matrix interfacial bonding under rapid-processing constraints, such as the kinetic selection of compatibilizers and fiber surface treatments, are evaluated. Finally, we analyze key structure-processing-property relationships and outline future directions in scaling up, reactive processing, and hybrid material development.

Zhang, Xuefeng [University of Maine]↗

DOE OSTI2022

Graph Neural Networks for low-energy event classification & reconstruction in IceCube

IceCube, a cubic-kilometer array of optical sensors built to detect atmospheric and astrophysical neutrinos between 1 GeV and 1 PeV, is deployed 1.45 km to 2.45 km below the surface of the ice sheet at the South Pole. The classification and reconstruction of events from the in-ice detectors play a central role in the analysis of data from IceCube. Reconstructing and classifying events is a challenge due to the irregular detector geometry, inhomogeneous scattering and absorption of light in the ice and, below 100 GeV, the relatively low number of signal photons produced per event. To address this challenge, it is possible to represent IceCube events as point cloud graphs and use a Graph Neural Network (GNN) as the classification and reconstruction method. The GNN is capable of distinguishing neutrino events from cosmic-ray backgrounds, classifying different neutrino event types, and reconstructing the deposited energy, direction and interaction vertex. Based on simulation, we provide a comparison in the 1 GeV–100 GeV energy range to the current state-of-the-art maximum likelihood techniques used in current IceCube analyses, including the effects of known systematic uncertainties. For neutrino event classification, the GNN increases the signal efficiency by 18% at a fixed background rate, compared to current IceCube methods. Alternatively, the GNN offers a reduction of the background (i.e. false positive) rate by over a factor 8 (to below half a percent) at a fixed signal efficiency. For the reconstruction of energy, direction, and interaction vertex, the resolution improves by an average of 13%–20% compared to current maximum likelihood techniques in the energy range of 1 GeV–30 GeV. The GNN, when run on a GPU, is capable of processing IceCube events at a rate nearly double of the median IceCube trigger rate of 2.7 kHz, which opens the possibility of using low energy neutrinos in online searches for transient events.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Additive manufacturing as a processing route for steel-aluminum bimetallic structures

Here we present results on the fabrication of steel-aluminum bi-metallic structures using directed energy deposition additive manufacturing. The challenges associated with the fabrication of a sharp transition from steel to aluminum are uncovered using ex-situ characterization techniques and thermo-mechanical modeling of the deposition process. It was found that the fabrication of a sharp steel-aluminum transition is challenging with extensive cracking observed at the interface. The cracking was attributed to the combined effect of residual stress development due to thermal expansion coefficient mismatch and the presence of ordered intermetallics with low ductility at the interface. Using a coupled thermodynamic and thermo-mechanical modeling approach, potential pathways to enable the fabrication of steel-aluminum bi-metallic structures using additive manufacturing are proposed. The results presented here can lay the foundation for future work on the fabrication of bi-metallic steel-aluminum structures using directed energy deposition.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Extended continuous cooling transformation diagram for 410 stainless steel encompassing δ → γ and γ → αʹ transformations determined by dilatometry

In this study, we use dilatometry to construct an extended Continuous Cooling Transformation (CCT) diagram for 410 stainless steel, capturing both δ → γ and γ → αʹ transformations specifically for directed energy deposition (DED) additive manufacturing (AM) applications. To ensure that the findings are representative of AM specific microstructures and compositions, dilatometry coupons were extracted from a wire arc DED wall, thereby preserving the inherent microstructural and compositional variability within the material. The on-heating phase transformations, including A c1 , A c3 , and γ → δ, were found to be essentially location independent, despite the typical heterogeneity associated with AM. Conversely, increasing cooling rates were observed to shift the start and finish temperatures of both δ → γ and γ → αʹ transformations to lower values. The resulting extended CCT diagram offers a more complete depiction of phase transformation behavior in the system, enabling accurate microstructure evolution modeling and residual stress predictions specifically for directed energy deposition additive manufacturing applications.

Additive manufacturing↗

DOE OSTI2023

Enhanced cutoff energies for direct and rescattered strong-field photoelectron emission of plasmonic nanoparticles

Abstract The efficient generation, accurate detection, and detailed physical tracking of energetic electrons are of applied interest for high harmonics generation, electron-impact spectroscopy, and femtosecond time-resolved scanning tunneling microscopy. We here investigate the generation of photoelectrons (PEs) by exposing plasmonic nanostructures to intense laser pulses in the infrared (IR) spectral regime and analyze the sensitivity of PE spectra to competing elementary interactions for direct and rescattered photoemission pathways. Specifically, we measured and numerically simulated emitted PE momentum distributions from prototypical spherical gold nanoparticles (NPs) with diameters between 5 and 70 nm generated by short laser pulses with peak intensities of 8.0 × 10 12 and 1.2 × 10 13 W/cm 2 , demonstrating the shaping of PE spectra by the Coulomb repulsion between PEs, accumulating residual charges on the NP, and induced plasmonic electric fields. Compared to well-understood rescattering PE cutoff energies for strong-field photoemission from gaseous atomic targets (10× the ponderomotive energy), our measured and simulated PE spectra reveal a dramatic cutoff-energy increase of two orders of magnitude with a significantly higher contribution from direct photoemission. Our findings indicate that direct PEs reach up to 93 % of the rescattered electron cutoff energy, in contrast to 20 % for gaseous atoms, suggesting a novel scheme for the development of compact tunable tabletop electron sources.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Prediction of Substrate Distortion in Powder DED Using Finite Element Model

Abstract Leveraging the capabilities of both additive and subtractive manufacturing to repair tooling and other high value items can result in significant cost and time saving opportunities. However, when dimensional accuracy of the repaired component must be held within a specified tolerance, distortion of the component induced during repair can lead to an out of specification final component. This work presents simulation of a novel method to mitigate part distortion using sacrificial support structures. A blown powder directed energy deposition system was utilized for deposition of sacrificial support structures and clad surface depositions. Sacrificial support structures were deposited on the underside of the substrate with varying geometries prior to clad surface depositions. A finite element model was developed and verified using experimental results. The simulation and experimental control results were found to match within 6%. It has been shown that simulation can be used to predict effects of sacrificial support structures on substrate distortion in a blown powder directed energy deposition process.

Burl, Alan G.↗

DOE OSTI2023

Additive Manufacturing for Powering the Blue Economy Applications: A Tidal Turbine Blade Case Study: Preprint

As the marine renewable energy industry continues to expand, innovation in the manufacturing space must grow accordingly to reduce costs and ensure the economic feasibility of new technologies. Additive manufacturing, more commonly known as 3D printing, provides an alternative for rapid prototyping of marine hydrokinetic technologies, particularly supporting Powering the Blue Economy initiatives of the U.S. Department of Energy Water Power Technologies Office. This study explores the application of additive manufacturing in the development of marine hydrokinetic structures, focusing on material and printing method selection, design, and analysis of a 3D-printed spar for an axial-flow tidal turbine blade. Corrosion-resistant metals were deemed ideal due to the loads and harsh marine environment the blade would experience. Laser metal deposition methods were determined to be the most effective and scalable for the considered scale. The designed spar adapts its geometry to the blade - a feature uniquely suited to additive manufacturing - and is intended to serve as the blade's primary structural component. A finite element model was used to study stresses and deformations under loading conditions. The spar was manufactured using 316L stainless steel through direct energy deposition, and defects were assessed and recorded. Future efforts will include mechanical testing of the spar. This research establishes a benchmark process for using additive manufacturing in developing marine hydrokinetic structures, paving the way for future optimization and techno-economic analysis.

additive manufacturing↗

DOE OSTI2020

Combined Force-Frequency Sampling for Simulation of Systems Having Rugged Free Energy Landscapes.

An adaptive, machine learning-based sampling method is presented for simulation of systems having rugged, multidimensional free energy landscapes. The method's main strength resides in its ability to learn both from the frequency of visits to distinct states and the generalized force estimates that arise in a system as it evolves in phase space. This is accomplished by introducing a self-integrating artificial neural network, which generates an estimate of the free energy directly from its derivatives. The usefulness of the proposed combined approach is examined in the context of two concrete examples, namely, an alanine dipeptide molecule in water and a polymer diffusing through a narrow pore. This new method is found to be robust, faster, and more accurate than approaches that rely only on frequency-based or generalized force-based estimations. After combining the proposed approach with overfill protection and support for sparse data storage and training, the method is shown to be more effective than comparable, previously available techniques and capable of scaling efficiently to larger numbers of collective variables.

Sevgen, Emre↗