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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Metal-to-Ceramic Joining Methods to Support Development of Advanced Ceramic-Based CSP Components

The National Renewable Energy Laboratory, Missouri University of Science and Technology (MS&T), Massachusetts Institute of Technology (MIT), and Colorado School of Mines (CSM) collaborated to design, develop, and test a material concept at bench scale which will be used to achieve a ceramic-to-metal (C2M) joint between a selected metal HTF loop material and a selected ceramic material used by the Gen3 CSP technology pathway. The final joint assembly will need to possess sufficient mechanical properties to withstand static high-temperature (650 degrees-700 degrees C) and high-pressure (20 MPa) and thermal cycling (between 650 degrees C and 100 degrees C) conditions. The material concept consists of three key components: (1) a ceramic matrix composite (CMC) that serves as a compliant transition material aiming to mitigate the stresses due to the mismatch of coefficient of thermal expansion (CTE) from a direct ceramic-to-metal joint, (2) a metal-end joint utilizing a multi-principal element alloy (MPEA) with changing percentage of particle loading to bond the candidate metal to the CMC, and (3) a ceramic-end joint utilizing a glass ceramic to bond the candidate ceramic to the CMC.

14 SOLAR ENERGY↗
DOE OSTI2025

Developing Open-Source Tools for Increasing the Efficiency of Synthetic Aviation Turbine Fuel Certification Process

FuelLib is an open-source Python-based fuel library, developed by NREL, that leverages the group contribution method (GCM) of [1] to systematically estimate the thermodynamic and transport properties of hydrocarbon fuels. FuelLib predicts these properties based on the molecular structure of individual compounds or compound families, using weight percentages of a fuel's composition, typically measured using techniques such as gas chromatography (GC). FuelLib enables property estimation over a wide range of temperatures and pressures of multi-component fuels in the absence of detailed molecular composition data, making it particularly valuable for complex fuel mixtures where detailed experimental characterization of fuel composition is unavailable. These capabilities contribute directly to synthetic aviation turbine fuels (SATF) development, supporting the short-term American Society for Testing and Materials (ASTM) qualification of drop-in fuels while potentially expanding ASTM boundaries to certify a broader range of fuels.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Development of High-Temperature Bonding Techniques to Enable High-Temperature Static or Dynamic Strain Measurements

Current light-water nuclear reactors rely on a variety of different sensors and sensor applications to meet their structural health monitoring needs throughout the entirety of the reactor primary, secondary, and containment systems. Optical fiber–based sensor technologies could provide solutions to reduce the sensor system footprint while enhancing the measurement fidelity and spatial resolution by leveraging distributed monitoring techniques. Moreover, advanced reactors may require optical fiber–based sensors for structural health monitoring because their operating temperatures will exceed the limits of conventional transducers used to acquire dynamic strain or acoustic data in nuclear power plants. Therefore, this report describes experiments targeting the development of high-temperature bonding techniques that would allow for potentially long lengths of fibers to be bonded to metallic reactor components in advanced reactor systems. The high temperatures experienced within target application, next-generation nuclear reactors, necessitate a high-temperature resistant bond to limit the amount of tension on the fiber at the target application temperature. The primary bonding method investigated in this work is brazing; hot-rolling has also been investigated to a lesser extent. Both techniques are well-suited to bonding optical fibers to large reactor components such as primary coolant piping, pressure vessels, or heat exchangers. Optical frequency domain reflectometry was used to monitor the strain in metal-coated optical fibers before, during, and after the high-temperature bonding process. On select optical fibers that were successfully bonded, additional thermal cycling was performed to assess the extent to which the fiber remained bonded based on the expected thermal expansion of the test specimen material. The results of the various experiments yielded the following general conclusions: (1) brazing is a viable technique for bonding and allows significant compressive strain to be applied to the fiber at room temperature; (2) hot-rolling is a viable technique as well, which has been more optimized than the brazing technique for bonding, but less residual compressive strain has been observed with this technique; and (3) both techniques will need further development and optimization to demonstrate bonding of a long length of fiber that can provably operate at relevant temperatures for an advanced nuclear reactor application.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Development of a High-Rate Lithium-Air Battery Using a Gaseous CO 2 Reactant

Li-air batteries are considered a potential alternative to Li-ion batteries for transportation applications due to their high theoretical specific energy. Most works in this area focus on use of O 2 as the reactant. However, newer concepts for using gaseous reactants (such as CO 2 , which has a theoretical specific energy density of 1,876 Wh/kg) provide opportunities for further exploration. The main objective of this project was the development of a novel strategy that enables operation of Li-CO 2 batteries at high-capacity and high-rate, with a long-cycle-life. The team was able to: (1) Synthesize two novel transition metal chalcogenide (TMC) catalysts that work in synergy with ionic liquid-based electrolytes to enhance the efficiency of reactions during discharge and charge processes; (2) Fabricate high-porosity cathode electrodes with 3D printing to increase electrode surface area and gas permeability; (3) Develop a multiscale modeling framework that integrates Density Functional Theory (DFT), Ab-Initio Molecular Dynamics (AIMD), classical Molecular Dynamics (MD), and Finite Element Analysis (FEA) to investigate atomic and cell-level properties of Li-CO 2 batteries; (4) Assemble a stackable Li-CO 2 pouch-cell able to deliver a capacity of >200 mAh. These achievements were realized through an integrated approach based on materials synthesis, testing, characterization, analysis, and computation. This project produced a thorough understanding of key chemical, electronic, and kinetic parameters that govern the operation of Li- CO 2 batteries in realistic conditions. The methodologies employed, and the insight generated, will be valuable beyond advancing the field of Li-CO 2 batteries

25 ENERGY STORAGE↗
DOE OSTI2026

Solar Radiation Research Laboratory (SRRL) Core Project Final Report: Fiscal Years 2022-2024

The Solar Radiation Research Laboratory (SRRL) at the National Laboratory of the Rockies (NLR) is a world-leading solar calibration and measurement facility and maintains and disseminates the World Radiation Reference (essentially the W/m2) for the United States that is essential for traceable and accurate measurements of solar radiation at all solar generation facilities. SRRL operates two calibration facilities that meet International Standards Organization-17025 (ISO-17025) standards and provide unique high-quality calibrations to NREL and other U.S. Department of Energy laboratories. The Baseline Measurement System (BMS) at SRRL provides a high-quality record of solar irradiance and surface meteorological conditions. SRRL capabilities are used to develop (1) improved methods for the calibration of solar radiometers; (2) new standards through the ISO, the International Electrotechnical Commission (IEC), and the American Standards for Testing of Materials (ASTM) International; (c) solar radiation and meteorological models; and (d) advanced instrumentation and methods for operating solar measurement stations. The SRRL datasets are also critical for the validation of new models and datasets, such as the National Solar Radiation Database (NSRDB). The research and development of solar radiation measurement systems and resource modeling techniques are essential for advancing the scientific basis for producing reliable resource data. Specifically, the spatial, temporal, and spectral (wavelength dependency) characteristics of the solar resource are required in several different time frames for various project phases.

14 SOLAR ENERGY↗
DOE OSTI2024

Nucleon Structure Studies at Jefferson Lab and the Electron Ion Collider

The research programs of Thomas Jefferson Laboratory (JLab) and the future Electron- Ion Collider (EIC) focus on one of the main goals of strong interaction studies : understanding the structure of nucleons in terms of the quarks and gluons composing them. Their structure is encoded in functions such as Generalized Parton Distributions (GPDs), which describe how quarks and gluons’ transverse position and longitudinal momentum are distributed inside nucleons. GPDs allow to obtain three-dimensional pictures of nucleons and to understand some of their fundamental properties, such as their internal pressure or the emergence of their spin from the dynamics of the partons composing them. At JLab and the EIC, electron beams are used to probe nucleons. Measurement of reactions such as Deeply Virtual Compton Scattering (DVCS) allows access to GPDs. The first longitudinally polarized-target experiment of the CLAS12 program at Jlab took place in 2022-2023. Combining polarized electron beams and nucleon targets, this experiment offers unique access to observables that allow the measurement of different types of GPDs. In particular, the DVCS beam- and target-spin asymmetries for protons and neutrons in deuterium will be measured for the first time. They give access to kinds of GPDs that are still poorly known, and the comparison between proton and neutron data will allow the extraction of the flavor dependence of the structure of nucleons. Specific analysis methods have been implemented to work with a polarized nuclear target and are presented in this thesis. These methods allow to obtain preliminary results for the asymmetries, waiting for the complete statistics to be available. In the long term, the experimental program for the EIC has been established with a strong emphasis on the measurement of the structure of nucleons at high energy. Measurements of reactions such as DVCS impose strict requirements on the electromagnetic calorimeter that will allow to measure the energy of the scattered electrons and photons. This calorimeter, which is under development, will be based on scintillating crystals read by Silicon Photomultipliers (SiPMs). A new type of glass-based scintillating material was tested, evaluating the possibilities to meet the technical requirements concerning their light yield and resistance to radiation damage in particular. Several models of SiPMs have been characterized, demonstrating they can operate over the vast energy range necessary to address the physics case at the EIC and providing guidelines for developing their readout electronics.

Pilleux, Noemie↗
DOE OSTI2025

Validation of a Custom Ball-on-Ring Apparatus and Consideration of Common Issues for Use in Further Testing (SULI Deliverables)

Ceramic materials are well-known for their high hardness and strength but are limited in their application due to low toughness and sudden failure. As a potential solution, inspiration can be taken from dental enamel nanostructure, where undulating rods cause cracks to branch or deflect, increasing the energy needed to cause total fracture of a ceramic part. Following the dental enamel structure, a novel ceramic which uses 3D printed Yttria stabilized Zirconia rods in an alumina matrix was developed. To test this bio-inspired ceramic material, a proper testing apparatus needed to be created and tested to verify its accuracy. For this project, a bespoke ball on ring testing apparatus was created and tested using both conventionally sintered alumina disks and purchased alumina disks to validate its accuracy. By comparing the Weibull distribution of rupture strengths measured by the tests to literature values, it was shown that the testing frame had a wide distribution of strength which did not align with literature values on the lower end. Through fractography, it was found that some samples fractured from the contact stress induced by the ball indenter, which could not be used to calculate rupture strength. This fracture was often linked to low stress to failure, which was initiated by a flaw on the surface near the indenter which acted as a stress concentrator. Removal of these samples from the data set increased the accuracy of the reported rupture strength values for the ceramic. Considering the equations for the magnitude of contact and flexural strength, along with observations of initiating flaws, several measures can be taken for testing the bio-inspired composite. These measures include proper polishing of both sides of the sample, reducing sample thickness, and potentially using a softer indenter material.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

ORNL Package Testing Program Overview

Radioactive materials are widespread in our everyday activities which are used in many different types of industries: Consumer products, Medicine, Industry, Energy, and Defense. In the United States there is about 3 million shipments of radioactive materials per year. With radioactive material being very widespread the number of new applications to ship these quantities increases daily. As such, ensuring the safe and secure transport of these materials is paramount, necessitating stringent packaging, transportation, and certification requirements. Shipments of radioactive materials have been made from Oak Ridge National Laboratory (ORNL) for the past 65 years. Since the 1940s ORNL has been at the forefront of the early development of regulations pertaining to the transport of radioactive shipments and associated regulatory testing. The early involvement resulted in ORNL being one of the leaders in the development of regulations and testing standards pertaining to the testing and design of packages. Today all package testing activities are conducted under the Package Testing Program (PTP) at ORNL at the Package Evaluation Facility (PEF). The PTP develops and evaluates testing solutions – ensuring that they are safe, efficient, and meet regulatory requirements ORNL PTP has extensive experience in the regulatory testing of radioactive material packages, supporting certification of Type A, Type, B, Type AF, and special form packages. The PEF serves as a one-stop-shop for design, testing, and certification of a wide variety of packages needed for shipment of radioactive materials. The facility provides the space, expertise, and equipment necessary to conduct rigorous performance testing under both normal and accident conditions or transport environments including free drop, dynamic crush, puncture, penetration, compression, vibration, water spray, water immersion, and thermal test. The PTP remains a key contributor to the safety and compliance of radioactive material transportation. This presentation will provide an overview of the program’s history, capabilities, and its ongoing role in advancing regulatory standards and transportation safety.

Martinez, Oscar [ORNL] (ORCID:0000000181814046)↗
DOE OSTI2025

Toward Standardized Microscale Tensile Testing for Two‐Photon Polymerization‐Fabricated Materials in Liquid

Two-photon polymerization (TPP) enables the fabrication of intricate 3D microstructures with submicron precision, offering significant potential in biomedical applications like tissue engineering. In such applications, to print materials and structures with defined mechanics, it is crucial to understand how TPP printing parameters impact the material properties in a physiologically relevant liquid environment. Herein, an experimental approach utilizing microscale tensile testing (μTT) for the systematic measurement of TPP-fabricated microfibers submerged in liquid as a function of printing parameters is introduced. Using a diurethane dimethacrylate-based resin, the influence of printing parameters on microfiber geometry is first explored, demonstrating cross-sectional areas ranging from 1 to 36 μm 2 . Tensile testing reveals Young's moduli between 0.5 and 1.5 GPa and yield strengths from 10 to 60 MPa. The experimental data show an excellent fit with the Ogden hyperelastic polymer model, which enables a detailed analysis of how variations in writing speed, laser power, and printing path influence the mechanical properties of TPP microfibers. The μTT method is also showcased for evaluating multiple commercial resins and for performing cyclic loading experiments. Collectively, this study builds a foundation toward a standardized microscale tensile testing framework to characterize the mechanical properties of TPP printed structures.

mechanical characterization↗
DOE OSTI2025

Assessing the Impact of Large Removable Beryllium Reflector Experiments on HFIR Performance and Safety Metrics

This study investigated the effect of various removable beryllium (RB) experiment configurations on High Flux Isotope Reactor (HFIR) metrics to address increasing interest in these facilities for materials and fuels irradiation research. The RB reflector contains eight large and four small irradiation experiment facilities that offer excellent neutron flux conditions to perform fission and fusion reactor materials and fuels irradiation research. This work aims to outline acceptable RB configurations based on safety, performance, and programmatic metrics. This study assessed experiment effects on reactivity, cycle length, fission rate density distributions, and neutron flux distributions using the Shift, HFIRCON, and SCALE ORIGEN codes. Initial evaluations focused on generic experiment materials including aluminum plugs, stainless steel plugs, molybdenum plugs, and aluminum plugs with gadolinium shields. Subsequent analyses of MiniFuel experiments were performed to evaluate a heterogenous experiment, consisting of a more complex geometry and bearing several materials, and to test the correlations developed with the generic materials on a real experiment. Furthermore, the effects of neutron poison concentrations in the standard beryllium plugs were evaluated. When assuming a reference RB configuration with eight large fresh beryllium plugs, perturbed configurations with three aluminum plugs, one stainless steel plug, one molybdenum plug, one gadolinium-shielded aluminum plug, and one MiniFuel experiment resulted in a cycle length reduction of less than 1.3 days, the current threshold before requiring additional approvals. Configurations with five aluminum plugs, one stainless steel plug, one molybdenum plug, one gadolinium-shielded aluminum plug, and two MiniFuel experiments meet the 1.3 day limit if irradiated beryllium plugs are considered. Fuel element fission rate density distributions remained within safety limits, with maximum local increases under 9%. Neutron flux calculations revealed large thermal flux depressions inside and around the perturbed RB facilities, while epithermal and fast neutron fluxes increased because of reduced neutron moderation by the perturbed materials. These findings provide valuable guidance for optimizing RB configurations to balance safety and performance at HFIR.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Development of Accelerated High Temperature Mechanical Testing Techniques

The Advanced Materials and Manufacturing Technologies (AMMT) Program focuses on advancing materials and manufacturing techniques for nuclear energy applications, particularly in the qualification of materials for high-temperature structural use. This report presents work on refining the creep testing of small specimen geometries. Efforts include the development of a new specimen geometry for sub-sized specimens, which were subjected to uniaxial creep tests. The results contribute to the understanding of material behavior under stress at elevated temperatures and offer potential improvements in creep data collection methods. These findings support ongoing advancements in material qualification processes essential for nuclear reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Convergent laser beam shapes: Unveiling the dynamics of Laser-induced elastic waves in composite materials

Overcoming the low signal-to-noise ratio (SNR) in laser ultrasonic testing of composite materials remains a significant challenge. Current efforts focus on enhancing SNR by inserting more energy into the material through temporal and/or spatial modulation of the laser beam. However, potential SNR improvements through wave convergence and wave energy manipulation have been overlooked. This paper addresses this gap by demonstrating the convergence of different wave types to a designated point and by showing the feasibility of directing absorbed laser energy into a specific wave type through spatial modulation of the laser beam. To achieve this, mathematical expressions for the convergent laser beams are derived. Various laser beam profiles are then introduced to the thermoelastic equations and solved using the finite element method. The sample under investigation is a transversely isotropic unidirectional carbon fiber reinforced plastic, characterized by anisotropic thermal expansion coefficients and thermal conductivities. Results reveal pronounced convergence of the intended wave type at the center due to laser beam shaping. This study showcases the ability to direct absorbed laser energy toward a specific wave type through spatial modulation of the laser beam and highlights the role of material anisotropy in energy focusing.

composite materials↗
DOE OSTI2024

Environmental Degradation in Advanced Reactor Environments

The Advanced Materials and Manufacturing Technologies (AMMT) program operating under the Department of Energy Office of Nuclear Energy is accelerating the qualification and deployment of additively manufactured materials in advanced reactor environments. Laser powder bed fusion (LPBF) has emerged as a promising additive manufacturing technique to fabricate complex components with the potential of tailored material properties. In the nuclear industry, metal additive manufacturing can offer numerous advantages, such as reduced lead times, streamlined quality assurance, and cost-effective low-volume production of new and replacement components with conventional or novel materials and geometries. The rapid and effective qualification of the effect of processing variability on the performance and degradation of additively manufactured materials is essential for the deployment of these components into advanced reactor environments. This talk presents an overview of the Environmental Effects area activities within AMMT. AMMT is performing irradiation and corrosion testing of several materials built by LPBF, including 316L and 316H stainless steels. Our irradiation efforts encompass neutron irradiation testing and ion irradiation testing to provide a robust technical basis for understanding the effect of process variability on materials degradation. We develop focused irradiation test plans that align well with risk-informed and technologically inclusive approaches to licensing. We will also discuss our plans and specific concerns for corrosion testing additively manufactured material, with a primary focus on molten salt and liquid sodium environments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

An Accelerated Testing and Analysis Framework for Qualification of Battery Materials Part I: A Case Study with LFP Cathodes

The growing demand for batteries used within automotive, aviation, and grid applications has exacerbated the need to supplement critical battery material feedstocks, such as those for anode and cathode active materials. New or supplementary material sources, however, universally comprise unique properties that can affect the lifetime and performance of resultant batteries. Even minor differences between new sources and established supplies can delay qualification, making it difficult for new suppliers to commercialize and resulting in a less resilient supply chain. Accordingly, the influence of composition, microstructure, and morphology on electrochemical performance should be characterized quickly and accurately to accelerate commercialization of new sources. This work introduces a tiered framework to assess new material viability and understand the influence of physicochemical properties on battery performance. The Tier 1 testing described here is rapid and low-effort to recognize materials with fundamental flaws and potentially disqualify them. Later testing would require more effort but provide higher-fidelity information with a goal of application-based validation. A case study examining commercial sources of LiFePO4 (LFP) is presented, using Tier 1 of the protocol to identify rapid electrochemical and physicochemical signals that correlate with performance and provide early go/no-go decisions for LFP materials without requiring long-term cycling.

25 ENERGY STORAGE↗
DOE OSTI2024

Summary of Gas Generation Behavior Observed in 3013 Surveillance and Monitoring Program Shelf-Life Experiments

Gas generation experiments have been conducted in small- and full-scale test containers at Los Alamos National Laboratory on samples of plutonium oxide material collected from plutonium processes across the DOE complex and tested at the bounding conditions for the Department of Energy 3013 Standard. The gas composition and pressures in the sealed experimental containers were measured over periods of months to years. These experiments have provided results for the formation and consumption of hydrogen and other gases. The conditions supporting the formation of flammable gas mixtures of hydrogen and oxygen in flammable gas mixtures were also determined. Different behaviors were observed between the materials tested based on their compositions, the stabilization performed on the material, and the post stabilization handling of the material. Many of the experiments are still ongoing. This report summarizes the results obtained for the gas generation behavior for high-purity plutonium oxides and salt-bearing impure plutonium oxides in sealed containers.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Reference Materials for Laser and Xenon Flash Thermal Diffusivity Systems

This report presents the status of current standard reference materials for thermal diffusivity testing. In most thermal properties testing systems, it is common to use standard reference materials to show the reproducibility of the tests and certify the instrument is producing results within expected uncertainty range. The definition of reference materials or standards vary depending on the quality control protocols of the project. For thermal diffusivity, although there were standards available by the National Bureau of Standards (NBS) 40 years ago, there has been no recent NIST standard reference material (SRM). There are only a few sources that produce and provide traceable reference standards for thermal diffusivity. The certificate typically expires in 5 years and only applies to the specific lot of materials. Other reference materials are provided by the testing systems manufacturers. They are mostly well-known reference materials or materials used by the equipment manufacturers with historic data. However, most these reference materials no longer carry valid certificates. Various reference materials will be discussed along with the industry practice when only secondary standards are available.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Accelerated Irradiation Testing and Post-Irradiation Characterization: U.S.-Based Capabilities for Advanced Nuclear Systems and Radioisotope Production

Irradiation experiments and post-irradiation examinations, together referred to as irradiation testing (IRT), are prerequisites for nuclear fuel and material qualification for the deployment of new and advanced reactors, as well as radioisotope production, thereby ensuring regulatory compliance. Qualified research and test reactors (RTRs) and testing facilities are essential to enable IRT to verify performance and safety under prototypical reactor conditions. In the past, qualification of new fuels or structural materials required about 20 years. Synergist strategies, advanced tools, and qualified methods are needed to greatly reduce this timeframe of IRT and radioisotope production. This study, termed accelerated-IRT, focuses on identifying gaps and leveraging U.S.-based RTRs and material testing capabilities, leveraging the preliminary evaluation and qualification of selected RTRs to provide a generic as well as specific-case solution paths forward, ensuring adherence to stringent regulatory standards. Furthermore, IRT and radioisotope production utilizing qualified RTRs necessarily includes modeling and simulation to support the design (i.e. neutronics, thermal, and structural aspects) and manufacturing of irradiation test specimens, vehicles, capsules, apparatuses, and flow loops. In addition, IRT can be improved by applying advanced manufacturing techniques and in-pile sensors and instrumentation, as discussed in this study.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗