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DOE OSTI2025

Numerical and experimental analysis of mechanically induced failure in electric vehicle battery modules

Mitigating thermal runaway and cell-to-cell propagation is essential for improving the safety of electric and hybrid vehicles. Enhancing digital twin capabilities to predict battery mechanical abuse is particularly critical for automotive and aerospace applications, where crashworthiness is a key concern. Understanding failure conditions and propagation in battery modules during mechanical abuse is complex due to interactions between structural deformation, heat transfer, electrochemical processes, exothermic reactions and mechanical fracture. While prior studies have focused on modeling cell-level behavior, extending these models to module or pack level is necessary for a system level understating of electric vehicle safety. This study develops coupled large deformation finite element models that simultaneously solve for electrochemistry, material failure, internal short circuit and thermal runaway propagation. The models account for mechanical and thermal interactions between lithium-ion cells and other battery components while the contact interfaces are evolving with time. Model-predicted voltage, temperature and force responses are compared with experimental data for validation. The results demonstrate that the approach captures key failure mechanisms, including thermal propagation through heat transfer, electrical propagation from short circuits in parallel-connected cells, and mechanical propagation via penetration and crack formation. These findings show that computational models are valuable tools for understanding battery module failure and providing insight that can reduce the need for extensive experimental testing.

25 ENERGY STORAGE↗

NASA NTRS2018

NASA Electronic Parts and Packaging Field Programmable Gate Array Single Event Effects Test Guideline Update

The following are updated or new subjects added to the FPGA SEE Test Guidelines manual: academic versus mission specific device evaluation, single event latch-up (SEL) test and analysis, SEE response visibility enhancement during radiation testing, mitigation evaluation (embedded and user-implemented), unreliable design and its affects to SEE Data, testing flushable architectures versus non-flushable architectures, intellectual property core (IP Core) test and evaluation (addresses embedded and user-inserted), heavy-ion energy and linear energy transfer (LET) selection, proton versus heavy-ion testing, fault injection, mean fluence to failure analysis, and mission specific system-level single event upset (SEU) response prediction. Most sections within the guidelines manual provide information regarding best practices for test structure and test system development. The scope of this manual addresses academic versus mission specific device evaluation and visibility enhancement in IP Core testing.

Field Programmable Gate Array (FPGA)↗

NASA NTRS2013

Exploration Laboratory Analysis FY13

The Exploration Laboratory Analysis (ELA) project supports the Exploration Medical Capability (ExMC) risk, which is stated as the Risk of Inability to Adequately Treat an Ill or Injured Crew Member, and ExMC Gap 4.05: Lack of minimally invasive in-flight laboratory capabilities with limited consumables required for diagnosing identified Exploration Medical Conditions. To mitigate this risk, the availability of inflight laboratory analysis instrumentation has been identified as an essential capability in future exploration missions. Mission architecture poses constraints on equipment and procedures that will be available to treat evidence-based medical conditions according to the Space Medicine Exploration Medical Conditions List (SMEMCL), and to perform human research studies on the International Space Station (ISS) that are supported by the Human Health and Countermeasures (HHC) element. Since there are significant similarities in the research and medical operational requirements, ELA hardware development has emerged as a joint effort between ExMC and HHC. In 2012, four significant accomplishments were achieved towards the development of exploration laboratory analysis for medical diagnostics. These achievements included (i) the development of high priority analytes for research and medical operations, (ii) the development of Level 1 functional requirements and concept of operations documentation, (iii) the selection and head-to-head competition of in-flight laboratory analysis instrumentation, and (iv) the phase one completion of the Small Business Innovation Research (SBIR) projects under the topic Smart Phone Driven Blood-Based Diagnostics. To utilize resources efficiently, the associated documentation and advanced technologies were integrated into a single ELA plan that encompasses ExMC and HHC development efforts. The requirements and high priority analytes was used in the selection of the four in-flight laboratory analysis performers. Based upon the competition results, a down select process will be performed in the upcoming year. Looking ahead, this unified effort has positioned each element for an in-flight lab analysis demonstration of select diagnostics measurements in the 2015 timeframe.

Krihak, Michael↗

NASA NTRS2018

NASA Electronic Parts and Packaging (NEPP) Field Programmable Gate Array (FPGA) Single Event Effects (SEE) Test Guideline Update

Test guidelines↗

NASA NTRS2018

Identification of Safety Metrics for Airport Surface Operations

A large fraction of safety incidents occurs on the ground during airport surface operations. Although these incidents are mostly non-fatal with a few exceptions, they are high profile incidents that remain a source of concern for the National Transportation Safety Board (NTSB), the Federal Aviation Administration (FAA), major airlines, and other stakeholders of the National Airspace System (NAS). These incidents have historically been mitigated by implementing changes to regulations, policies, and procedures over time. This approach has minimized but not eliminated the risk of occurrence of safety incidents. It is thus important to develop integrated techniques to assess, model, and prevent these incidents by analyzing the risk and likelihood of occurrence and communicating results of the analysis to decision-making personnel who can mitigate and prevent incidents in real time. The work presented in this paper builds on a previously developed architecture for safety, Real-Time Safety Monitoring (RTSM), to enable monitoring and prediction of the safety of the NAS. In the RTSM framework, hazards to flight are translated to safety metrics such as wake vortex encounters or loss of separation, that can be modeled and analyzed offline and also predicted and monitored in real time (online). The intent of this paper is to integrate predictable incidents that occur during surface and ground operations into the safety portfolio of the RTSM project by (i) identifying suitable information sources from which ground incidents can be studied, (ii) developing safety metrics correlated with surface operations, and (iii) recommending suitable data sources that can be quantified and used for the computation of pertinent safety metrics.

safety↗

NASA NTRSDate not supplied

Dynamic Adjustment of Model Parameters Using Assimilated Boundary Layer Height

The NASA Global Modeling and Assimilation Office is exploring the assimilation of boundary layer height (PBLH) derived from a variety of observations, including radiosondes, GNSS-RO, space- and ground-based lidar, and radar wind profilers. Previous work using the Goddard Earth Observing System (GEOS) has shown that within the lower troposphere, the representation of thermodynamic structure is strongly affected by model parameterizations. In assimilation experiments, parameterizations can compensate for analysis thermodynamic increments and reduce the observation information carried forward in time. To mitigate this effect, the present study explores a dynamic parameter adjustment based on the PBLH analysis field. The PBLH analysis increment is used to adjust model parameters that influence the depth of parameterized boundary layer mixing in both stable and convective regimes. Replay (nudging) experiments and cycled data assimilation experiments are used to evaluate the approach. The parameter adjustment is shown to reduce model compensation of the analysis thermodynamic tendencies and bring model parameterized mixing depths into closer agreement with observed PBLH.

Nathan Arnold↗

DOE OSTI2025

Supercritical water desalination and oxidation (SCWDO): Effectiveness on complex solutions, technoeconomic, and CO 2 impact for produced water treatment

The modern energy-economy is increasingly causing the production of highly saline brines, including from produced water. Supercritical water desalination can concentrate and extract minerals from these brines, but the effects of mixed salt interactions, organic degradation with additives, and the technology's economics are not well understood at supercritical condition. The present study evaluated and experimentally studied an integrated supercritical water desalination and oxidation (SCWDO) process for treating real-produced water samples from oil/natural gas field. The complex interactions between the various anions and cations in produced water were extensively evaluated. Most of the divalent and trivalent ions were extracted below 250 °C while the majority of the monovalent salt were removed between 380 to 410 °C. The treated real produced water was of drinking water quality, with <500 mg/l of total dissolved solid (TDS) and with 100% organics removal. Furthermore, the heat liberated during the organic oxidation could be utilized internally and for electricity generation for enhanced the energy efficiency and lower cost of produced water treatment. With system optimization, the proposed SCWDO process can essentially be made a net zero energy process. A novel process flow diagram for the commercial scale self-powered hybrid SCWDO technology was proposed as a cost-effective produced water treatment to mitigate the environmental crises. Techno-economic analysis showed that produced water treatment cost with SCWDO can be reduced to 2–3 $/m 3 and can be up to 60 % cheaper to traditional deep well reinjection. Additionally, the proposed SCWDO process could achieve net negative CO 2 emission.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Bipolar plate flow channel designs for vanadium redox flow battery: a review

Vanadium redox flow battery is one of the preferred systems for grid scale energy storage due to long service life (>20000 cycles), higher efficiency (>85 %), deep discharge capability (>95 % DoD), and inherent scalability and safety. Among system components, flow field is most critical as it governs electrolyte distribution, mass transport and hydraulic performance. Here, this review examines emerging flow channel geometries, highlighting the impact of channel width (0.66 to 1.5 mm), depth (1 to 1.5 mm) and land width (0.5 to 1.5 mm) can reduce pressure drop to <10 kPa while enabling power densities above 600 mW.cm -2 . A key finding is that low channel width to depth ratio (<1) enhances voltage and energy efficiencies by improving under rib convection. The review also provides an overview of progress and perspective in bipolar plate materials, manufacturability, and shunt current mitigation strategies for stack scaling up. Cost analysis emphasizes the influence of flow field designs on the levelized cost of storage and pathways towards the US DOE's $\$$0.05 per kWh energy generation cost target. In addition, opportunities for AI/ML/DT tools assisted design and data driven optimization strategies are also outlined to accelerate next generation flow field development.

Efficiency optimization↗

DOE OSTI2026

Dynamic aperture studies at the Fermilab recycler ring

As part of the Proton Improvement Plan II (PIP-II), Fermilab aims to increase beam intensity delivered to neutrino experiments. In this context, higher intensity injection into the Recycler Ring enhances space charge effects, pushing operations closer to third-order resonances. These resonances reduce the Dynamic Aperture (DA), leading to increased beam loss. This study presents simulations of DA as a function of tune in the Recycler Ring, incorporating chaos indicators such as the Reversibility Error Method (REM) and Frequency Map Analysis (FMA). The effectiveness of existing resonance mitigation strategies is evaluated by quantifying their ability to delay DA degradation. Additionally, the study examines how space charge detuning and DA limitations dictate viable operational tune points for the Recycler Ring.

Gonzalez-Ortiz, Cristhian [Fermilab]↗

DOE OSTI2024

Securing Digital Energy Infrastructure: Procurement, Contracting, and Supply Chain Risk Management Guidance

Recognizing the scale of this industry challenge, the United States (U.S.) Department of Energy (DOE) Grid Deployment Office (GDO) and Cybersecurity Energy Security & Emergency Response office have launched a multi-year BESS supply chain security initiative to identify consequence-driven approaches to addressing BESS supply chain security and provide resources to support prioritization of supply chain security efforts associated with the procurement of BESS equipment and services. This guide is one element of the supporting resources to be provided and sets forth a framework and guidance for procurement bidding, selection, risk analysis, and agreements stakeholders can implement to mitigate cybersecurity risks across the entirety of battery system component ecosystem, including the interconnected software and hardware required for control and monitoring BESSs.

25 ENERGY STORAGE↗

DOE OSTI2026

Feasibility Analyses for the Microgrid of the Mountain in the Cordillera Central Region of Puerto Rico

Distributed energy resource (DER) development can benefit communities through improvement of access to reliable electricity and a resilient energy system. Many place-specific considerations must be accounted for when designing electrical systems with co-located generation and loads. This paper presents an overview of four studies focusing on different aspects for regional DER development in the Cordillera Central region of Puerto Rico, including a grid and load stability study with the introduction of solar energy generation, microgrid design based on the solar resource in the area, resilience considerations during power outage scenarios, and qualitative risk aspects for components in the microgrid. Additionally, a conceptual substation microgrid analysis is conducted using the Microgrid Design Toolkit (MDT) to evaluate trade-offs between cost and energy availability, providing insights into optimal design strategies. A microgrid resilience assessment is performed using the Resilient Nodal Cluster Analysis Tool (ReNCAT) to identify critical loads and evaluates their accessibility during outages, emphasizing the importance of community needs. Finally, a qualitative risk assessment utilizing Hazard and Operability Analysis (HAZOP) methods highlights potential hazards and mitigations for microgrid components, ensuring robust system design and operation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

NOvA in 10 Minutes

NOvA is a long-baseline neutrino oscillation experiment based at Fermilab, IL, USA, that observes $\nu_\mu \ (\bar{\nu}_\mu) \to \nu_\mu\ (\bar{\nu}_\mu)$ disappearance and $\nu_\mu \ (\bar{\nu}_\mu) \to \nu_e \ (\bar{\nu}_e)$ appearance oscillations from a beam of muon neutrinos (anti-neutrinos) provided by the Fermilab's NuMI beamline. The experiment consists of two functionally identical active liquid scintillattor tracking calorimeters, both situated 14.6 mrad off-axis to the beam direction. The detectors are made out of extruded PVC cells arranged in alternating horizontal and vertical planes for 3-dimensional reconstruction of neutrino events. The NOvA experiment has a wide-ranging scientific program that includes studying standard 3-flavor neutrino oscillations, resolution of neutrino mass orderings, measuring the CP-violating phase, $\delta_{CP}$, beyond standard model (BSM) phenomenon such as non-standard interactions (NSI) and sterile neutrino searches, neutrino-nucleus cross-section measurements, exotics, astrophysics and more. The NOvA experiment leverages its identical detector technology to mitigate systematic uncertainties for its neutrino oscillation analysis. This talk will provide an overview of the experiment's detector design and the data-driven techniques used by the experiment in its neutrino oscillation analysis.

Choudhary, Brajesh [Delhi U.]↗

NASA NTRS1980

A methodology for the environmental assessment of advanced coal extraction systems

Procedures developed to identify and assess potential environment impacts of advanced mining technology as it moves from a generic concept to a more systems definition are described. Two levels of assessment are defined in terms of the design stage of the technology being evaluated. The first level of analysis is appropriate to a conceptual design. At this level it is assumed that each mining process has known and potential environmental impacts that are generic to each mining activity. By using this assumption, potential environmental impacts can be identified for new mining systems. When two or more systems have been assessed, they can be evaluated comparing potential environmental impacts. At the preliminary stage of design, a systems performance can be assessed again with more precision. At this level of systems definition, potential environmental impacts can be analyzed and their significane determined in a manner to facilitate comparisons between systems. At each level of analysis, suggestions calculated to help the designer mitigate potentially harmful impacts are provided.

Sullivan, P. J.↗

NASA NTRS2000

Spacecraft Autonomy and Automation: A Comparative Analysis of Strategies for Cost Effective Mission Operations

The evolution of satellite operations over the last 40 years has drastically changed. October 4, 1957 (during the cold war) the Soviet Union launched the world's first spacecraft into orbit. The Sputnik satellite orbited Earth for three months and catapulted the United States into a race for dominance in space. A year after Sputnik, President Dwight Eisenhower formed the National Space and Aeronautics Administration (NASA). With a team of scientists and engineers, NASA successfully launched Explorer 1, the first US satellite to orbit Earth. During these early years, massive amounts of ground support equipment and operators were required to successfully operate spacecraft vehicles. Today, budget reductions and technological advances have forced new approaches to spacecraft operations. These approaches require increasingly complex, on board spacecraft systems, that enable autonomous operations, resulting in more cost-effective mission operations. NASA's Goddard Space Flight Center, considered world class in satellite development and operations, has developed and operated over 200 satellites during its 40 years of existence. NASA Goddard is adopting several new millennium initiatives that lower operational costs through the spacecraft autonomy and automation. This paper examines NASA's approach to spacecraft autonomy and ground system automation through a comparative analysis of satellite missions for Hubble Space Telescope-HST, Near Earth Asteroid Rendezvous-NEAR, and Solar Heliospheric Observatory-SoHO, with emphasis on cost reduction methods, risk analysis and anomalies and strategies employed for mitigating risk.

Wright, Nathaniel, Jr.↗

NASA NTRS2008

Trajectory Planning by Preserving Flexibility: Metrics and Analysis

In order to support traffic management functions, such as mitigating traffic complexity, ground and airborne systems may benefit from preserving or optimizing trajectory flexibility. To help support this hypothesis trajectory flexibility metrics have been defined in previous work to represent the trajectory robustness and adaptability to the risk of violating safety and traffic management constraints. In this paper these metrics are instantiated in the case of planning a trajectory with the heading degree of freedom. A metric estimation method is presented based on simplifying assumptions, namely discrete time and heading maneuvers. A case is analyzed to demonstrate the estimation method and its use in trajectory planning in a situation involving meeting a time constraint and avoiding loss of separation with nearby traffic. The case involves comparing path-stretch trajectories, in terms of adaptability and robustness along each, deduced from a map of estimated flexibility metrics over the solution space. The case demonstrated anecdotally that preserving flexibility may result in enhancing certain factors that contribute to traffic complexity, namely reducing proximity and confrontation.

Idris, Husni R.↗

NASA NTRS2010

The HYTHIRM Project: Flight Thermography of the Space Shuttle During the Hypersonic Re-entry

This report describes a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. A background and an overview of several multidisciplinary efforts that culminated in the acquisition of high resolution calibrated infrared imagery of the Space Shuttle during hypervelocity atmospheric entry is presented. The successful collection of thermal data has demonstrated the feasibility of obtaining remote high-resolution infrared imagery during hypersonic flight for the accurate measurement of surface temperature. To maximize science and engineering return, the acquisition of quantitative thermal imagery and capability demonstration was targeted towards three recent Shuttle flights - two of which involved flight experiments flown on Discovery. In coordination with these two Shuttle flight experiments, a US Navy NP-3D aircraft was flown between 26-41 nautical miles below Discovery and remotely monitored surface temperature of the Orbiter at Mach 8.4 (STS-119) and Mach 14.7 (STS-128) using a long-range infrared optical package referred to as Cast Glance. This same Navy aircraft successfully monitored the Orbiter Atlantis traveling at approximately Mach 14.3 during its return from the successful Hubble repair mission (STS-125). The purpose of this paper is to describe the systematic approach used by the Hypersonic Thermodynamic Infrared Measurements team to develop and implement a set of mission planning tools designed to establish confidence in the ability of an imaging platform to reliably acquire, track and return global quantitative surface temperatures of the Shuttle during entry. The mission planning tools included a pre-flight capability to predict the infrared signature of the Shuttle. Such tools permitted optimization of the hardware configuration to increase signal-to-noise and to maximize the available dynamic range while mitigating the potential for saturation. Post flight, analysis tools were used to assess atmospheric effects and to convert the 2-D intensity images to 3-D temperature maps of the windward surface. Comparison of the spatially resolved global thermal measurements to surface thermocouples and CFD prediction is made. Successful demonstration of a quantitative, spatially resolved, global temperature measurement on the Shuttle suggests future applications towards hypersonic flight test programs within NASA, DoD and DARPA along with flight test opportunities supporting NASA's project Constellation.

Horvath, Thomas J.↗

NASA NTRS2012

Upset Simulation and Training Initiatives for U.S. Navy Commercial Derived Aircraft

Militarized versions of commercial platforms are growing in popularity due to many logistical benefits in the form of commercial off-the-shelf (COTS) parts, established production methods, and commonality for different certifications. Commercial data and best practices are often leveraged to reduce procurement and engineering development costs. While the developmental and cost reduction benefits are clear, these militarized aircraft are routinely operated in flight at significantly different conditions and in significantly different manners than for routine commercial flight. Therefore they are at a higher risk of flight envelope exceedance. This risk may lead to departure from controlled flight and/or aircraft loss1. Historically, the risk of departure from controlled flight for military aircraft has been mitigated by piloted simulation training and engineering analysis of typical aircraft response. High-agility military aircraft simulation databases are typically developed to include high angles of attack (AoA) and sideslip due to the dynamic nature of their missions and have been developed for many tactical configurations over the previous decades. These aircraft simulations allow for a more thorough understanding of the vehicle flight dynamics characteristics at high AoA and sideslip. In recent years, government sponsored research on transport airplane aerodynamic characteristics at high angles of attack has produced a growing understanding of stall/post-stall behavior. This research along with recent commercial airline training initiatives has resulted in improved understanding of simulator-based training requirements and simulator model fidelity.2-5 In addition, inflight training research over the past decade has produced a database of pilot performance and recurrency metrics6. Innovative solutions to aerodynamically model large commercial aircraft for upset conditions such as high AoA, high sideslip, and ballistic damage, as well as capability to accurately account for scaling factors, is necessary to develop realistic engineering and training simulations. Such simulations should significantly reduce the risk of departure from controlled flight, loss of aircraft, and ease the airworthiness certification process. The characteristics of commercial derivative aircraft are exemplified by the P-8A Multi-mission Maritime Aircraft (MMA) aircraft, and the largest benefits of initial investigation are likely to be yielded from this platform. The database produced would also be utilized by flight dynamics engineers as a means to further develop and investigate vehicle flight characteristics as mission tactics evolve through the years ahead. This paper will describe ongoing efforts by the U.S. Navy to develop a methodology for simulation and training for large commercial-derived transport aircraft at unusual attitudes, typically experienced during an aircraft upset. This methodology will be applied to a representative Navy aircraft (P-8A) and utilized to develop a robust simulation that should accurately represent aircraft response in these extremes. Simulation capabilities would then extend to flight dynamics analysis and simulation, as well as potential training applications. Recent evaluations of integrated academic, ground-based simulation, and in-flight upset training will be described along with important lessons learned, specific to military requirements.

Donaldson, Steven↗

NASA NTRS2014

Middle Man Concept for In-Orbit Collision Risks Mitigation, CAESAR and CARA Examples

This paper describes the conjunction analysis which has to be performed using data provided by JSpOC. This description not only demonstrates that Collision Avoidance is a 2- step process (close approach detection followed by risk evaluation for collision avoidance decision) but also leads to the conclusion that there is a need for a Middle Man role. After describing the Middle Man concept, this paper introduces two examples with their similarities and particularities: the American civil space effort delivered by the NASA CARA team (Conjunction Assessment Risk Analysis) and the French response CAESAR (Conjunction Assessment and Evaluation Service: Alerts and Recommendations). For both, statistics are presented and feedbacks discussed. All together, around 80 satellites are served by CARA and/or CAESAR. Both processes regularly evolve in order either to follow JSpOC upgrades or to improve analysis according to experience acquired during the past years.

conjunction↗