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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Using Hardware-In-The-Loop Methodology to Develop Test Systems

Hardware in the Loop (HIL) testing methodologies have become widespread in industry. Typically, they focus on developing control algorithms for systems such as autonomous vehicles or aircraft. An oft overlooked aspect of product development is the design and fabrication of a test system for validating that the product meets requirements. Abstractly, a test system differs little from a control system—testers provide signals to the unit, monitor feedback, and base decisions on the results. While the time scales may differ, the functionalities are conceptually similar. Viewed in this light, it becomes natural to extend HIL approaches to tester development. By replacing a physical unit with a proxy model deployed to a real-time or pseudo real-time target, test systems can be developed in parallel with the design and fabrication of a first production unit. This saves considerable time in the life cycle from conceptual design to realized product. This manuscript demonstrates the process flow using a capacitive discharge unit as an exemplar.

42 ENGINEERING↗
DOE OSTI2024

Enabling Ultra-Compact, Lightweight, Efficient, and Reliable 6.6 kW On-Board Bi-Directional Electric Vehicle Charger with Advanced Topology and Control

The research explored new topologies, control methods, mechanical integration, and thermal management methods for electric vehicle (EV) on-board chargers. The team investigated capacitor-based power conversion, leveraging the high energy densities inherent to capacitive energy storage compared to inductive methods. The proposed topologies simultaneously enabled high power density and high efficiency of the design. The proposed architecture was demonstrated in a 6.6 kW bi-directional charger prototype. The research pursued several directions to improve system performance. Innovative topologies were studied for both the main power conversion stage as well as the single-phase twice-line-frequency energy buffer. To ensure robust and efficient operation, new control methods were developed to integrate these two subsystems. To achieve high power density in the full system solution, the mechanical structure of the charger is highly optimized to maximally fill the converter box volume. In parallel with the mechanical design effort, the converter was packaged with high-performance cooling methods which removed heat from key areas of power dissipation in the converter. The thermal management system was optimized to minimize its weight and volume, ultimately motivating the design of a custom additively manufactured cold-plate. The full system achieves a peak power of 7 kW with less than 0.3% total harmonic distortion (THD) and greater than 0.994 power factor in power factor correction (PFC) operation, corresponding to a total box-volume power density of 47.9 kW/L and gravimetric power density of 24.6 W/g. The system achieves a peak efficiency of 98.9%, with 97.9% efficiency at maximum power.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

3D Multiphysics Model for Large Scale Planar Cell: Inductance Investigation in Impedance Analysis

Developed a comprehensive 3D multiphysics model to analyze impedance behavior in large-scale planar Solid Oxide Fuel Cells (SOFCs). The model investigates how impedance varies across operating conditions and cell components, with a particular focus on inductive loops or negative capacitance at the air electrode. It was found that the Inductive loop disappears in the low-frequency zone when the activation overpotential or faradic current is not temperature-dependent. These findings offer new insights into SOFC impedance behavior.

impedence analysis↗
DOE OSTI2025

DC-Link Capacitor Design for a Neutral-Point-Less Three-Level Dual-Phase Inverter for Traction Application

Conventional multilevel inverters, such as neutral￾point-clamped and T-type inverters, have gained popularity in electric vehicle applications due to their advantages, including high voltage range, high power capability, low switching losses, low total harmonic distortion, and low electromagnetic interference. However, these traditional multilevel inverters require a neutral point connection to generate a zero-voltage vector. The neutral point current oscillates at three times the fundamental frequency, leading to voltage imbalance and overvoltage stress on the power modules. Additionally, the use of two stacked DC-link capacitors increases the volume required for the same overall capacitance and complicates packaging due to ripple current and heat dissipation from separate components. This is a significant concern for traction drive units, where space is limited. In this paper, a neutral-point-less multilevel dual three￾phase inverter topology is investigated for traction inverter applications. Simulation results demonstrate that the proposed topology effectively retains the benefits of multilevel operation while utilizing a single DC-link capacitor. The inverter model was simulated in conjunction with an industry-standard battery model to evaluate the potential for capacitor size reduction compared to a conventional three-level inverter.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Rheo–Electric Foundations and Engineering of Carbon Slurry Flow Electrodes

Flowable carbon slurry electrodes promise continuous, scalable electrochemical desalination and energy storage when their rheology (flow and stability) and electronic connectivity are jointly optimized. This report integrates six complementary thrusts that we executed under the Laboratory Directed Research and Development (LDRD) project: (i) a fast, ex situ, centrifuge-compatible method to quantify pellet (packed slurry) electronic conductivity, with a validated cell constant (“shape factor”) and quantitative structure–property insights for carbon mixtures; (ii) a controlled circulation study showing that peristaltic pumping can irreversibly alter particle size and morphology over laboratory-relevant durations; (iii) development of a miniature jet pump that preserves particle integrity while achieving entrainment ratios of 2–4 at practical flow rates; (iv) a comprehensive mapping of how a representative non-ionic surfactant (Tween 20) collapses the carbon gel network, separating network-percolation losses from intrinsic particle contact resistance; (v) in-situ visualization revealing how gravitational settling and flow-driven mixing compete to control charge transport, with dynamic bed layers preventing saturation while achieving 30-fold local concentration enhancement; and (vi) a simple, widely adoptable fabrication route to structured, gas-nitrided titanium nitride (TiN) titanium current collectors that dramatically lower interfacial losses and enable geometry-driven performance gains. Together, these results provide a coherent toolchain and design rules to accelerate formulation screening, de-risk device prototyping, and standardize characterization for carbon slurry electrodes in flow-electrode capacitive deionization (FCDI), electrochemical flow capacitor (EFC), and related systems.

25 ENERGY STORAGE↗
DOE OSTI2024

Robustness and printed sensor qualification

A limiting factor of additive manufactured (AM) sensors for in-pile applications is the development of appropriate interconnection and packaging strategies that can maintain reliable performance in extreme environments. Failure mechanisms in these harsh conditions could include, but not limited to, materials interaction (i.e., intermetallic formation) and coefficient of thermal expansion (CTE) mismatch between the individual components of the sensors. To mitigate premature failure and enable the successful sustained operation of AM sensors, non-destructive qualification tests are used as an intermediate process control step used for verifying robustness and reliability of the sensor before they are deployed. A materials system of interest is the use of barium strontium titanium oxide (BST) films on stainless steel 316L (SS316L) substrate. Due to BST’s high dielectric constant and tunable dielectric properties, there is an interest for its application as an insulation/encapsulation layer for capacitive strain gauges when printed on structural materials. Previous work on the BST/SS316L material system, however, showed that the BST cracks when exposed to temperatures up to 600 °C due to CTE mismatch between the printed BST film and the metallic substrate. When comparing different fabrication techniques, less surface cracking was observed in the samples that deposited thinner (i.e., 2-20 μm) than samples that were thicker (i.e., 135 µm – 300 µm). The objective of this report is to establish a qualification process that will determine and address any challenges (i.e., mechanical failure of thick prints) of the AM sensor prior to its application in experimental tests. To demonstrate the qualification process in this report, laser spallation and uniaxial tensile tests using dynamic and quasi-static loading, respectively, will be discussed.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Innovating Distributed Embedded Energy Prize (InDEEP): A Lessons Learned Report

The U.S. Department of Energy's Water Power Technologies Office (WPTO) launched the Innovating Distributed Embedded Energy Prize (InDEEP) in March 2023 to accelerate innovation in Distributed Embedded Energy Conversion Technologies (DEEC-Tec) for ocean wave energy. Administered by the National Laboratory of the Rockies (NLR) with technical support from Sandia National Laboratories (SNL), InDEEP focused on the development of small, distributed, and embeddable energy converters (DEECs) and their integration into scalable DEEC-Tec metamaterials for marine renewable energy applications. Spanning three phases over two years, InDEEP awarded approximately $2.3 million to teams from academia, industry, and startups. Phase I emphasized conceptual design. Phase II moved into the prototyping of individual DEECs. Phase III required integration into functional DEEC-Tec metamaterial prototypes. Across 60 submissions, teams explored a wide range of energy conversion mechanisms - including piezoelectric, variable-capacitance, ionic, and inductive methods. Note, the prize did not include the design nor demonstration of ocean wave energy conversion systems. Rather, the prize only required participants to design and demonstrate individual DEECs and corresponding DEEC-Tec metamaterials. This prize utilized a mix of novel and proven techniques to attract participants from outside marine energy, including an engagement leaderboard, robust recruitment, technical expert mentorship, and a suite of technical trainings. Key insights from the competition emphasized that DEEC-Tec metamaterials must be intentionally designed to produce beneficial emergent behaviors - advantages that go beyond simply combining multiple DEEC units. Top-performing teams showed that thoughtful design of system architecture, coordinated deformation, and systems adaptabilities could unlock meaningful performance gains both at the DEEC system level and DEEC-Tec metamaterial system level. A critical realization was that many DEEC-Tec metamaterials could benefit from being designed to accept lower-frequency energy inputs and shift those into higher-frequencies per each DEEC making up the respective DEEC-Tec metamaterial. Other important takeaways included the need for rigorous and quantitative performance testing, effective integration of power conditioning electronics, and the pivotal role of material science in enabling innovative, adaptive DEEC-Tec-based energy conversion designs. InDEEP also helped establish a growing DEEC-Tec community of practitioners, attracting participants from beyond traditional marine energy sectors. Through a strong support infrastructure, InDEEP fostered early-stage innovation and laid a foundation for future DEEC-Tec-based ocean wave energy conversion solutions - positioning DEEC-Tec as a promising pathway toward scalable, resilient ocean wave energy conversion. Through focused R&D of individual DEECs and their integration into DEEC-Tec metamaterials, alongside a growing, multidisciplinary community catalyzed by InDEEP, there is a strong opportunity to drive a disruptive shift in ocean wave energy conversion design and development. This convergence of novel architectures, emergent behaviors, and collaborative innovation positions DEEC-Tec as a transformative approach, moving the field from rigid, centralized energy conversion-based designs to resilient, modular systems highly adaptable for real-world ocean wave energy conversion applications.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

M3AS-25IN1002073: Analysis of data from irradiation testing of printed strain gauges in prototypic nuclear environments

Advancement in additively manufactured strain gauges help address critical technology gaps to accurately monitor real-time materials behavior in reactor experiments. This is critical as it provides data to inform predictive models and simulations that enhance the development of reactors and fuel cycle systems. In this report, additively manufactured strain gauges are exposed to a neutron irradiation environment at the Ohio State University Research Reactor. This report goes over a 2-week campaign for neutron irradiating printed resistive strain gauges and capacitive strain gauges. These results complement the prior separate effects (i.e., mechanical strain, temperature, etc.) testing that were performed on these additive manufactured sensors and presented in prior milestone reports. These results also help progress our understanding of their usage in harsh environment applications. The outcome of developing advanced sensing and instrumentation capabilities plays an important role in increasing the safety, reliability, and energy efficiency of both next-generation and existing nuclear reactors.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Charge And Dynamic Current On Tubular Antennas For Various Drive Conditions

The mixed boundary value problem of a tubular conductor is solved using an approximate representation of its Fourier coefficients. A two term solution is derived, which represents the solution over an extremely broad range of aspect ratios. This representation is used to find the electrostatic solution and capacitance of a charged tube as well as the solution of a tube in a uniform field and its dipole moment. This second case is directly useful as a model for a monopole electric field probe. This approximation is a special case of a representation using a combination of Chebyshev and Legendre polynomials. Combining the charged tube and tube in a uniform field allows the solution of voltage driven tubular antennas. Comparisons are made with numerical solutions using piecewise sinusoidal representations of the current. The results are also generalized to the dynamic case and up to and beyond the first resonance. Simple corrections for finite gap and delta gap drives to magnetic frill drives are examined using infinite tube integral transform representations. Corrections between magnetic frill drives and coaxial drives are also given. Approximate drive corrections using conformal mapping and an effective radius are also discussed. Finally, this efficient current representation is applied to the magnetic problem involving simple tubular solenoids.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Application of printed strain gauges in prototypical nuclear reactor conditions

This report discusses the current development and testing of additively manufactured temperature sensors and resistive/ capacitive strain gauges. This has potential to improve the sensor design and manufacturing techniques to meet the requirements of in-pile monitoring of mechanical properties and structural health of materials and specimens in current and advanced nuclear test reactors (i.e., in terms of environment conditions, sample geometry, and materials compatibility). The developmental additively manufactured strain gauges are exposed to separate effects testing (i.e., mechanical strain (up to 1000 µe), high temperature (up to 700 °C)) to determine environmental factors that affect the performance of the strain gauge. The robustness and integrity of a printed strain gauge layer exposed to a molten salt environment for up to 500 hours was evaluated, with the goal of assessing material compatibility of printed strain sensors for instrumented surveillance test articles in molten salt reactors. In addition, sensor qualification methodologies are further developed for determining the reliability and robustness at the interface of the additively manufactured strain gauge materials.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Short Circuit Detection and Voltage Sense for High Voltage Ionization Tube Power Supplies

Fermilab's PIP-II upgrade requires new rack-mounted power supplies for Beam Loss Monitor (BLM) ionization tubes compatible with the microTCA 4.1 standard, supporting high-side current measurement for short circuit detection, voltage sense telemetry, and low-side current measurement for beam loss readout. This work presents the design and preliminary schematic of such a supply. A resistive current sensing approach was chosen over inductive, optical, and Hall-effect alternatives for its independence from cable length and component availability. A 500 mΩ inline shunt steps the 2 kV common mode voltage down to roughly 70 V, producing a ~27 μV pulse during a short, which is amplified 500x, compared against a 14-bit DAC threshold, and latched to drive a fault line. Voltage sense steps the 2 kV output down at a 1V/1000V ratio, buffers it with a low bias current amplifier, and digitizes it via a 24-bit ADC over SPI. Onboard power is regulated from 12 V down to isolated 5 V and 3.3 V rails, with capacitive isolation on FPGA communication lines. Lumped parameter models were developed for the ionization tube (0.327 nF, 20 to 200 GΩ dynamic resistance) and the RG-58 coaxial cable to support the design. Component selection is complete and a preliminary schematic has been drawn in Altium Designer, forming the foundation for future prototyping and validation.

Yu, Kellen [Cornell U.]↗
DOE OSTI2025

Study of the Design and Characteristics of a Modified Pulsed Plasma Thruster with Graphite and Tungsten Trigger Electrodes

The paper presents experimental results for a modified pulsed plasma thruster (PPT) with solid propellant, using a coaxial anode–cathode design. Graphite from pencil leads served as propellant, and a tungsten trigger electrode was tested to reduce carbonization effects. Experiments were performed in a vacuum chamber at 0.001 Pa, employing diagnostics such as discharge current/voltage recording, power measurement, ballistic pendulum, time-of-flight (TOF) method, and a Faraday cup. Current and voltage waveforms matched an oscillatory RLC circuit with variable plasma channel resistance. Key discharge parameters were measured, including current pulse duration/amplitude and plasma channel formation/decay dynamics. Impulse bit values, obtained with a ballistic pendulum, reached up to 8.5 μN·s. Increasing trigger capacitor capacitance reduced thrust due to unstable “pre-plasma” formation and partial pre-discharge energy loss. Using TOF and Faraday cup diagnostics, plasma front velocity, ion current amplitude, current density, and ion concentration were determined. Tungsten electrodes produced lower charged particle concentrations than graphite but offered better adhesion resistance, minimal carbonization, and stable long-term performance. The findings support optimizing trigger electrode materials and PPT operating modes to extend lifetime and stabilize thrust output.

Faraday cup↗
DOE OSTI2024

N-Doped Graphene (N-G)/MOF(ZIF-8)-Based/Derived Materials for Electrochemical Energy Applications: Synthesis, Characteristics, and Functionality

In recent years, graphene-type materials originating from metal–organic frameworks (MOFs) or integrated with MOFs have exhibited notable performances across various applications. However, a comprehensive understanding of these complex materials and their functionalities remains obscure. While some studies have reviewed graphene/MOF composites from different perspectives, due to their structural–functional intricacies, it is crucial to conduct more in-depth reviews focusing on specific sets of graphene/MOF composites designed for particular applications. In this review, we thoroughly investigate the syntheses, characteristics, and performances of N-G/MOF(ZIF-8)-based/derived materials employed in electrochemical energy conversion and storage systems. Special attention is given to realizing their fundamental functionalities. The discussions are divided into three segments based on the application of N-G/ZIF-8-based/derived materials as electrode materials for batteries, electrodes for electrochemical capacitors, and electrocatalysts. As electrodes for batteries, N-G/MOF(ZIF-8) materials can mitigate issues like an electrode volume expansion for Li-ion batteries and the ‘shuttle effect’ for Li-S batteries. As electrodes for electrochemical capacitors, these materials can considerably improve the ion transfer rate and electronic conductivity, thereby enhancing the specific capacitance while maintaining the structural stability. Also, it was observed that these materials could occasionally outperform standard platinum-based catalysts for the electrochemical oxygen reduction reaction (ORR). The reported electrochemical performances and structural parameters of these materials were carefully tabulated in uniform units and scales. Through a critical analysis of the present synthesis trends, characteristics, and functionalities of these materials, specific aspects were identified that required further exploration to fully utilize their inherent capabilities.

Electrochemistry↗
DOE OSTI2024

Generating Electricity with Hydraulically Amplified Self-Healing Electrostatic (HASEL) Transducers

This study identifies hydraulically amplified self-healing electrostatic (HASEL) transducers as electricity generators, contrary to their conventional role as actuators. HASELs are soft, variable-capacitance transducers inspired by biological muscles which were developed to mimic the flexibility and functionality of natural muscle tissues. This research characterizes HASELs as generators by reversing their energy conversion mechanism—generating electricity through mechanical deformation. The study assesses the practical laboratory performance of HASELs by analytic modeling and experimental evaluation. Outcomes of the study include the following: (i) up to 2.5 mJ per cycle per 50 mm wide HASEL pouch of positive net energy generation in experimental testing—corresponding to an energy density of 2.0 mJ cm−3; (ii) a maximum theoretical energy density of 4.2 mJ cm−3; (iii) the electromechanical characteristics governing efficient conversion; and (iv) design considerations to enhance HASEL generator performance in future applications. This study broadens HASEL’s applicability and utility as a multi-functional transducer for renewable energy and general adaptive electricity generation.

13 HYDRO ENERGY↗
DOE OSTI2025

Glancing Angle Deposition in Gas Sensing: Bridging Morphological Innovations and Sensor Performances

Glancing Angle Deposition (GLAD) has emerged as a versatile and powerful nanofabrication technique for developing next-generation gas sensors by enabling precise control over nanostructure geometry, porosity, and material composition. Through dynamic substrate tilting and rotation, GLAD facilitates the fabrication of highly porous, anisotropic nanostructures, such as aligned, tilted, zigzag, helical, and multilayered nanorods, with tunable surface area and diffusion pathways optimized for gas detection. This review provides a comprehensive synthesis of recent advances in GLAD-based gas sensor design, focusing on how structural engineering and material integration converge to enhance sensor performance. Key materials strategies include the construction of heterojunctions and core–shell architectures, controlled doping, and nanoparticle decoration using noble metals or metal oxides to amplify charge transfer, catalytic activity, and redox responsiveness. GLAD-fabricated nanostructures have been effectively deployed across multiple gas sensing modalities, including resistive, capacitive, piezoelectric, and optical platforms, where their high aspect ratios, tailored porosity, and defect-rich surfaces facilitate enhanced gas adsorption kinetics and efficient signal transduction. These devices exhibit high sensitivity and selectivity toward a range of analytes, including NO2, CO, H2S, and volatile organic compounds (VOCs), with detection limits often reaching the parts-per-billion level. Emerging innovations, such as photo-assisted sensing and integration with artificial intelligence for data analysis and pattern recognition, further extend the capabilities of GLAD-based systems for multifunctional, real-time, and adaptive sensing. Finally, current challenges and future research directions are discussed, emphasizing the promise of GLAD as a scalable platform for next-generation gas sensing technologies.

Chemistry↗
DOE OSTI2026

Partially Ionized Plasma Physics and Technological Applications

Partially ionized plasma physics has attracted increased attention recently due to numerous technological applications made possible by the increased sophistication of computer modelling, the depth of the theoretical analysis, and the technological applications to a vast field of manufacturing for computer components. Partially ionized plasma is characterized by a significant presence of neutral particles in contrast to the fully ionized plasma. The theoretical analysis is based upon solutions of the kinetic Boltzmann equation, yielding the non-Maxwellian electron energy distribution function (EEDF), thereby emphasizing the difference with a fully ionized plasma. The impact of the effect on discharges in inert and molecular gases is described in detail, yielding the complex nonlinear phenomena resulting in plasma selforganization. A few examples of such phenomena are given, including the non-monotonic EEDFs in the discharge afterglow in a mixture of argon with the molecular gas NF3; the explosive generation of cold electron populations in capacitive discharges, hysteresis of EEDF in inductively coupled plasmas. Recently, highly advanced computer codes were developed in order to address the outstanding challenges in plasma technology. These developments are briefly described in general terms.

non-Maxwellian electron energy distribution functi↗
DOE OSTI2024

Exploring Mixed Ionic–Electronic-Conducting PVA/PEDOT:PSS Hydrogels as Channel Materials for Organic Electrochemical Transistors

Here, we report the preparation and evaluation of PVA/PEDOT:PSS-conducting hydrogels working as channel materials for OECT applications, focusing on the understanding of their charge transport and transfer properties. Our conducting hydrogels are based on crosslinked PVA with PEDOT:PSS interacting via hydrogen bonding and exhibit an excellent swelling ratio of ~180–200% w/w. Our electrochemical impedance studies indicate that the charge transport and transfer processes at the channel material based on conducting hydrogels are not trivial compared to conducting polymeric films. The most relevant feature is that the ionic transport through the swollen hydrogel is clearly different from the transport through the solution, and the charge transfer and diffusion processes govern the low-frequency regime. In addition, we have performed in operando Raman spectroscopy analyses in the OECT devices supported by first-principle computational simulations corroborating the doping/de-doping processes under different applied gate voltages. The maximum transconductance (gm~1.05 μS) and maximum volumetric capacitance (C*~2.3 F.cm -3 ) values indicate that these conducting hydrogels can be promising candidates as channel materials for OECT devices.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Experimental Investigation of Steel-Borne Acoustic Pulses for Fault Pinpointing in Pipe-Type Cable Systems: A Scaled-Down Model Approach

Pipe-type cable systems, including high-pressure fluid-filled (HPFF) and high-pressure gas-filled cables, are widely used for underground high-voltage transmission. These systems consist of insulated conductor cables within steel pipes, filled with pressurized fluids or gases for insulation and cooling. Despite their reliability, faults can occur due to insulation degradation, thermal expansion, and environmental factors. As many circuits exceed their 40-year design life, efficient fault localization becomes crucial. Fault location involves prelocation and pinpointing. Therefore, a novel pinpointing approach for pipe-type cable systems is proposed, utilizing accelerometers mounted on a steel pipe to capture fault-induced acoustic signals and employing the time difference of arrival method to accurately pinpoint the location of the fault. The experimental investigations utilized a scaled-down HPFF pipe-type cable system setup, featuring a carbon steel pipe, high-frequency accelerometers, and both mechanical and capacitive discharge methods for generating acoustic pulses. The tests evaluated the propagation velocity, attenuation, and pinpointing accuracy with the pipe in various embedment conditions. The experimental results demonstrated accurate fault pinpointing in the centimeter range, even when the pipe was fully embedded, with the acoustic pulse velocities aligning closely with the theoretical values. These experimental investigation findings highlight the potential of this novel acoustic pinpointing technique to improve fault localization in underground systems, enhance grid reliability, and reduce outage duration. Further research is recommended to validate this approach in full-scale systems.

Moutassem, Zaki↗