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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

RidgeAlloy: A high pressure die casting alloy that captures the approaching wave of automotive body sheet scrap

Oak Ridge National Laboratory (ORNL) has recently launched an effort to economically expand the North American aluminum supply chain by designing and developing a new family of Al-Mg-Si-Fe-Mn structural die cast aluminum alloys that can be made from up to 100% mixed 5xxx and 6xxx series automotive post-consumer sheet scrap and do not require heat treatment. The goal is to develop an alloy capable of capturing the approaching scrap wave of aluminum sheet intensive vehicles (in the 2030’s) into integrated structural high pressure die castings, rather than down-cycling these high-grade sheet alloys into non-structural castings. ORNL discovered a significant gap in the commercial thermodynamic databases that were unable to predict the trends of a key primary intermetallic phase as a function of composition. Experiments were performed to correct this gap and to create a unique, corrected quaternary database for Al-Mg-Si-Fe. High throughput computational methods, including solidification simulations, were used to identify a composition volume capable of avoiding this embrittling primary intermetallic phase, even at higher Fe + Si contents. Laboratory scale castings validated the thermodynamic and solidification predictions and resulted in lab-cast alloys with little primary intermetallic, and which met or exceeded structural casting properties requirements for yield strength and ductility. An accelerated demonstration of an HPDC automotive part was conducted in collaboration with two U.S. small businesses. Ingots made from 100% recycled 5xxx and 6xxx series scrap (plus Fe) were used to die cast one variant of this new family of Al-Mg-Si-Fe-Mn alloys (with high Si + Fe content) into a mid-sized HPDC structural-type automotive component. The HPDC alloy demonstration part showed good properties (especially ductility) and good castability for a complex component.

Plotkowski, Alex [ORNL] (ORCID:0000000154718681)↗
DOE OSTI2025

Shock propagation in aerogel and TPP foams for inertial fusion energy target design

Achieving practical inertial fusion energy (IFE) requires the development of target designs with well-characterized microstructure and compression response. We measured shock dynamics in low-density (17.5–500 mg/cm 3 ) aerogel and two-photon polymerization (TPP) foams using x-ray phase contrast imaging (XPCI) methods and the Velocity Interferometer System for Any Reflector. By analyzing shock front evolution, we examined how target type and density influence shock propagation and energy dissipation. Talbot-XPCI shows that aerogels support a smooth, bowed shock front due to their homogeneous nanometer-scale pore network. In contrast, TPP foams exhibit irregular, stepwise propagation driven by interactions with their periodic micrometer-scale lattice. Shock velocity follows a power-law relation: aerogels deviate from classical ρ −1/2 scaling due to pore-collapse dissipation, while TPP foams follow the trend with larger uncertainties from density variations. Comparisons with xRAGE simulations reveal systematic underestimation of shock speeds. These results provide the first experimental constraints on shock propagation in TPP foams over a wide density range and highlight the influence of internal structure on anisotropic shock behavior. Our findings support improved benchmarking of EOS and hydrodynamic models and inform the design of foam architectures that promote implosion symmetry in IFE capsules.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Multiphysics Design Optimization and Additive Manufacturing of Nuclear Components (Final CRADA Report - Executive Summary)

Westinghouse Electric Company (WEC) actively participated in the advancement of the nuclear fuel and reactor design space and requested the help of Oak Ridge National Laboratory (ORNL) in the creation of a new design tool set. This report details the creation of a collection of software tool sets that are linked together to collectively assist WEC design engineers in developing novel ideas outside the normal scope of traditional nuclear fuel and reactor design formulas. Specifically, Siemens HEEDS, a design space exploration and parametric optimization software, monitored and changed parameters in a collection of softwares to meet the team’s objective. The HEEDS parametric optimization method, SHERPA, was developed to control the Siemens NX CAD platform to adjust the native CAD of a hexahedral spacer grid. This new geometry can be used to execute a topological design optimization by the NX Topology software add-in. The resulting geometry is additively manufacturable. This topological optimization occurred twice—once on the spacer grid’s spring, and once on the dimple geometry. These new geometries were imported by Siemens’ STAR-CCM+, a multiphysics structural and fluid dynamic computational solver in which the spring geometry is deflected to match the rod insertion configuration. Along with the dimple geometry, this new deflected spring was used to complete a hydraulic assessment of a single-unit cell comprising one rod, one spring, and two dimples. The HEEDS SHERPA algorithm ranks the design based on the final mass of the unit cell and the hydraulic pressure drop performance. The ORNL team demonstrated the ability to use this software and provided engineering judgement to apply modern aerospace aerodynamic design. The effort has been focused on thinking outside the conventional design space and redesigning a spacer grid to perform beyond the WEC set objectives. Furthermore, the ORNL team also demonstrated that the HEEDS optimization routine can independently develop a design that meets the WEC design goals. Although these designs were at a low technology readiness level, their demonstration confirmed the team’s capability to create novel advanced nuclear concepts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Physics basis for the reference flat-top plasma scenario in the ST–E1 fusion power plant

As part of the U.S. Department of Energy’s Milestone-Based Fusion Energy Development Program, Tokamak Energy has completed the pre-concept design of the ST–E1 fusion power plant. ST–E1 is envisaged to operate in two phases: a pilot plant phase, targeting sustained net power production of 300 - 500 MWe for a duration >1 hr, followed by a commercial power plant phase targeting steady-state operations and a normalised overnight capital cost of ⩽12 000 $\$$/kWe. The design process adopted was highly iterative, integrating all major plant systems and progressing in a phased fidelity approach. At the pre-conceptual stage, the emphasis has been on exploring the design space, identifying the main system-level trade-offs, and making the key decisions that define the overall plant concept, rather than optimising a single operating point. This paper, part of a focused collection detailing the ST–E1 pre-concept design, addresses the development of a series of reference flat-top plasma operating points for the pilot plant phase. A modelling workflow was established to develop and assess candidate plasma design points and explore key dependencies. The workflow includes integrated core plasma modelling, magnetohydrodynamic (MHD) stability assessment, equilibrium generation, scrape-off-layer and exhaust modelling, heating & current drive design and optimisation, and turbulent transport modelling. Using this framework, the impact of several key parameters on the flat-top operating space was investigated, including the density limit, core radiation fraction and divertor power loading, level of external heating and curent drive power and assumed pedestal characteristics. The MHD stability, controllability and micro-stability characteristics of these plasmas were also analysed. These investigations informed the definition of a set of fully non-inductive, flat-top reference operating points that satisfy the high-level ST–E1 mission, including a low and high density case, a case that is stable to resistive wall modes and a case with reduced divertor power loading.

ST–E1↗
DOE OSTI2026

Additively Manufactured Graded Composite Transition Joints for Dissimilar Metal Weldments in Advanced Ultra-Supercritical Power Plant (Final Technical Report)

In this project, we successfully achieved all the goals we proposed: ① Code Development; ② Transition Joint Design; ③ Lab-scale GCTJ Testing Piece Development; ④ Heat Treatment; ⑤ Welding of DMW; ⑥ Mechanical Characterization; ⑦ Corrosion; ⑧ Fabrication of Prototype GCTJ; ⑨In-field Test in SWRI and ⑩Tech-economic Analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Multibody for Everybody (M4E) - A Linearization Approach to Enable Frequency Domain Analysis, Time Integration and Control Co-Design

1.1 Background/Objectives: Marine energy represents a promising yet underexploited source of power. To increase the harvested power, significant efforts have been made to improve wave energy converter (WEC) modeling capabilities and optimize power take-off (PTO) performance; however, these efforts have often treated WEC dynamics, PTO design, and controller development sequentially. In contrast, control co-design (CCD) is emerging as a promising strategy to address these issues directly, creating a growing need for fast analysis tools suitable for repeated simulation and parametric studies [1]. To support this need, this work presents the Multibody for Everybody (M4E) [2] linearization module, which employs a symbolic toolbox to provide deeper insight of WEC design parameters. The objective is to demonstrate that a minimal-coordinate linearization of articulated WEC dynamics can provide accurate wave response predictions and substantial computational savings relative to nonlinear time-domain simulation, while preserving compatibility with broader wave-energy analysis workflows, enabling CCD. 1.2 Approach/Activities: The proposed approach linearizes the equations of motion, generated by M4E, in minimal coordinates about a selected operating point and combines the resulting system with frequencydomain hydrodynamic terms to incorporate the reduced mass, damping, stiffness, and forcing operators. The linearized model is used for both impedance-based response amplitude operator (RAO) prediction and rapid regular-wave time integration. The methodology is demonstrated on a single-flap device and a FOSWEC configuration, with linearized M4E responses compared against the corresponding nonlinear M4E simulations and WEC-Sim results. Regular-wave time histories, RAO trends, and runtime differences are assessed. The framework is also compatible with broader wave-energy workflows, including coupling to WecOptTool, although that capability is not the focus of this work [3]. 1.3 Results/Lessons: The linearized M4E model reproduces key regularwave response characteristics such as integration and Response Amplitude over multiple frequencies. This module matches nonlinear M4E and WEC-Sim results while substantially reducing integration cost. Thus, the proposed framework can serve as a rapid analysis layer for articulated WEC design, parameter studies, and controls-oriented workflows. The analysis is most appropriate in the near-equilibrium regime, about the linearization point.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

IEA Wind TCP Task 49: Reference Site Conditions for Floating Wind Arrays

This report, prepared within Work package 1 of IEA Wind Task 49, presents reference site conditions for floating wind arrays to serve as a design basis for the techno-economic design of reference floating wind arrays. Data of the reference sites presented here are publicly available in an open database and thus support fast development and comparable design of floating wind arrays for various relevant conditions. The development of these reference sites drew on existing open access datasets and ongoing research projects of task participants. Six classes were identified that describe relevant key conditions for the design and development of floating wind arrays: met-ocean conditions, seabed conditions, coastal infrastructure, environmental impact, socio-economic impact, as well as regulations and permissions. The reference sites for the techno-economic design of floating wind arrays are based on a concept with building blocks to synthesize purpose-built site representations. In each of the identified classes with influencing design factors, building blocks are used to describe the characteristic properties and their spread. However, the latter three classes (i.e., environmental impact, socio-economic impact, regulations and permissions) are not included in the reference site conditions due to limited knowledge and lack of reliable criteria to quantify their impact on the techno-economic design in numeric parameters. Building blocks with key parameters for the techno-economic design of floating wind arrays are provided for met-ocean conditions, seabed conditions, and coastal infrastructure. For met-ocean conditions, multiple sites were selected for detailed analysis that represent a range of conditions across the pipeline of floating wind projects. Wind conditions and sea states are separated, and each location considers both the severity of wind and waves e.g. one site may have a moderate wave condition but severe wind condition. From this pipeline, eleven representative sites were selected where both site-specific analysis was available within the consortium, and where they represent different parts of the global pipeline. The eleven sites are: Hannibal (Italy), Humboldt (US), Ulsan (South Korea), MoneyPoint One (Ireland), Havbredey (UK), Fukushima (Japan), Utsira Nord (Norway), Gulf of Maine (US), Sud de la Bretagne II (France), Sorlige Nordsjo II (Norway). Each of these sites is summarized in the main report while more details about the studies and analyses behind the datasets are provided in the appendix. For seabed conditions, general information about the geotechnical parameters is provided and a baseline is established for the geotechnical parameters and stratigraphy that may be encountered on the sites. A set of six 'synthetic cases' is defined as building blocks providing the different parameters required for design under each case/soil condition. For the coastal infrastructure, general information about the main requirements is provided that a port should comply with to provide a satisfactory service during the construction of floating offshore wind arrays. Minimum port infrastructural requirements are provided for three types of ports.

17 WIND ENERGY↗
DOE OSTI2024

Distribution System Behind-the-Meter DERs: Estimation, Uncertainty Quantification, and Control

This paper summarizes the three-year technical activities of the IEEE Task Force (TF) on behind-the-meter (BTM) distributed energy resources (DERs): estimation, uncertainty quantification, and control. The potential grid services from BTM DERs are discussed in detail. The paper also reviews the state-of-the-art for BTM DERs visibility, uncertainty quantification, and, optimization and control. Furthermore, different aspects of the market structures associated with BTM DERs are covered, including emerging market and business models. Finally, needs and recommendations are provided for additional areas such as system protection, computing capabilities, algorithm development, market structure design, cyberinfrastructure and security, and hardware and software developments.

behind-the-meter↗
DOE OSTI2025

SPC-71260 Rev 0 MARVEL Heat Extraction Subsystem Secondary Coolant Equipment (SCE) Design/Build

A. The Microreactor Applications Research Validation and Evaluation (MARVEL) reactor will offer experimental capabilities that are not currently available at DOE’s national laboratories. Idaho National Laboratory (INL), operated for the U.S. Department of Energy (DOE) by Battelle Energy Alliance, LLC (BEA) (Contractor hereafter) is procuring services for the design, analysis, fabrication, testing and delivery of a Secondary Coolant Equipment system (SCE). This specification contains the requirements for design, analysis, fabrication, testing and delivery of the SCE as described herein. The MARVEL reactor is a microreactor which uses eutectic sodium-potassium alloy (NaK) as a primary coolant. The primary coolant is circulated through four primary loops by natural convection of the coolant. In each loop is a closed well which will accommodate an intermediate heat exchanger (IHX) for extracting heat from the loop. These wells will be referred to in this specification as the “IHX wells.” It is intended for the IHX containment to also be filled with NaK. The MARVEL design team has determined that a Heat Extraction System (HES) using pumped NaK will be used to extract heat from the IHXs and deliver it to a downstream system for power generation or alternate process heat users. This Heat Extraction System will enable MARVEL operations including the ability to test, demonstrate, and address issues related to installation, startup, and operations. In addition, it will allow down-stream utilization of process heat for various uses. The objective of this specification is to develop the final design for the HES Secondary Coolant Equipment system (SCE) that will be used as the core of the HES. This system provides control of the NaK circulation between the MARVEL reactor and the subsequent process heat utilization systems. It does not include design of the Intermediate Heat Exchangers and piping inside the T-REXc pit in which the reactor is located. B. The MARVEL microreactor will be installed in the Transient Reactor Test Facility (TREAT) building in the Transient Reactor Test (TREAT) Micro-Reactor Experiment Cell (T-REXc) C. An INL Subcontractor has developed a conceptual design for this system per SPC-71145, referred to in that specification as the Process Heat Extraction System. SPC-71260 is based on the pumped NaK loop concept developed under SPC-71145. D. The SCE system design and (as option scope) fabrication shall be provided by the awardee of the subcontract (Subcontractor hereafter) pertaining to this Specification. Prior to shipment, the SCE will be fabricated, assembled, and tested at the Subcontractor’s facility. After successful completion of acceptance testing, the SCE and associated equipment will be shipped to the Materials and Fuels Complex (MFC) at the INL (Contractor’s Facility hereafter) to be installed by others in TREAT/T-REXc.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2025

An Overview of the Molten Salt Thermal Properties Database–Thermophysical, Version 4.0 (MSTDB-TP V.4.0)

A central repository of thermophysical and thermochemical properties of molten salt compositions of relevance to molten salt reactors (MSRs) is vital in supporting the broad community of MSR developers, who are at various stages of developing and deploying their reactor designs. In general, these MSR designs differ significantly from developer to developer (e.g., with respect to the hardness of the neutron spectra, level of fissile loading, target multicomponent temperatures and power levels, and moderating capabilities). Therefore, the fuel and coolant salts being considered vary greatly: they may be chlorides or fluorides, they utilize different actinides at different ratios, and the cations in the melt are selected based on perceived advantages and disadvantages. Considering the general need for thermal properties, and the vastness of the array of potential candidate salt mixtures, the Molten Salt Thermal Properties Database (MSTDB) was initiated in 2018 with the goal of providing thermophysical and thermochemical characterization of key molten salt compounds and mixtures across their temperature and compositional domains. The MSTDB is thus divided into the thermophysical arm (MSTDB-TP) and the thermochemical arm (MSTDB-TC). The MSTDB is an effort funded by the Department of Energy, Office of Nuclear Energy (DOE-NE) Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, and the MSR Campaign. This report provides an overview of the MSTDB-TP v4.0 in terms of the data contained within, the state of the tools used to access the data, the availability of predictive models that leverage the raw data in the database, the preliminary status of developmental efforts that are currently underway, and an account of future goals for MSTDB-TP. The primary goal for the update from MSTDB-TP v.3.1 to v4.0 was the incorporation of surface tension data into the database; this property is important for thermal hydraulics modeling and species transport in other tools that have been developed under the NEAMS program. A breakdown of the surface tension data that have been added into MSTDB-TP v4.0 is provided herein, and the manner in which the quality of the data has been assessed is also documented. For MSTDB-TP v4.0, newly published thermophysical property data—primarily from collaborative experimental efforts under the MSR Campaign—have been incorporated into the database, and the resulting expansion is documented here. Because of the size to which MSTDB-TP has grown, the raw data format has now been recast into JavaScript Object Notation (JSON) format for easier connection with the MSTDB-TP application programming interface (API). Saline; the pre-existing comma-separated value (CSV) format has been deprecated but is still maintained, accessible, and up to date. As a final effort in packaging the MSTDB-TP v4.0 update, the graphical user interface (GUI) for MSTDB has been updated to allow full accessibility to the density and viscosity predictive models, which are based on Redlich-Kister expansions of MSTDB-TP raw data. Some other major aspects of this report, in terms of preliminary and future work, include: (1) documentation of the formalism and preliminary testing of a kinetic theory model that may act as a predictive model for thermal conductivity; (2) documentation of the candidate predictive models that may be considered in the future for surface tension, making use of the surface tension data now in MSTDB-TP v4.0; (3) a preliminary account of a data collection process that will enable the filling of additional gaps within MSTDB-TP, namely with data which have been collected computationally (e.g., through ab initio molecular dynamics).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

TRIZ-Based Design Improvement for Facilitating Transmission Control Unit Remanufacturing

Design for Remanufacturing (DfRem) centers on enhancing product design and operations to facilitate remanufacturing while increasing both economic and environmental sustainability. DfRem requires a comprehensive understanding of product characteristics, production conditions, and operational constraints. Thus, DfRem requires a systematic methodology to identify and implement alternative designs. Among many critical steps in remanufacturing, disassembly is essential because it directly supports remanufacturing by separation of product components for cleaning, inspection, and other subsequent process steps. This study proposes a TRIZ-based framework to improve product design for disassembly in support of remanufacturing. The framework is applied to a transmission control unit (TCU) case study. The current TCU design prevents remanufacturing due to the sealant-based component joinery, which complicates disassembly and risks damaging the printed circuit board (PCB). After defining technical contradictions for the TCU product design and reviewing the suggested TRIZ principles to solve the conflicts, a cantilever snap-fit design alternative is developed. The economic feasibility of the snap-fit design is assessed by comparing the current and snap-fit design costs for three life cycles. The cost analysis demonstrates that the cost of the snap-fit design remains the same as the current design. Additionally, the snap-fit design offers substantial cost savings for three life cycles compared to the current design. We demonstrate how snap-fit design supports both environmental and economic sustainability.

42 ENGINEERING↗
DOE OSTI2024

COMPUTER-AIDED LATTICE DESIGN AND ADVANCED MODELING FOR THE DEVELOPMENT OF LIGHTWEIGHT STRUCTURAL MATERIALS

The notion of a “fission battery” conveys a vision focused on realizing very simple “plug-and-play” nuclear systems that can be integrated into a variety of applications requiring affordable, reliable energy in the form of electricity and/or heat and function without operations and maintenance staff. Fission batteries require lightweight structural materials to increase their mobility, and the lightweight materials must demonstrate structural resilience under various conditions. The objective of this work is to develop lattice structured lightweight structural material featuring a good combination of mechanical properties using advanced modeling and simulation together with an advanced additive manufacturing technique such as laser powder bed fusion. The preliminary results show that different lattice structures and types can be successfully meshed using nTopology software, and the lattice structure data can be successfully transformed to Multiphysics Object-Oriented Simulation (MOOSE) Environment input. Finite Element Analysis (FEA) displays that, at macro/engineering scale simulation, the weight saving design has an obvious effect on tensile behavior such as effective elastic modulus and yield stress. The novel approaches of this work are (1) development of lattice structures for improved mechanical properties using advanced simulation and modeling techniques; and (2) model predictions of the mechanical properties (e.g., strength and stress distribution) of macroscopic materials in order to preliminarily select a lattice structure for additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Cooperative Education

Los Alamos National Laboratory (LANL) is a multidisciplinary national laboratory that conducts research and development in national security, engineering, materials science, computational modeling, and advanced manufacturing. The laboratory develops innovative technologies to address complex scientific and engineering challenges. This project focuses on the development and evaluation of high-performance absorbing structures through computational design, simulation, and engineering analysis. Absorbing structures are used in applications where damage mitigation, structural protection, and material efficiency are critical performance requirements. The increasing demand for lightweight, high-strength, and highly efficient structural systems has created a need for improved design methodologies capable of maximizing absorption while minimizing weight and material usage. The project utilizes advanced engineering software, including 3D CAD software and FEA, to generate and optimize structural concepts. Computational simulations are performed to evaluate structural behavior under loading conditions, while mathematical analyses are conducted using Python-based tools as well as established analytical equations from material and structural mechanics. The project benefits LANL by supporting the development of advanced design methodologies and improving the understanding of material and structural performance. During the internship term, a significant portion of the design development, simulation, and data analysis activities will be completed. Success of the project depends on collaboration among engineering mentors and technical staff members. Work will be conducted at Los Alamos National Laboratory using laboratory computing resources and engineering software.

42 ENGINEERING↗
DOE OSTI2025

Innovative Deep-Water Mooring Systems for Floating Wind Farms (DeepFarm): Cooperative Research and Development (Final Report)

The DeepFarm project, led by Principle Power Inc (PPI), focused on design, modeling and development of innovative mooring and anchoring systems for semi-submersible floating wind turbine platforms in a deep water, commercial-size wind farm. It explored the possibility of sharing anchors amongst the floating platforms within the farm, and considers site conditions representative of the West Coast and Hawaii, with a variety of water depths, as case studies to ensure that the sensitivity to water depth and park size are well understood. NREL and PPI worked together to develop and apply NREL's computational tools for modeling floating wind farm dynamics and costs.

17 WIND ENERGY↗
DOE OSTI2025

Dipole Bend Magnets: Design Considerations

This analysis provides a design of a dipole bend magnet for a beamline, stepping through various considerations while assembling a design. This report can be used as a basis of a bending dipole magnet applicable to LANSCE, a scalable point design for other applications, or as a systematic process for developing a magnet design from scratch. The goal is more to answer, 'Is it reasonable?' than to address correction factors. In this specific case, the dipole should provide 3 kG within a 6.35-cm (2.5") gap across an area provided by 25×15-cm pole pieces. This provides roughly 17° and 21° deflection for proton at 3.0 and 2.1 MeV, respectively.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

From minimum-viable-products to full models: a step-wise development of diagnostic forward models in support of design, analysis and modelling on the ST40 tokamak

Like most magnetic confined fusion experiments, the ST40 tokamak started off with a small subset of diagnostics and gradually increased the diagnostic set to include more complex and comprehensive systems. To make the most of each operational phase, forward models of various diagnostics are used and developed to aid design, provide consistency-checks during commissioning, test analysis methods, and build workflows to constrain high-level parameters to inform interpretation, theory and modelling. For new models and new analysis workflows, minimum-viable-products are released early, and their complexity is increased in a step-wise manner, facilitating the support of all programme phases on multiple parallel applications, while enabling learning opportunities and feedback loops. In this contribution we review the philosophy, scope and architecture of the framework under development. We discuss the details of some forward models, with examples on how they are used to aid diagnostic design, to investigate analysis methodologies through synthetic data, and how they are embedded in experimental analysis workflows. We compare previously published experimental results with new, more advanced analysis workflows employing more recent, detailed models and new diagnostic data, providing confirmation of the published material from the 2021–22 experimental campaign.

integrated data analysis↗
DOE OSTI2025

Understanding and controlling the fundamental photochemistry of protonic solar energy conversion (Final Scientific/Technical Report)

The selectivity and activity of most fuel-forming reactions are tunable by the concentration of electrons, holes, protons, and/or hydroxides. That is one reason why traditional solar energy conversion processes are used to drive these reactions, where light directly increases the concentration of electrons and holes. We, instead, took a different approach, using light to increase the concentration of protons and/or hydroxides. For this, we leveraged photophysical and solid-state physics theories, techniques, and design strategies previously developed for the study of traditional solar energy conversion processes. We designed and fabricated several materials platforms based on molecular photoacid and photobase dyes coupled with ion-exchange polymer membranes and assessed their fundamental photoelectrochemistry. We demonstrated control over built-in electric potentials, photovoltages, proton-transfer kinetics, and efficiency limits to our approach. Understanding the basic science of these dye-sensitized protonic membranes and their photochemical mechanisms is of use to the DOE-relevant processes of solar photochemical fuel formation, solar photodialytic desalination, and solar cells. Moreover, functional materials that we developed from this project may be of use to several broad-reaching fields and may provide the foundation for a completely new, inexpensive, and robust solar energy conversion technology.

14 SOLAR ENERGY↗
DOE OSTI2025

From TPL assessment to design optimization: Wave energy converter control co-design applied to the RM3

The Reference Model (RM) project developed six marine energy converter concepts using a sequential design methodology, which, while widely adopted in the industry, often overlooks interactions between system components, resulting in suboptimal designs. One such example is the Reference Model 3 (RM3), a two-body point absorber wave energy converter (WEC). An assessment using the Technology Performance Level (TPL) revealed that RM3’s low power-to-cost ratio, partly due to expensive steel construction, limits its techno-economic performance. Here, this study aims to redesign RM3 by reducing its scale and employing control co-design to integrate WEC and Power Take-Off (PTO) dynamics, constraints, and cost considerations within an optimization framework. We demonstrate the limitations of RM3’s current PTO design and explore the benefits of scaling down to enhance techno-economic viability by lowering material costs. Using WecOptTool, we conduct a parameter sweep over gear ratios and spring stiffnesses for various Commercial Off-The-Shelf generators in irregular wave conditions. Our findings emphasize the importance of aligning PTO components with WEC dynamics, showing that control co-design and strategic scaling can improve RM3’s power-to-cost ratio. This study presents a transferable example of applied control co-design for other WECs, supporting early-stage developers in their design decisions.

Off the shelf components↗