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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 307 records · Page 17

Electrodialysis: An effective methodology to purify the leachate of spent Li-ion batteries

The electrification of transportation and the transition of society towards low or net-zero carbon emissions has led to a skyrocketing global demand for Li-ion batteries. After a service life of three to ten years, Li-ion batteries have less than 80 % of their initial capacities and draw near to the end of their lives for practical utilization. Due to potential supply chain shortages and the value embodied in Li-ion batteries, it is imperative to recycle them, to recover the materials, and to improve the circularity and the sustinability of the industry. How to cost-effectively purify spent batteries while reducing time, energy, and waste emissions is a challenge faced by Li-ion battery recyclers. The first electrochemical membrane reactor reported in our group hasa high selectivity towards lower Cu 2+ , Al 3+ and Fe 3+ ions (<5 ppm) and retains >95% of the Ni 2+ , Co 2+ and Mn 2+ ions in the leachate. An advanced electrochemical membrane reactor was developed in this study. Further, not only does the new reactor have the same selectivity as the original reactor, but other advantages including a faster leachate processing rate (up to 10X faster). The advanced reactor can also directly generate acid at the anode side; eliminating the reactor restoration step. The prominent advantages that this electrodialysis technology has over chemical-precipitation methods include: (1) ion recovery efficiencies do not diminish after removing the impurities, Ni 2+ , Co 2+ and Mn 2+ , even at a higher initial Ni 2+ ion concentrations; in comparison, chemical precipitation has Ni 2+ , Co 2+ and Mn 2+ ion recovery efficiencies reduced significantly when the initial Ni 2+ , Co 2+ and Mn 2+ ion concentrations increase. (2) electrodialysis does not change the concentrations of Ni 2+ , Co 2+ and Mn 2+ ions significantly, but chemical precipitation could reduce Ni 2+ and Co 2+ ions to less than half of their initial values. Through electro-dialyzing the leachate, the H 2 evolution reaction mechanism was found to switch from the Volmer-acid Heyrovsky mechanism to the Volmer-alkaline Heyrovsky mechanism at a pH of around 3.7.

25 ENERGY STORAGE↗

Fusion for Space Propulsion

The need for fusion propulsion for interplanetary flights is discussed. For a propulsion system, there are three important system attributes: (1) The absolute amount of energy available, (2) the propellant exhaust velocity, and (3) the jet power per unit mass of the propulsion system (specific power). For efficient and affordable human exploration of the solar system, propellant exhaust velocity in excess of 100 km/s and specific power in excess of 10 kW/kg are required. Chemical combustion obviously cannot meet the requirement in propellant exhaust velocity. Nuclear fission processes typically result in producing energy in the form of heat that needs to be manipulated at temperatures limited by materials to about 2,800 K. Using the fission energy to heat a low atomic weight propellant produces propellant velocity of the order of 10 kinds. Alternatively the fission energy can be converted into electricity that is used to accelerate particles to high exhaust velocity. However, the necessary power conversion and conditioning equipment greatly increases the mass of the propulsion system. Fundamental considerations in waste heat rejection and power conditioning in a fission electric propulsion system place a limit on its jet specific power to the order of about 0.2 kW/kg. If fusion can be developed for propulsion, it appears to have the best of all worlds - it can provide the largest absolute amount of energy, the propellant exhaust velocity (> 100 km/s), and the high specific jet power (> 10 kW/kg). An intermediate step towards fusion propulsion might be a bimodal system in which a fission reactor is used to provide some of the energy to drive a fusion propulsion unit. There are similarities as well as differences between applying fusion to propulsion and to terrestrial electrical power generation. The similarities are the underlying plasma and fusion physics, the enabling component technologies, the computational and the diagnostics capabilities. These physics and engineering capabilities have been demonstrated for a fusion reactor gain (Q) of the order of unity (TFTR: 0.25, JET: 0.65, JT-60: Q(sub eq) approx. 1.25). These technological advances made it compelling for considering fusion for propulsion.

Thio, Y. C. Francis↗

Instability and Target Design in a Z-Pinch Driven Pulsed Fission / Fusion Engine

Advanced forms of propulsion are required to drastically improve upon the limits of existing technology and enable deep space exploration. Nuclear reactors, both fission and fusion, have great potential as systems with high energy density for spacecraft propulsion. There are a variety of nuclear propulsion concepts that have been proposed over the last several decades. Some of these rely on the confinement of plasmas by both magnetic and inertial means. When discussing the plasma confinement one must consider the stability of the system. The conditions of the plasma dictate the burn rate of the nuclear fuel; therefore, the plasma must maintain a minimum set of conditions in order to achieve an adequate burn. Instabilities limit plasma confinement through growing fluctuations in density and pressure. This results in turbulent mixing and loss of confinement. Thus it is desirable to find ways of managing the impact of instabilities that arise in order for a sufficient burn of the fuel such that surplus energy can be converted into a propulsive force. Note that the same instabilities plague the confinement of plasmas for terrestrial power generation. Over the last several years there has been research relating to the development of a Pulsed Fission-Fusion Engine (PuFF) conducted by the authors and others at their respective institutions. The propulsion system concept centers on the use of a z-pinch to compress a plasma in order to induce nuclear reactions. The plasma along with the additional energy released by the fission and fusion processes is expanded with a magnetic nozzle to produce thrust. The concept, if developed, is expected to have an improvement in specific impulse of several orders of magnitude in comparison with chemical propulsion systems. The z-pinch has been explored in the past as a method to confine a plasma via magnetic confinement fusion (MCF) for power generation. It suffers; however, from instabilities that so far have prevented break even conditions.

Taylor, Brian↗

Nuclear: The Energy of Tomorrow

The Awards Dinner Plenary Seminar by Dr. Simon Pimblott, Laboratory Fellow at the Idaho National laboratory and Nuclear Science and Technology Directorate Chief Scientist.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Nuclear Electric Propulsion Brayton Power Conversion Working Fluid Considerations

NASA has considered Nuclear Electric Propulsion (NEP) for high V missions since the late 1950’s, but the current technology readiness level of the requisite powertrain needs to be raised for such a mission. The powertrain includes reactor, power conversion, power management, electric propulsion, and thermal management components that must be integrated to minimize system (kg/kWe) and to finalize a propulsion system architecture within the 2025-2027 timeframe requires advancing these component technologies to technology readiness level (TRL) 5 and Advancement Degree of Difficulty (AD2) 3 in an expeditious manner with minimal risks. This paper will only address the power conversion (heat to electric) components of that system. Based on both internal and industry studies, a primary conclusion of this work is that a single-spool supercritical Xe-He radial flux Brayton heat engine combined with a permanent magnet synchronous alternator can potentially be developed with the least technical risk to meet the technology readiness schedule and required NEP system performance metrics.

Nuclear↗

2025 Advances in NekRS: Supporting improved performance for nuclear applications

This report presents several 2025 advancements in NekRS, a high-fidelity spectral element CFD code developed at Argonne National Laboratory to support the NEAMS thermal-hydraulics program. The forthcoming v25 release consolidates several of these advances, adding new features for portability across heterogeneous GPU architectures, real-time in situ visualization, improved turbulence modeling, and conjugate heat transfer coupling. Over the past year, NekRS has demonstrated strong scalability and performance on DOE’s leading exascale platforms, including Aurora and Frontier, confirming its readiness for some of the largest and most complex simulations attempted to date. These achievements provide a powerful new platform for high-fidelity data generation, which in turn supports the development and validation of advanced closure models critical for reactor safety and design. Significant algorithmic innovations have also been introduced. A new global runtime h-refinement capability simplifies workflows by reducing mesh preparation burdens and enabling coarse-to-fine restarts. Building on this, a novel multigrid strategy was implemented to accelerate pressure and transport solves at scale, addressing long-standing bottlenecks in exascale CFD. Together, these developments improve both the efficiency and accessibility of high-fidelity simulations for reactor-relevant problems. Collectively, these enhancements represent a major step forward in simulation technology, positioning NekRS as a cornerstone of NEAMS efforts to enable accurate, efficient, and scalable high-fidelity analysis of advanced nuclear systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

In-Situ Resource Utilization Modeling of a Lunar Water Processing System

A key element of achieving a sustained surface presence, such as defined in NASA’s Artemis plan, is In-Situ Resource Utilization (ISRU). ISRU is the practice of using local resources to provide mission consumables that reduce system launch mass requirements, and regenerate resources (chiefly, water and oxygen) for propulsion and life support supporting both Lunar and Martian missions. ISRU systems require multiple complex processes, such as excavation, chemical reactors, and electrolysis subsystems that must operate in harmony to optimize the overall system process from beginning to end. The Mission Analysis and Integration Tool (MAIT) was previously developed with MATLAB in FY22 to connect individual subsystem models into a customized, flexible framework for the purpose of technology downselect, optimization, and end-to-end process planning. Beginning in FY24, MAIT was leveraged and evolved using MATLAB/Simulink due to its ability to communicate with a vast number of other programming languages and makes up the backbone of data flow between inputs and outputs to the subsystem models. MAIT initially evaluated a suite of ISRU-related technologies, including the water processing Lunar Auger Dryer for ISRU (LADI) system with integrated upstream excavation and downstream electrolysis subsystems. With individual models consolidated, the MAIT tool generated over 60,000 cases during its parametric sweeps; these system iterations produced valuable insight into the optimal LADI geometry for minimizing energy demands, estimating carbothermal reactor and radiator mass relationships, and calculated the power dynamics of the electrolysis unit. Advanced efforts with advanced models will include examining multiple production targets to demonstrate the ability to scale ISRU technologies supporting the Space Technology Mission Directorate’s (STMD) commercialization strategy, and increase the MAIT software capability to handle a wide array of ISRU system models beyond the Lunar environment, e.g. production of propellant for a Martian lander.

Avery Carlson↗

Commercial integration of advanced nuclear energy with Artificial Intelligence (AI): Possible implications

The integration of advanced nuclear technologies (both fission and fusion) with artificial intelligence (AI) presents unprecedented national security challenges and opportunities. As fusion energy approaches commercial viability alongside advanced Small Modular Reactors (SMRs), their integration with AI and Artificial General Intelligence (AGI) systems could fundamentally transform the global energy and AI landscapes — two pillars of national security. This document briefly examines how AI could accelerate nuclear energy development and deployment while altering existing power structures, a lot could be done to deepen the discussions. Simultaneously, it observes how nuclear-powered AI may expedite advances toward AGI and beyond. These issues are deeply interconnected and thus need to be examined as a whole and more comprehensively than what’s being summarized here. For instance, AI-powered autonomous operation of nuclear facilities could reduce human error but introduce new cybersecurity vulnerabilities and uncertainties. Further investigation would also address how AI-enhanced nuclear technologies might complicate proliferation concerns through advanced fuel cycle management, nuclear materials production and safeguard. The strategic advantage gained by first entities achieving successful AI-nuclear integration could reshape global and national security framework. Timely analysis of these implications may be crucial for policymakers seeking to harness these technologies' benefits while effectively mitigating their potential risks.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Nuclear Electric Propulsion Brayton Power Conversion Working Fluid Considerations

NASA has considered Nuclear Electric Propulsion (NEP) for high ∆V missions since the late 1950s, but the current technology readiness level of the requisite power-train needs to be raised for such a mission. The powertrain includes reactor, power conversion, power management, electric propulsion, and thermal management components that must be integrated to minimize system a (kg/kWe) and to finalize a propulsion system architecture within the 2025-2027 timeframe requires advancing these component technologies to technology readiness level (TRL) 5 and Advancement Degree of Difficulty (AD2) 3 in an expeditious manner with minimal risks. This paper will only address the power conversion (heat to electric) components of that system. Based on both internal and industry studies, a primary conclusion of this work is that a single-spool supercritical Xe-He radial flux Brayton heat engine combined with a permanent magnet synchronous alternator can potentially be developed with the least technical risk to meet the technology readiness schedule and required NEP system performance metrics.

Nuclear Electric Propulsion (NEP)↗

Review of the Tri-Agency Space Nuclear Reactor Power System Technology Program

The Space Nuclear Reactor Power System Technology Program designated SP-100 was created in 1983 by NASA, the U.S. Department of Defense, and the Defense Advanced Research Projects Agency. Attention is presently given to the development history of SP-100 over the course of its first year, in which it has been engaged in program objectives' definition, the analysis of civil and military missions, nuclear power system functional requirements' definition, concept definition studies, the selection of primary concepts for technology feasibility validation, and the acquisition of initial experimental and analytical results.

Ambrus, J. H.↗

Analysis of the Solid Products from the OSCAR and the AOWG Trash Processing Systems

Two trash conversion systems that process space logistical trash for conversion into gases and liquids have minor solid product formation consisting of primarily high carbon ash, inorganic salts, and aluminum metal flakes. These solid products necessarily comprise part of the system output because the thermal degradation processes intentionally operate at temperatures below aluminum vaporization and do not convert all solid inorganics or carbon-based compounds into gaseous compounds (i.e., CO 2 or CH 4 ). The two systems included the Orbital Syngas/Commodity Augmentation Reactor (OSCAR) combustion system funded by the NASA Space Technology Mission Directorate (STMD) located at NASA’s Kennedy Space Center, and the Advanced Organic Waste Gasifier (AOWG) steam reforming system developed by Pioneer Astronautics in Lakewood, Colorado, and funded by the NASA Small Business Innovation Research (SBIR) Exploration Systems Development Mission Directorate (ESDMD). OSCAR residual solids were collected from suborbital flight and ground-based laboratory testing, while all AOWG samples were collected from ground testing. This report discusses the solid product characterization, including elemental analyses performed with scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDS), and a surface chemistry performed with x-ray photoelectron spectroscopy (XPS). A particle size analysis was performed with sieves, followed by SEM analyses. These analyses were performed to elucidate what high value products can be extracted or utilized from the solid products for follow on infusion into chemical feedstocks, manufacturing additives, or in-situ construction-based material needs.

OSCAR↗

Methods development towards automated, physics-informed, quantitative quality control of TRISO-SiC

Tristructural-isotropic (TRISO) fuel particles have been developed as a high-performance fuel for use in high-temperature gas-cooled reactor (HTGR) systems due to their high efficiency and stability under both normal and off-normal conditions. Broader deployment of this technology in advanced nuclear applications may benefit from quantitative quality assurance and quality control (QA/QC) methods that directly link TRISO properties to downstream performance. A key TRISO property is the SiC layer microstructure, which influences fission product retention during irradiation. However, existing QA/QC for the TRISO-SiC microstructure comprises only a qualitative visual inspection; therefore, there is a clear opportunity for the development of quantitative methods for TRISO QA/QC. Here, to this end, previous work has demonstrated an image processing approach to grain boundary (GB) identification and subsequent extraction of microstructural metrics; however, extensive twinning within the SiC layer complicates such analyses because twin GBs significantly influence microstructural metrics but are not expected to contribute to fission product transport. This study presents the initial development, training, and testing of an ML-based image segmentation algorithm designed to identify and remove twin GBs from standard backscattered electron micrographs, providing an industrially applicable, quantitative, and physically meaningful QA/QC approach for the TRISO-SiC microstructure. Although pixel-wise performance metrics for the twin predictions are low, the change in grain area and the number of GB pixels after twin removal predicted by the ML workflow are within 1% of the true values calculated using crystallographic data. This suggests that the model is well capable of predicting overall twin boundary structures and grain morphology, and continued advancement of this approach could enable automated, scalable, and physics-informed QA/QC for TRISO-SiC microstructures, supporting the reliable qualification of coated particle fuels for next-generation reactor systems.

Computer vision↗

Advanced Materials and Manufacturing Technologies Nondestructive Examination Efforts at Idaho National Laboratory: Report of FY-24 Efforts

This report details FY-24 nondestructive examination (NDE) efforts at Idaho National Laboratory (INL) in support of the Advanced Materials and Manufacturing Technologies (AMMT) program. While the goal of this endeavor is to develop a multi-modal, multi-length scale workflow for nondestructive characterization of advanced manufactured (AM) nuclear reactor components, substantial development remains until this is a reality. In support of this effort X-ray computed tomography (XCT), X-ray diffraction (XRD), neutron computed tomography (nCT), neutron diffraction, lock-in thermography (LIT), multi-point lock-in thermography (MLIT), and positron annihilation spectroscopy (PAS) were all used on AM specimens to examine defects such as voids, porosity, and residual stress. In addition to summarizing the results of these NDE applications, recommendations for integrating these into a more comprehensive undertaking to promote NDE of engineering-scale components are also included.

36 MATERIALS SCIENCE↗

Control System Upgrade for Canal ARC SAW

Upgrading the specific components of the Arc Saw, such as the HMI, the components of the chassis involving the I/O modules, servo motor modules, and PLC modules offers numerous advantages. By enhancing the HMI, the operators will benefit having a user-friendly interface, enabling smoother control and monitoring of the ARC SAW’s functionality. Upgrading the modules will contribute to an improved precision and responsiveness in changing modes of the ARC SAW as well as the adjusting the saw blades position, further enhancing the system's overall performance. These upgrades, while maintaining the same functionality, enable the latest technological advancements without needing significant changes or disruptions to existing operations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Digital-Twin-Enabling Technologies for Online Condition Monitoring of Nuclear Power Plant Components

Online condition monitoring is an area of active research that may enable improved scheduling, maintenance, and safety of nuclear power plant components, reducing unnecessary derates while simultaneously improving operational capacity. Digital twins are one avenue to conduct online condition monitoring and are currently being explored by national laboratories and universities alike. Digital twins for online condition monitoring are, in essence, state concurrent models that emulate a physical process which predicts a parameter and compares it against a measured value. However, digital twins may also provide additional insights by combining and interpreting various sources of information. These insights may be used for preventative maintenance scheduling optimization or early fault detection and are projected to be valuable for meeting requirements under 10 CFR 50.55a. However, digital twin technologies are still under significant development; quantifying model uncertainties, improving unique fault identification, and multimodal sensor fusion are some areas under investigation. Therefore, in this work, we discuss and review the various enabling technologies, in the form of advanced sensors, instrumentation, and modelling methods, that may be used to implement and enhance digital twins for online condition monitoring. A potential use case for pump-motors is presented to demonstrate how these various pieces of enabling digital twin technologies may integrated together for online condition monitoring. Challenges and opportunities associated with the pump-motor digital twin enabling technologies are also identified and discussed.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Intelligent Manufacturing for Extreme Environments Conference Proceedings

The Intelligent Manufacturing for Extreme Environments (IMEE) workshop was held at the Center for Advanced Energy Studies (CAES) in Idaho Falls, Idaho, May 2–3, 2023, in support of the United States (U.S.) National Science Foundation (NSF) Established Program to Stimulate Competitive Research: Workshop Opportunities (EPSCoR-WO) program. This workshop featured keynote speakers, panels, and breakout sessions with 58 participants. Nuclear reactors need to operate under extreme service conditions, such as high temperatures, corrosive environments, and high-radiation doses. Hence, reactor components must be able to withstand those conditions. The participants envision a future where on demand manufacture of components for small modular reactors (SMRs), microreactors, and other advanced reactor designs are possible. In this future, regulatory bodies accept validated manufacturing processes and standardized feedstocks, thus eliminating the need for individual component testing. However, the necessary technologies and regulatory policies needed for this future do not exist today. Successful innovation would revolutionize the nuclear power sector, enable fast commercial development, create economic opportunities in the U.S., reduce the carbon footprint and associated risks, and promote a skilled and highly competitive workforce. The objective of the workshop was to convene world-class experts, researchers, educators, and students to identify gaps and envision solutions for five interrelated challenges for intelligent manufacturing in extreme environments. The key outcomes of the conference were: (1) to take the opportunity for researchers and educators to network and form collaborations; and (2) to produce a full report to inform policy-makers, industry, and the academic community of various challenges and opportunities in the nuclear energy sector.

36 MATERIALS SCIENCE↗

The spherical tokamak advanced reactor (STAR) fusion power plant design

Scientific and technical advancements have been made that improve fusion’s prospects to provide a new energy source, showing enhanced plasma confinement conditions with plasma temperatures reaching or exceeding 100 million degrees. Overshadowing this progress is the challenge involved in developing an economically viable fusion power plant design. Many proposed next-step DEMO and pilot plant designs are extensions of existing physics-focused experimental devices defined to understand and control plasma operations to achieve and sustain a fusion reaction. Transitioning scientific and technical advancements into a functional power plant requires a dedicated focus on architectural designs that integrate diverse technologies, while optimizing physics conditions, with a focus on economic viability. This holistic approach is essential in turning the promise of fusion energy into a reality. The Spherical Tokamak Advanced Reactor (STAR) is a fusion power plant conceptual design with the architectural focus that strives to balance physics, engineering, and cost considerations. In conclusion, it has been set up to introduce relevant physics, engineering and concept features that an intermediate pilot plant might follow, with the goal of meeting system performances and economic requirements that lead to a commercially competitive fusion power plant.

Blanket segmentation↗