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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Citywide indoor air sampling mirrors wastewater and clinical for environmental surveillance of respiratory viruses

Wastewater surveillance of respiratory pathogens can provide timely estimates of viral activity and disease trends in a population. Indoor air surveillance could be used similarly with some advantages but remains largely unvalidated at the community -scale. Here, an indoor air surveillance program was employed as part of public health environmental surveillance in Chicago, Illinois, USA. Ten air samplers were placed in healthcare and congregate living settings across the city. Weekly air samples were evaluated for influenza A, influenza B, respiratory syncytial virus, and SARS -CoV-2 over two respiratory virus seasons (2023 -2025). Citywide, aggregated air sample positivity and viral load were closely correlated with local clinical case and wastewater surveillance data across all respiratory viruses. Virus trends in air data often preceded clinical and wastewater, although this varied across pathogens and respiratory virus seasons. Further, whole -genome sequencing of SARS -CoV-2 showed close correlation of variant proportions across all datasets. At the building -scale, air samples obtained from a single sampling device provided efficient respiratory virus surveillance, with respiratory pathogen levels mirroring citywide clinical surveillance data. These data demonstrate that air surveillance can provide respiratory virus case and variant trend data at a building or community -scale, serving as an alternative or complementary tool for public health environmental surveillance.

Wilton, Rosemarie↗
DOE OSTI2026

Hazard and risk analysis framework for nuclear power plant–based integrated energy systems

Employing integrated energy systems (IESs) with nuclear power plants (NPPs) can improve NPP utilization by leveraging dedicated thermal and electric power delivery, but it may also increase operational safety risks. This paper presents a framework to identify and quantify hazards and risks for such IESs. The framework combines accidentology to review past industrial accidents with failure modes and effects analysis (FMEA) to identify potential future incidents. Hydrogen explosion and toxic chemical release hazards are of particular concern. Explosion consequences are quantified using the Bauwens-Dorofeev (Bauwens) and trinitrotoluene equivalent mass (TNT-EM) methods, while chemical release consequences are computed using the Gaussian atmospheric dispersion method. Operational disturbances from direct electrical and thermal integration that may affect NPP safety are modeled using probabilistic risk analysis (PRA). Hazards and risks are then evaluated for regulatory compliance. The framework is applied to IESs comprising pressurized or boiling water reactors supplying three levels of thermal and electrical power to industrial customers. Case studies include high-temperature steam electrolysis hydrogen plants of varying capacities and a synthetic fuel production plant. Sensitivity analysis examines piping component failures in the PRA model as a precursor to cost estimation for thermal extraction line design. Additionally, Fussel-Vessely (FV) and risk increase importance (RII) measures identify risk-informed design improvements for the thermal extraction system. FMEA highlights hazards such as loss of offsite power, prompt loss of electrical load, loss of thermal output, and immediate steam diversion, in addition to hydrogen explosions and toxic chemical releases. Both Bauwens and TNT-EM methods suggest maintaining several hundred meters of separation between the NPP and hydrogen facility to mitigate explosion risks. PRA results show a maximum initiating event frequency increase of 1.15% and an overall risk increase of 0.28%. Importance measure analysis identifies upstream pipe leak isolation components as critical. Evaluating the results against safety regulations, it is concluded that hazards and risks can be managed to comply with regulations through risk-informed thermal and electrical connection designs, component selection, maintenance programs, and safe separation distances between NPPs and integrated industrial facilities.

08 - HYDROGEN↗
DOE OSTI2025

Tolerance Studies for the IMCC Rectilinear 6D Ionization Cooling Channel

As one of the main proposed future colliders that will enable us to reach energy scales capable of probing Beyond the Standard Model phenomena, muon colliders present unique challenges. To reach the desired luminosity, namely 1, 10, and 20 ab-1 for 3, 10, and 14 TeV, respectively, the six-dimensional emittance of the muon beam needs to be reduced significantly in a process described as muon cooling. The currently proposed system for muon cooling by the International Muon Collider Collaboration involves 6D initial cooling post-muon charge separation through rectilinear channels (A) before and rectilinear channels (B) after muon bunch merge, as well as a final 4D transverse cooling. This work focuses on the former stage of cooling with B rectilinear channels. First, we will compare its cooling performance against the rectilinear channel studied by the Muon Accelerator Program. Then, we do tolerance studies on all B stages, focusing on properties of the Radiofrequency (RF) cavities used in the channels and how they affect 6D emittance and transmission. We will evaluate the impact of these modifications on the overall performance of the rectilinear 6D cooling channel.

Karaaslan, Inci [Chicago U., EFI] (ORCID:000000033↗
DOE OSTI2025

Test and Evaluation of Radiofrequency Tamper Indicating Devices for Remote Monitoring of Advanced/Small Modular Reactors

Advanced and small modular reactors (A/SMRs), due to their versatile nature, are likely to be used in remote locations to provide electrical power or other services in regions that are difficult to access or have limited transportation infrastructure. This will result in limited on-site staff, therefore driving A/SMR vendors to consider remote monitoring as a solution to support nuclear security. Maintaining Continuity of Knowledge (CoK) of nuclear material quantities and locations is vital to nuclear security, and remote monitoring of active tamper indicating devices (TIDs) has been well established as a component of International Atomic Energy Agency (IAEA) Safeguards since the early 2000s. Active TIDs, such as radiofrequency TIDs (RFTIDs), immediately alarm upon unauthorized access attempts, promoting timely detection. In contrast, passive TIDs require a surveillance regime and offer delayed detection. Active TIDs deter insiders and enable prompt detection of malicious acts. They can be used on nuclear material containers and controlled entry points like vaults and toolboxes. Therefore, the implementation of RFTIDs into security programs bolsters overall nuclear material control, and provides a visible deterrent, with primary efficacy in mitigating the insider threat and potentially allowing for Security by Design considerations. They are a strong candidate technology for maintaining nuclear security of A/SMRs but need to be evaluated for feasibility and implementation into the wider physical protection system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Evaluation of 3D pixel silicon sensors for the CMS Phase-2 Inner Tracker

The high-luminosity upgrade of the CERN LHC requires the replacement of the CMS tracking detector to cope with the increased radiation fluence while maintaining its excellent performance. An extensive R&D program, aiming at using 3D pixel silicon sensors in the innermost barrel layer of the detector, has been carried out by CMS in collaboration with the FBK (Trento, Italy) and CNM (Barcelona, Spain) foundries. The sensors will feature a pixel cell size of 25 × 100 µm 2 , with a centrally located electrode connected to the readout chip. The sensors are read out by the RD53A and CROCv1 chips, developed in 65 nm CMOS technology by the RD53 Collaboration, a joint effort between the ATLAS and CMS groups. This paper reports the results achieved in beam test experiments before and after irradiation, up to a fluence of approximately 2 . 6 × 1 0 16 n eq /cm 2 . Measurements of assemblies irradiated to a fluence of 1 × 10 16 n˙eq/cm 2 show a hit detection efficiency higher than 96% at normal incidence, with fewer than 2% of channels masked, across a bias voltage range greater than 50 V . Even after irradiation to a higher fluence of 1.6 × 10 16 n˙eq/cm 2 , similar performance is maintained over a bias voltage range of 30 V , remaining well within CMS requirements.

3D pixel↗
DOE OSTI2024

Performance Improvements of the Griffin Solvers in FY24

The Griffin code is a MOOSE-based reactor physics application jointly developed by Idaho National Laboratory and Argonne National Laboratory under the Department of Energy Office of Nuclear Energy Nuclear Energy Advanced Modeling and Simulation Program. This fiscal year, we have made significant efforts to improve the performance of transport solver options and cross-section generation for the efficient use of Griffin in advanced reactor applications. For the HFEM-PN solver, the residual evaluations of HFEM kernels were optimized by utilizing the pre- computed averaged cross sections for individual elements. Numerical integration involving the evaluation of basis functions at quadrature points was bypassed by facilitating precomputed element mass matrices for response matrices. Red-black iterations were improved by introducing a new generalized minimum residual based solver. The memory usage of response matrix storage was significantly reduced by applying basis function rotations on interfaces and calculating volumetric odd-parity moments on the fly. Additionally, the adjoint flux and transient calculation capabilities of the HFEM-PN solver were successfully implemented and verified using the TWIGL benchmark problem. For the DFEM-SN solver, memory footprint and computation time were significantly reduced by not treating angular flux vectors as the MOOSE nonlinear system vectors. Specifically for IQS, scalar adjoint weighting was introduced to further eliminate angular adjoint flux storage in the MOOSE auxiliary system. It was demonstrated through the three-dimensional Advanced Burner Test Reactor core problem that the memory usage for transient calculations with the IQS method was reduced by over 7.5× compared to before the optimizations. For the self-shielding application programming interface, a new double-heterogeneity treatment method, named the Bell Function-Based Analytic Two-Region Slowing Down Method, was developed to efficiently flux-volume homogenize TRISO particles with the matrix. Additionally, optimizations were made to hyper- fine group (HFG) slowing down calculations by pretabulating collision probability coefficients and grouping isotopes, significantly reducing the computational time for calculating scattering sources per HFG. Lastly, the pin power reconstruction module was extended to account for temporal behavior in a microreactor analysis problem, specifically for a control drum transient. Verification tests for each of these improvements demonstrated significant performance enhancements and memory reduction.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Fluoride-Cooled High-Temperature Pebble-Bed Reactor Reference Plant Model Updates

This work presents the latest improvements to, and investigations performed with, the Fluoride-Cooled High-Temperature Pebble-Bed Reactor reference plant models for the United States Nuclear Regulatory Commission. These models, developed with the Comprehensive Reactor Analysis Bundle, or BlueCRAB, serve as the foundation for the future development of detailed design evaluation models based on license applications. BlueCRAB is the code suite proposed for non-light-water reactor systems safety analyses, and it incorporates various simulation tools developed by the Nuclear Energy Advance Modeling and Simulation program, including the Griffin code for reactor physics, the Pronghorn and SAM codes for core thermal fluids, the BISON code for solid conduction and fuel performance, and the SAM code for system analysis. The primary objective of this work is to assess the level of readiness of BlueCRAB for modeling fluoride-cooled high-temperature pebble-bed reactors. We first developed numerical models in BlueCRAB that include the key physics for this technology, ensuring an adequate level of fidelity for modeling the core performance during accident scenarios. This was followed by simulation of transient scenarios, two loss-of-forced-cooling events (one protected and one unprotected), and two control rod withdrawal events (one delayed and one prompt supercritical reactivity insertion). The analysis includes comparisons between the 2-D thermal fluid porous media models in Pronghorn and SAM, comparisons between coupled Pronghorn-Griffin and coupled SAM-Griffin models for two loss-of-forced cooling events and one control rod withdrawal event, and comparisons between SAM single-solve and domain-overlapping approaches for multi-scale thermal fluid coupling. In addition, we performed comparisons between 3-D, 2-D, and 0-D neutronic models for the two control rod withdrawal scenarios with Pronghorn-Griffin. The results show that the BlueCRAB models led to physically intuitive solutions for the scenarios examined. The changes in the various scalar and vector fields such as the neutron flux, power, temperatures, densities, pressures, and velocities are all within the expected ranges, and their distributions can be explained from the system response of the transients and the geometric and material variations. Several comparisons suggest that the porous media models in Pronghorn and SAM can lead to similar solutions, even though they are based on different methodologies. The simulations demonstrate that there are differences between the various levels of fidelity, and it is advisable to have flexible tools that can cover the breadth and depth of needs that may arise in future technical evaluations. We believe that BlueCRAB’s capabilities represent a significant asset for confirmatory analyses aimed at resolving important safety questions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Y-12 National Security Complex Biological Monitoring and Abatement Program—2024 Calendar Year Report

This report provides the results of the CY 2024 sampling of East Fork Poplar Creek (EFPC) as part of the Y-12 National Security Complex (Y-12) Biological Monitoring and Abatement Program (BMAP). The results are presented in the context of historical trends. The Y-12 BMAP was developed in 1985 to demonstrate that the effluent limits established for Y-12 protected the classified uses of the receiving stream, particularly the growth and propagation of aquatic life (Loar et al. 1989). Over the years, the BMAP has become an important and valuable long-term measure of stream conditions resulting from actions and activities at the Y-12 Complex. The BMAP currently consists of three tasks: (1) bioaccumulation monitoring, (2) benthic macroinvertebrate community monitoring, and (3) fish community monitoring. The benthic macroinvertebrate community monitoring task includes studies to evaluate the receiving stream’s biological integrity annually in comparison with Tennessee Water Quality Criteria following Tennessee Department of Environment and Conservation (TDEC) protocols. In addition to presenting the EFPC biological monitoring results, this report includes results from Comprehensive Environmental Response, Compensation, and Liability Act–funded BMAP programs in Bear Creek and McCoy Branch (presented in Appendixes A and B, respectively), as required in the Y-12 National Pollutant Discharge Elimination System (NPDES) permit. Additional biological testing at the Y-12 Complex includes toxicity testing of select storm drains as required in the NPDES permit. Although toxicity testing is not formally part of the BMAP, toxicity testing results from 2024 are provided in Appendix C.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Geology of the One Earth Energy Site

The One Earth Energy site is one of two sites in the Illinois Storage Corridor (ISC) project. The objectives of the ISC project is to accelerate commercial deployment of carbon capture utilization and storage at two individual sites and receive approvals for Underground Injection Control (UIC) Class VI permits for construction at each site. At the One Earth Energy site, an extensive data collection program was undertaken, which included the drilling of a test well (One Earth Energy #1 [OEE #1]), four 2D seismic lines, and a small 3D seismic survey. The OEE #1 well was drilled in 2022 and acquired extensive core, log, and testing data to characterize the subsurface geology of the site. Coring was focused on the storage interval, the Mt. Simon Sandstone, and the confining interval, the Eau Claire Formation. The core and log data were used to evaluate the sedimentology and sequence stratigraphy, as well as to develop the conceptual geologic model. This report includes the geological summaries of the Mt. Simon Sandstone and the Eau Claire Formation. The extensive analysis of the log data is included in the petrophysical section, showing ranges of porosity, estimated pore size, and the mineral content of selected zones in the well. The separate petrographic technical report entitled “Petrographic and Advanced Geologic Characterization Report on One Earth Energy #1 (API# 1211325373)”, report number DOE-UIUC-0031892-04, details thin section point-counting analysis that includes mineralogical and pore space analysis, including grain size analysis, annotated thin section photomicrographs, scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDS), and statistics of grain size analysis on Mt. Simon thin sections from OEE #1. The final OEE #1 well data to be included in this geology report is the routine core analysis of both whole core plugs and rotary sidewall core plugs. In addition to the OEE #1 well, four 2D seismic lines and a small 3D survey were acquired as part of the overall subsurface geological characterization. This geology report references the seismic interpretation report, entitled “One Earth Energy Site Seismic Interpretation Task 5.0”, report number DOE-UIUC-0031892-07. This report details the stratigraphic and structural interpretation of the 2D and 3D seismic data acquired at the One Earth Energy site. The 2D seismic data was acquired in 2019 and 2021, and the 3D survey was acquired in 2022. The objectives of the seismic programs were to contribute to the subsurface characterization of the Mt. Simon-Eau Claire Storage Complex by evaluating the continuity of potential storage reservoirs and containment intervals across the project area, and to determine if any geologic features are present that would increase containment risk to the proposed carbon storage project.

09 BIOMASS FUELS↗
DOE OSTI2025

Deposit and Evaluate Material Across Extremes of Process Windows

Additive manufacturing (AM) can be a viable pathway to fabricate near-net-shape parts for next generation nuclear reactors. Stainless steel 316H (SS 316H) has been identified as a material of interest in the Advanced Materials and Manufacturing Technologies program to accelerate the use of AM for nuclear energy applications. Heterogeneity in material performance is one of the biggest challenges to qualification of AM SS 316H for in-service applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Exposing Process‐Level Biases in a Global Cloud Permitting Model With ARM Observations

The emergence of global convective‐permitting models (GCPMs) represents a significant advancement in climate modeling, offering improved representation of deep convection and complex precipitation patterns. In this study, we evaluate the performance of the Simple Cloud‐Resolving E3SM Atmosphere Model (SCREAM) using its doubly periodic configuration (DP‐SCREAM) against large eddy simulations and modern observational data sets from the Atmospheric Radiation Measurement program. We introduce several new transitional cloud regime cases, such as the transition from shallow to deep convection and from stratocumulus to cumulus, as well as cold‐air outbreak scenarios. The results reveal both strengths and limitations of SCREAM, particularly in the accurate simulation of cloud transitions and midlevel convection, with varying degrees of sensitivity to horizontal and vertical resolution. Despite improvements at higher resolutions, key biases remain, including the abrupt transition from shallow to deep convection and the lack of congestus clouds. These findings underscore the need for further refinement in turbulence parameterizations and vertical grid resolution in GCPMs.

Bogenschutz, Peter A. [Lawrence Livermore National↗
DOE OSTI2024

Salt Hydrate Eutectic Thermal Energy Storage for Building Thermal Regulation (Final Technical Report)

Thermal energy storage is anticipated to play an important role in developing the power grid of the future - a power grid that meets increasing demands of users, is resistant to disruptions, but also allows for greater penetration of renewable resources. Specifically, thermal energy storage materials can be integrated into HVAC systems and building envelopes, where they can be used to shift power demands for building climate control from periods of peak demand to periods of low demand. Phase change materials (PCMs) are compelling as low-cost, high energy density thermal energy storage materials for building thermal management. However, there is a lack of high performance low-cost PCMs within the specific temperature ranges which would most effectively allow for power load shifting. Inorganic salt hydrates represent a promising class of PCMs, but their inherent limitations cause them to be currently unavailable for reliable building applications. The overarching goals of this research effort are to: 1) Discover low-cost, high volumetric density salt hydrate eutectic PCMs to store low-quality heat (10 to 40 °C); 2) Introduce a high thermal conductivity matrix to reduce the time constant for energy storage to ~0.1 to 1 hr, incorporate nucleation catalysts to decrease undercooling, and utilize microencapsulation and shape stabilization approaches, minimizing moisture loss/gain, mitigating phase separation, and maintaining stable melting behavior over the lifetime of the compounds; 3) Evaluate the impact these systems have on peak load shifting, and the potential for overall energy savings under different climatic scenarios and building configurations. These goals will be achieved by an integrated research program consisting of six cohesive research subtasks: 1) Materials discovery of eutectic salt hydrate PCMs by using computationally predicted thermodynamic equilibria, coupled with high-throughput experimental validation, 2) Rapid experimental screening of nucleation catalysts identified through robust computational databases, 3) Embedding salt hydrate PCM into a low cost and scalable high conductivity matrix, 4) Microencapsulation of salt hydrate microspheres using hybrid inorganic-polymer microencapsulation approach, 5) Shape stabilization by thermoreversible salt hydrate salogels, and 6) Analysis of end-use using thermal simulations, and characterization of mock-up energy storage finished components.

25 ENERGY STORAGE↗
DOE OSTI2025

Creation of a Weather Drivers Test Suite for Inclusion in ASHRAE Standard 140

Weather conditions are an important boundary condition for building performance simulation (BPS) calculations. For existing test cases in ASHRAE Standard 140 "Method of Test for Evaluating Building Performance Simulation Software" (ANSI/ASHRAE 2020), it was assumed that the software being tested could adequately read and interpret the weather data in the provided standard weather files. As differences between the programs have been reduced and as more programs have shifted to sub-hourly time steps this assumption has become more stretched. To address these concerns a new test suite testing a program's ability to read and interpret the data from a standard weather file was developed. The purpose of the test suite is to test the use of the typical data used from standard weather files.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Megawatt-Scale Low Temperature Electrolyzer Research Capability

The development and installation of a flexible low-temperature electrolyzer research capability at the multi-MW scale with integrated renewables will help lower the cost barrier to entry for electrolyzer manufactures needing at scale system and stack evaluation and enable more electrolyzer manufactures to accelerate to commercialization with building block scale demonstration and validation. This NREL capability represents a DOE HFTO investment to support the $1B DOE Clean Hydrogen Electrolysis Program working to achieve the Hydrogen Shot goal of $1 for 1 kg hydrogen in 1 decade, lower greenhouse gas emissions and criteria pollutants, build clean energy infrastructure, and provide pathways to private sector uptake.

electrical grid↗
DOE OSTI2026

Nuclear Data Libraries Sensitivity Studies for ORSA Using SCALE

Subcritical assemblies offer valuable training capabilities in nuclear criticality safety (NCS) for individuals handling fissile material. At Oak Ridge National Laboratory(ORNL), the Oak Ridge Subcritical Assembly (ORSA), a new experimental facility, is being established to provide hands-on training for the Nuclear Criticality Safety Program (NCSP).It is essential to accurately determine the neutron multiplication factor (keff) to ensure that ORSA remains subcritical and safe during operations. This study investigated the sensitivity of keff to variations across Evaluated Nuclear Data File (ENDF/B) libraries, consisting of ENDF/B-VII.1, ENDF/B-VIII.0, and ENDF/B-VIII.1. The analysis was conducted using the CSAS6 sequence in the SCALE-6.3 code system. Individual isotopes in the ORSA model were replaced one at a time with ENDF/B-VII.1 as the base library and changing to ENDF/B-VIII.0or ENDF/B-VIII.1. The results demonstrated that the changes in keffof the nuclides associated with the ORSA model were mostly within the uncertainty of the base model (~24 pcm), except for primary nuclides like Uranium-235and H-poly with few other nuclides. The relative delta keff values of Uranium-235 and H-poly, expressed in pcm, were +280 and -212 in ENDF/B-VIII.0 and +332 and -275 in ENDF/B-VIII.1, respectively, which were notable changes in reactivity. These results demonstrated that ORSA was largely insensitive to variations across these nuclear data libraries.

Hong, Evan [North Carolina State University]↗
DOE OSTI2025

The HTR-Proteus Benchmark: Analysis and Use as a Verification and Validation Case

This presentation outlines the evaluation and application of the HTR-Proteus benchmark as a verification and validation (V&V) case for advanced reactor modeling tools. The work supports the U.S. Department of Energy’s HALEU Availability Program (HAP) and the joint DOE/NRC DNCSH project, which aims to reduce criticality safety uncertainties in commercial-scale HALEU fuel cycle and transportation systems. The HTR-Proteus experiments, conducted at the Paul Scherrer Institute, provide high-fidelity data for TRISO-fueled, graphite-moderated pebble bed reactors with high neutron leakage—conditions relevant to HALEU transport scenarios. This study focuses on Cores 4.2 and 4.3 of the HTR-Proteus benchmark, analyzing key sources of uncertainty including pebble packing, TRISO particle positioning, and core height. Using Project Chrono for realistic pebble geometries and Serpent, SHIFT, and MCNP for neutronics simulations, the study quantifies the impact of these uncertainties on the effective multiplication factor (keff). Results show that a sample size of 110 pebble configurations is sufficient to converge keff, with ±30 pcm uncertainty due to packing randomness. TRISO positioning and core height variations also significantly influence keff, highlighting the importance of detailed modeling in V&V efforts. The benchmark serves as a valuable test case for validating the Griffin reactor physics code and improving confidence in HALEU system simulations.

73 - NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2026

Establishment of a Vertically Integrated Domestic Manufacturing Process for Production of Substrates Needed for Manufacture of Gas Diffusion Layers

In this project, AvCarb, LLC evaluated the baseline performance metrics of commercial carbon veils and their corresponding Gas Diffusion Layers (GDLs) with the goal of establishing an optimized, vertically integrated production system for wet-laid nonwoven substrates used in gas diffusion media for electrochemical energy storage and conversion devices. Mechanical testing and microstructural characterization were conducted and used to develop a multiscale computational model capable of simulating and predicting the performance of GDLs in fuel cells. Although the project successfully generated foundational transport and modeling data, it was terminated prior to identifying the critical GDL design parameters necessary for full optimization. The program aimed to improve carbon veil fabrication through enhanced fiber dispersion, fiber-fiber adhesion control, and improved web formation, enabling the production of high-quality, uniform substrates. Simulations were intended to guide mixing and solution delivery system design and process conditions, followed by production-scale trials to evaluate fiber dispersion, web uniformity, and mechanical robustness. At full deployment, the proposed production line would have been capable of producing approximately 650,000 m² of carbon veil annually. This capability remains strategically important, as the United States currently lacks a domestic source of wet-laid nonwoven carbon substrates that satisfy the stringent quality requirements for fuel-cell GDLs and electrolyzers representing an ongoing supply-chain vulnerability. Beyond supply-chain benefits, the project established a robust benchmarking dataset for existing commercial carbon veils while advancing next-generation material concepts targeting improved performance and manufacturing consistency.

Olson, Cynthia Lemay↗