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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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DOE OSTI2025

Mechanical Solutions Scan Report

Power lines, poles, and towers are the backbone of the United States (U.S.) electric-power grid. These transmission and distribution networks route electricity from generator to loads. The characteristics of these routes are rapidly changing -- trending towards decentralized renewable generation, electric heating, vehicle charging, and large data-center loads. Coupled with aging infrastructure and the increased frequency of extreme weather events, there is concern about the future reliability and transmission capacity of conductors and adjacent components. This scan report seeks to provide an overview of mechanical solutions to challenges caused by extreme weather events associated with components of transmission and distribution infrastructure, including conductor heat sag, ice accumulation, wind, and wildfire. Many options could increase transmission capacity or reliability, and these are at various stages of technological readiness. Some have only been lab tested, while some have been widely deployed in the U.S. or overseas for decades. The solution categories and providers featured in this report are intended to be comprehensive at the time of publication and to serve as a reference for decision-makers concerned about transmission and distribution reliability. There are two other categories of large, complex solutions, which are not covered in this report: replacing existing conductors with advanced conductors and implementing digital grid enhancing technologies. A separate scan report titled “Advanced Conductor Scan Report,” which discusses advanced carbon-core conductors, was published by the Idaho National Laboratory (INL) in 2023. Information on digital technologies, such as dynamic line ratings, power-flow controllers, and other power electronics and communications-based devices, can be found on the Grid- Enhancing Technologies landing page. Mechanical grid-enhancing technologies, or solutions covered in this report, often do not require full equipment replacement and do not rely on digital components. Mechanical technologies are overlooked because they may be older, simpler, or seemingly “more obvious” than digital or carbon-core technologies. However, it is wise to consider mechanical solutions in a thorough evaluation of grid enhancing technology solutions.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Standard Analysis Report INV-SAR-81, Revision 0 Chemical and Cement Components 2023 Inventory Estimates for the Interim State Performance Assessment of the Waste Isolation Pilot Plant

This standard analysis report provides the estimates for the chemical (oxyanions and complexing agents) and cement components with a data collection cut-off date of December 31, 2023. These estimates will be included in a Performance Assessment Inventory Report developed for the U.S. Department of Energy (DOE) interim state repository configuration performance assessment (PA) for the 2026 Compliance Recertification Application (CRA).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Application of Ocean Thermal Energy Conversion (OTEC) Systems for Powering Safety Monitoring Systems of Offshore Oil and Gas Operations, OESI 2.0 M-1 T-1-P1.1 – Objective 3 Report: Collocation of OTEC with Offshore Oil and Gas Activities

This report is a component of a comprehensive research initiative aimed at evaluating the technoeconomic feasibility of deploying Ocean Thermal Energy Conversion (OTEC) systems to power safety monitoring systems for offshore oil and gas operations in the Gulf of America (GOA). The overarching study has three primary objectives: summarizing existing oil and gas equipment monitoring systems, modeling OTEC as a renewable marine energy source, and exploring the collocation of OTEC power sources with offshore oil and gas activities to offset power demand. This report specifically addresses Objective 3, focusing on the integration of OTEC systems with floating oil and gas facilities.

02 PETROLEUM↗
DOE OSTI2024

Thermomechanical Behavior of Advanced Manufactured Parts, Subcomponents, and Their Weldments for Gen3 CSP

Generation 3 (Gen3) concentrating solar power (CSP) plants may require the use of molten chloride salt storage systems, solar receivers, and supercritical-CO 2 primary heat exchangers (PHX). The temperatures that would be expected in these parts and subcomponents could approach 760°C for hot side and 500°C for cold side at peak operating conditions. With the design limitations, highly corrosion- and creep-resistant alloys are needed for maximizing component lives. This report presents the results for the project "Thermomechanical Behavior of Advanced Manufactured Parts, Subcomponents, and their Weldments for Gen3 CSP", award number DE-EE00036334. In this project, creep enhanced ferritic alloy Grade 91, austenitic stainless-steel (SS) 304H, Ni claddings Ni201 and C22, and nickel-based superalloys Inconel 740H and Haynes 282 and 230 were evaluated for potential applications in Gen3 CSP systems. Advanced manufacturing of these parts, subcomponents and their welds, was investigated and a full technoeconomic analysis was made in comparison to conventional manufacturing techniques. The manufacturing techniques explored are explosion clad welding and combustion synthesis/combustion reaction for transfer pipes, additive manufacturing (AM) including laser-powder bed fusion (L-PBF) and electron beam AM (EBAM) with wire feedstock for PHX and solar receivers, and conventional fusion welding for similar and dissimilar joining of these various parts and subcomponents.

14 SOLAR ENERGY↗
DOE OSTI2026

NRC Reactor Operating Experience Analysis and Trend Summary: 2024 Update

This report presents a summary of the Nuclear Regulatory Commission’s (NRC’s) reactor operating experience analyses with data through 2024 as well as the reliability and frequency trends identified in the 2024 update reports for the component performance studies, loss-of-offsite power analysis, initiating events analysis, and system studies provided on the NRC Reactor Operating Experience Results and Databases website (https://nrcoe.inl.gov/).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Testing of Participant's Power Electronics Component for Circuit Performance and Efficiency (CRADA Final Report)

The "Solar SEED Smart Controller is a charge control device to condition solar power to load voltage with or without Battery (also called a "DC Power Platform") invented by David Gibbs and T4D Labs Inc. T4D Inc. and the SEED Smart Controller invention were selected for American Made Challenges Solar Prize, which includes voucher for NREL to provide technical assistance.

14 SOLAR ENERGY↗
DOE OSTI2026

On High-Temperature Dynamometer Test Stand Development

RePED is a novel prototype alternator that has been designed and built to operate at 35 kW under 250 degrees C ambient temperature conditions. The operating efficiency will be measured using a 225-kW motor to drive the machine in a back-to-back configuration. The goal is to determine if the RePED alternator can deliver 35 kW at a rotational speed of 1,000 rpm while operating in 250 degrees C ambient temperature and have a minimum efficiency of 60%. Dynamometer testing of a high-temperature alternator for geothermal drilling presents several unique challenges, especially around maintaining and managing the various sources and types of energy passing through the system without impacting data quality. The objectives of this report are to (1) describe the test stand in detail, the relative orientation of each major component, and the data acquisition system and (2) discuss the behavior of the test stand components such that this report can serve as a reference document for future projects.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Understanding failure in austenitic steels: Key considerations for molten salt storage in CSP applications

Owing to their excellent properties, austenitic stainless steels are extensively used in boilers, furnaces, molten salt tanks, and other applications that are subjected to extreme mechanical loads and high-temperature conditions. Their high corrosion and creep resistance make them suitable for high-temperature operating environments. Additionally, good fatigue resistance and favorable mechanical and visual properties are essential. However, the premature failure of several components at elevated temperatures has been previously reported. Although the failure analysis of components in service is complex, processes such as cold work and welding have been identified as contributing factors to the performance degradation of these steels. This study aims to analyze the various documented failure modes and mechanisms in austenitic steels, including creep, cracking, stress relaxation cracking, and fatigue, to better understand the multi-objective design requirements for these alloys as structural materials for high-temperature molten salt tanks in Concentrating Solar Power (CSP) plants. Stabilized austenitic grades, such as AISI 347H, demonstrate superior resistance to creep and corrosion-related degradation when compared to non-stabilized grades like AISI 316L at temperatures relevant to concentrated solar power (CSP) applications. In contrast, nickel-based alloys offer enhanced corrosion resistance, albeit at a higher cost. This review underscores that creep, stress relaxation cracking, and thermo-mechanical fatigue are the predominant long-term failure risks in CSP hot tanks.

14 SOLAR ENERGY↗
DOE OSTI2024

Lifespan Impacts to Infrastructure, Renewable Energy Components and Energy Storage Components Related to Fluoropolymer Use

This report focuses on the use of fluoropolymers in infrastructure materials (building construction materials, transportation, and electrical transmission and distribution); renewable energy generation components (specifically wind and solar); and energy storage components (lithium-ion batteries and fuel cells) and product lifespan impacts if fluoropolymers were no longer available or allowed in commerce. Additionally, environmental considerations for fluoropolymer manufacture, use, and end-of-life disposal are discussed. This document is the second of two companion reports. The first report, Assessment of Fluoropolymer Production and Use With Analysis of Alternative Replacement Materials, contained an analysis of use of fluoropolymers and their potential replacement technologies in aerospace, automotive, battery, building construction, chemical processing, electronics, infrastructure, semiconductor, solar panel, and wind energy industries sectors, along with qualitative life cycle assessment (LCA) and cost-benefit analysis of replacing fluoropolymers. This report does not focus on the lifecycle aspects of use of fluoropolymer or alternatives in the designated applications. For more information on those topics, see aforementioned report.

25 ENERGY STORAGE↗
DOE OSTI2026

Bubble explosion induced melt pool instabilities in electron beam melting of aluminum alloy

Electron beam melting (EBM) is an additive manufacturing technology that can process materials and manufacture components otherwise impossible or uneconomical. However, defects, including porosity and surface irregularities, are widely reported in EBM-built components, and their formation mechanisms are not fully understood. Here, using in-situ high-speed synchrotron X-ray imaging, we reveal that bubble explosions in Al6061 during EBM induce melt pool instabilities contributing to defect formation. The melt pool and keyhole evolve through three stages: (1) initial formation of a melt pool, (2) subsurface bubble formation and explosion, and (3) periodic keyhole oscillation. During scanning, periodic bubble explosions can eject molten liquid as spatters and disturb the vapor depression and melt pool, contributing to surface humping, that may trigger lack-of-fusion defects in subsequent layers. The physical insights we report could provide guidance for EBM machine development, process innovation, alloy design and model development.

36 MATERIALS SCIENCE↗
DOE OSTI2025

EGS Collab Experiment 2: Continuous Active Source Seismic Monitoring (CASSM)

The dataset contains continuous active-source seismic monitoring (CASSM) data collected during EGS Collab Experiment 2, conducted from February to September 2022 at the Sanford Underground Research Facility in Lead, South Dakota. This experiment aimed to investigate enhanced geothermal systems through high-pressure fluid injections at depths of 1200-1500 meters. The seismic monitoring system included 16 three-component piezoelectric accelerometers and 24 hydrophones installed in boreholes around the injection zones, recording signals from piezoelectric seismic sources. Data were acquired using both continuous and triggered recording systems, with sampling rates of up to 100 kHz. The raw data are organized by timestamps and stored in .dat format, with accompanying log files. Calibration certificates for selected accelerometers are provided to aid in correcting sensor responses, though users are advised to consider possible effects of enclosures and installation on sensor performance. Users are strongly advised to consult the accompanying report, which outlines the experimental setup, data acquisition, sensor specifications, and recording systems.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

West Valley Demonstration Project (WVDP) Annual Site Environmental Report (ASER) for Calendar Year 2023

The report, prepared for the U.S. Department of Energy West Valley Demonstration Project office (DOE-WVDP), summarizes the environmental protection program at the WVDP for calendar year (CY) 2023. Monitoring and surveillance of the facilities used by the DOE are conducted to verify protection of public health and safety and the environment. The report is a key component of DOE’s effort to keep the public informed of environmental conditions at the WVDP. The quality assurance protocols applied to the environmental monitoring program ensure the validity and accuracy of the monitoring data. In addition to demonstrating compliance with environmental laws, regulations, and directives, evaluation of data collected in 2023 continued to indicate that WVDP activities pose no threat to public health or safety, or to the environment.

Record of Decision↗
DOE OSTI2024

Acoustic-based monitoring and machine learning of component status for microreactor applications

This report provides a description and assessment of recent efforts to couple acoustic-based experimental measurements and characterization with machine learning models in order to enhance structural health monitoring capabilities for nuclear microreactors. With resilient embedded sensors in development by others supported by programs funded by the US Department of Energy’s Office of Nuclear Energy, the work described herein builds upon ongoing efforts to improve non-destructive testing technology that relates measured acoustic signatures to component stresses and/or structural defects, using a combination of new experimental measurements and machine learning architectures. The experimental procedure remained similar to that developed for the previous year’s demonstration of damage detection by the authors, with the same damaged sample tested under similar applied stress conditions. Notably, a new mounting fixture was designed and implemented to improve measurement consistency and a more sophisticated laser Doppler vibrometer was employed to make high-fidelity vibration measurements. Two nominally identical sets of training data were collected for each experimental setup to better understand the repeatability of the experiment and to better test the generality of trained neural network models. Additionally, we obtained new high-quality 3D mode shapes of the damaged test article at various stress and excitation levels, providing greater insights into the physical response of the sample during testing. Previously, we demonstrated that a machine learning model based on a convolutional neural network can predict structural details of an artificially introduced interface (intact, rough cut, smooth cut), and the applied torque level. In this study, we have transitioned to graph-based neural network architectures to better develop and test a flexible framework that is more suitable to being transferred away from controlled benchtop experiments and into more applied settings where less-structured data inputs may be expected. In general, performance testing of a graph neural network on frequency-domain representations of the data indicates strong and consistent identification of test conditions for datasets recorded on damaged components. With goals of predicting damage location and other changing experimental conditions using limited datasets, predictive models using a graph neural network architecture correctly predicted the applied torque level with an accuracy of 85% using only a single measurement point and predicted within one torque level in 95% of test windows. Predictions of damage location had limited success due to the symmetry and minimal number of the damage scenarios presented during model training. Results were ambiguous as to whether the model could detect the location of the artificial damage, or if it was instead learning the location of a given measurement point on the part and subsequently detecting which points were closest to the location of the damage. This finding will be factored into upcoming planned work on damaged graphite components, where new experimental tests with a larger number and variety of damage scenarios are expected to provide improved validation of recent developments in monitoring methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

A multi model ensemble reveals net climate benefits from regenerative practices in US Midwest croplands

Process-based cropping systems models (CSMs) are key components of measurement, monitoring, reporting, and verification frameworks of carbon markets, but model-specific differences limit their applicability across diverse pedo-climatic conditions and agronomic practices. Multi-model ensemble (MME) provides an opportunity to better estimate changes in soil organic carbon (SOC) and nitrous oxide (N 2 O) emissions from agronomic practices at scale. We used an MME across 46 million hectares of US Midwest cropland at a resolution of 4-km 2 to assess the aggregate ability of different regenerative practices to sequester SOC and N 2 O emissions compared to their counterfactual dynamic baselines. MME was validated against long-term trials and compared to its constituent CSMs, showing greater accuracy and lower uncertainty. The results show that adopting no-till combined with cover crops increased SOC stocks by 0.36 ± 0.12 Mg ha -1 yr -1 , corresponding to a net regional SOC gain of 16.4 Tg C yr -1 compared to business-as-usual baselines. These benefits are halved when each management is practiced individually, and the SOC gains are only fully realized with low initial carbon stock. By including N 2 O emissions, we can assess the overall climate mitigation potential, specifically, the extent to which carbon sequestration can offset direct N 2 O emissions. The magnitude of this potential varies depending on management practices and geographic location with net climate benefits on average ranging from 0 to 3 Mg CO 2 -eq ha -1 yr -1 . High-resolution MME results allow for robust estimates of climate mitigation, reducing barriers to carbon market participation and supporting regenerative agriculture initiatives at scale.

carbon credits↗
DOE OSTI2024

Non-nuclear Component Signatures for Warhead Dismantlement Confirmation

The verification of warhead dismantlement is expected to be an important component in future arms reduction treaties. Historic approaches developed with future arms control treaty verification in mind often involve intrusive measurements, process monitoring, and/or inspector presence to provide confidence that an authentic warhead has been dismantled. This work explores the possibility of reducing the negative impacts of these invasive approaches while also delivering a method that is more likely to provide non-sensitive data that can be shared with not only other nuclear weapons states but also non-nuclear weapons states partners. This work explores a novel approach for verifying dispositioned non-nuclear weapon components, providing confidence post-dismantlement that a treaty accountable item that was dismantled was in fact a treaty-relevant nuclear weapon system as declared. This method provides an alternative to intrusive inspection processes in nuclear weapons production environments, which would require significant changes to the host’s operational behaviors. It achieves this by identifying intrinsic neutron-induced signatures of non-nuclear components to determine their authenticity and estimate the duration they were exposed within a nuclear weapons system using technologies that are already in use for other national security applications. Intrinsic radiation effects studies are already a part of the stockpile aging and surveillance evaluations. However, none of these technologies and approaches have been previously considered for verification applications of non-nuclear component disposition. In this report, we introduce modeling studies that have been used to identify the most promising candidate parts and materials with signatures that are measurable and actionable. These models have been validated with laboratory measurements of signatures induced by the exposure of candidate materials to neutrons over a range of times. Predictive modeling then demonstrates the methodology for estimating exposure times and/or limits. Laboratory measurements of authentic non-nuclear parts from a dismantled warhead demonstrate the feasibility of employing these signature measurements. And finally, a concept of operations (CONOPS) for the potential use of this methodology is presented.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2025

FRAM Version 7.1’s Bias

The Fixed-Energy Response-Function Analysis with Multiple Efficiency (FRAM) code was developed at Los Alamos National Laboratory to measure the gamma-ray spectrometry of the isotopic composition of plutonium, uranium, and other actinides. For FRAM versions 4 and earlier, the reported uncertainties of the results come from the propagation of the statistics in the peak areas only. No systematic error components are included in the reported uncertainties. For FRAM versions 5 and 6, we examined the FRAM analytical results of both the archival plutonium data and the data specifically acquired for the isotopic uncertainty analysis project and found the relationship between the bias and other parameters. We worked out the equations representing the biases of the measured isotopes from each measurement using internal spectral parameters, such as peak resolution and shape, region of analysis, and burnup (for plutonium) or enrichment (for uranium). The resulting biases were included in the reported uncertainties of FRAM v.5 and v.6.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

West Valley Demonstration Project (WVDP) Annual Site Environmental Report (ASER) for Calendar Year 2024

The report, prepared for the U.S. Department of Energy West Valley Demonstration Project office (DOE-WVDP), summarizes the environmental protection program at the WVDP for calendar year (CY) 2024. Monitoring and surveillance of the facilities used by the DOE are conducted to verify protection of public health and safety and the environment. The report is a key component of DOE’s effort to keep the public informed of environmental conditions at the WVDP. The quality assurance protocols applied to the environmental monitoring program ensure the validity and accuracy of the monitoring data. In addition to demonstrating compliance with environmental laws, regulations, and directives, evaluation of data collected in 2024 continued to indicate that WVDP activities pose no threat to public health or safety, or to the environment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

West Valley Demonstration Project (WVDP) Annual Site Environmental Report (ASER) for Calendar Year 2025

The report, prepared for the U.S. Department of Energy West Valley Demonstration Project office (DOE-WVDP), summarizes the environmental protection program at the WVDP for calendar year (CY) 2025. Monitoring and surveillance of the facilities used by the DOE are conducted to verify protection of public health and safety and the environment. The report is a key component of the DOE’s effort to keep the public informed of environmental conditions at the WVDP. The quality assurance protocols applied to the environmental monitoring program ensure the validity and accuracy of the monitoring data. In addition to demonstrating compliance with environmental laws, regulations, and directives, the evaluation of data collected in 2025 continued to indicate that WVDP activities posed no threat to public health or safety, or to the environment.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗