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DOE OSTI2026

Flow pattern and void fraction characterization in nitrogen/water flows through a diamond-type triply periodic minimal surface lattice

Here, this study presents, to the authors knowledge, the first experimental investigation on the void fraction and flow patterns in two-phase flows through a diamond-type Triply Periodic Minimal Surface (TPMS) lattice. An additively manufactured TPMS structure was tested under upward co-current flow of a water/nitrogen mixture. Superficial velocities varied for a total of 42 test conditions (gas: 0.01–2.4 m/s; liquid: 0.01–2.4 m/s; mass flux: 20–2370 kg/m 2 ·s). High-speed video and X-ray imaging enabled time-averaged void fraction measurements and identified six distinct flow regimes which were used to develop a flow pattern map. Comparison of the void fraction data with correlations from literature demonstrated the Rouhani and Axelsson (1970) [49] correlation modified by Steiner (1993) [52] provided the best agreement, which was improved with empirically fit coefficients. This approach predicted the void fraction with errors < ±20% for 64% of the data, with a mean absolute percent deviation (MAPD) of 23%. The measured frictional pressure drop was compared to correlations from literature which captured the observed trends but did not provide good accuracy. The best agreement was found after optimizing the empirical coefficients of the Muller-Steinhagen & Heck (1986) [56] correlation; this approach captured 33% of the data within ±20% with a MAPD of 46% over the full range and captured 71% of the data within ±20% a MAPD of 13.3% at mass fluxes >1100 kg/m 2 -s. These results provide foundational insight into TPMS two-phase flow behavior and inform modeling and design of advanced heat exchange components incorporating TPMS geometries.

42 - ENGINEERING↗

DOE OSTI2024

Thermal and hydraulic performance of volumetrically heated triply periodic minimal surface heaters

Advanced heat transfer surfaces, mainly Triply Periodic Minimal Surfaces (TPMSs) have great potential to increase heat transfer performance over traditional heat transfer surfaces due to their tortuous flow path and higher surface area-volume ratio. The emergence of additive manufacturing of nuclear fuel motivates experimental investigation of such advanced geometries in the context of a nuclear reactor core. Here, this study employed a novel method to explore the performance of gyroid and diamond TPMS geometries. Volumetrically heated heaters were additively manufactured from conductive polymer filament, and airflow was used to simulate the convective heat transfer from the core within a nuclear reactor. The mass flow and volumetric generation rates were varied, local Nusselt number correlations were obtained using embedded thermocouples to measure the solid and fluid temperature, and friction factor correlations were developed using differential pressure measurements. The gyroid TPMS presented a friction factor 1.5 times higher than the diamond TPMS and 90 times that of the rod bundle. TPMS geometries showed Nusselt numbers 8–10 times higher than that of the rod bundle, also maintaining colder internal temperatures, which suggested that they could sustain 250–275 % higher power density than the rod bundle for a given centerline temperature. Hence, having the potential to greatly increase the safety margins and power output of a nuclear reactor core with similar volume.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Computational flow modeling of triply periodic minimal surfaces as feed channel spacers in ultra-high pressure reverse osmosis applications

Triply periodic minimal surfaces (TPMS) are a special class of mathematical surfaces characterized by a high surface area-to-volume ratio. They have generated considerable interest in fields such as acoustics, heat transfer, and membrane-based filtration processes. This study evaluates the performance of four different TPMS designs—Schoen Gyroid, Schoen Crossed Layers of Parallels (CLP), Schoen Transverse Crossed Layers of Parallels (tCLP), and Schwarz-Primitive—when used as feed channel spacers under ultra-high pressure reverse osmosis (UHPRO) conditions, at approximately 200 bar. Our experimentally validated computational fluid dynamics model reveal different flow patterns within the feed channels for each of the four TPMS designs, leading to varying hydrodynamic and permeation properties. Under the simulated UHPRO conditions, the Gyroid and tCLP designs yield up to a 23% increase in average permeate velocity and a 14% reduction in average membrane-surface concentration relative to a non-woven spacer of the same porosity. Furthermore, the enhanced performance comes with an increased feed channel pressure drop, although it only constitutes less than 4% of the operating pressure when extrapolated for a meter-long membrane module. Additionally, the study analyzes the effects of varying inlet velocity and spacer porosity on membrane performance. Overall, this research provides valuable insights into the potential use of TPMS spacers in UHPRO applications.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Triply Periodic Minimal Surfaces Lattice Neutronics Scoping Studies

Triply Periodic Minimal Surfaces (TPMS) have seen extensive research in heat exchanger development due to their enhanced heat transfer performance. When applied to nuclear reactor cores, TPMS can more efficiently dissipate heat to the coolant, permitting increased power densities. The increased power density can be used to develop smaller reactors while retaining power output. Although TPMS core geometries promise enhanced heat transfer, the neutronic behavior of such geometries require further inquiry. In this study, the neutron multiplication and buckling are compared between variations of TPMS and traditional pincell core designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Multi-physics Topology OPtimization and Additive Manufacturing for High-temperature Heat Exchangers

This research significantly advances the understanding of high-temperature heat exchanger design through an integrated approach that combines topology optimization (TO), triply periodic minimal surface (TPMS) structures, additive manufacturing (AM) and thermohydraulic testing. Each of these components contributes uniquely to a unified, high-performance design, fabrication and testing workflow. Topology optimization serves as the foundation of the design methodology by providing a systematic way to determine the most effective material layout for separating hot and cold fluids while maximizing thermal performance. The researchers introduced a novel three-material optimization framework using two density fields to represent hot fluid, cold fluid, and solid domains. This approach enables automated discovery of optimal shapes and flow paths that cannot be intuitively designed, especially under constraints imposed by manufacturing technologies. Furthermore, constraints such as minimal wall thickness and overhang angles were embedded into the optimization process, ensuring that resulting designs are not only thermally efficient but also manufacturable using modern additive techniques. In parallel, the study delves into the use of Gyroid-based TPMS geometries for constructing the core of the heat exchanger. TPMS structures are known for their high surface area, excellent fluid mixing capabilities, and minimal pressure drop characteristics. The researchers applied a data-driven modeling framework using Heteroscedastic Sparse Gaussian Process Regression (HSGPR) combined with genetic algorithms. This allowed for the rapid evaluation and optimization of key geometric parameters such as frequency, iso-value, and phase shift. The result was a set of Gyroid structures tailored for high heat transfer and low flow resistance, demonstrating clear improvements over conventional straight-channel designs. After the designing process, additive manufacturing played a critical role by turning these highly complex, optimized geometries into physical components. Utilizing Laser Powder Bed Fusion (LPBF) with Haynes 282, the study demonstrated the feasibility of fabricating these heat exchangers at high precision. Post-processing methods, including dilation-erosion operations, were applied to ensure local features adhered to self-supporting constraints. The fabricated structures were then subjected to thermohydraulic testing under conditions representative of supercritical CO 2 Brayton cycles, validating the predicted performance and confirming the viability of the full design-to-fabrication pipeline. Finally, thermohydraulic testing across the above studies served as a crucial experimental validation of advanced heat exchanger. Under consistent high-temperature and high-pressure conditions using supercritical CO 2 , the testing demonstrated that both TO and Gyroid-based TPMS designs significantly outperformed conventional straight-channel HXs. The TO design achieved a 115% increase in UA and NTU and a 27.6% boost in gravimetric power density, while the data-driven optimized Gyroid design delivered a 166% increase in UA and NTU and improved effectiveness from 68.7% to 86.1%. These results validate the simulation models, confirm the manufacturability of complex geometries under AM constraints, and provide key insights into design-performance trade-offs, thereby advancing the development of high-efficiency, compact heat exchangers for extreme environments.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Thermal Performance of Triply Periodic Minimal Surface Lattice Structures in Single-Phase Dielectric Fluid Cooling of Power Electronics

Additive manufacturing has transformed thermal management by enabling the production of complex, optimized geometries that conventional manufacturing methods cannot achieve. This study investigates the single-phase convective heat transfer performance of gyroid triply periodic minimal surface (TPMS) lattice structures with functional porosity. TPMS structures provide high surface area to volume ratios and are amenable to 3D printing. A gyroid numerical model was created and validated against an existing experimental study with a similar feature size to the investigated geometries. The TPMS structure has a periodic width of 1.6 mm, a length of 10 mm, and a height of 4 mm, with a functional porosity ranging from 0.5 to 0.8, decreasing with distance from the heated surface. Three different flow configurations were examined for an inlet fluid temperature of 70 °C. The inlet velocities range from 0.01 to 1.2 m/s, corresponding to a Reynolds number range of 10–900 with a heat flux of 50 W/cm 2 applied at the base. AmpCool ® AC-110 dielectric fluid (Prandtl number 59.5) was used as the coolant. Thermal performance and friction characteristics were studied for the three flow orientations. The parallel flow configuration was identified as the most efficient for heat removal. A detailed analysis of the numerical results highlights the underlying physics behind the thermal performance differences among the flow configurations.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Experimental Characterization of High-Surface Area Thermal Energy Storage

There is growing interest in energy storage technologies due to the expansion of renewable energy sources that are inherently intermittent and the increasing frequency of extreme weather events that disturb the power grid. Power consumption in buildings makes up approximately 76% of all electricity usage on the grid and is primarily used for thermal applications such as space conditioning, hot water, and cooking. This makes thermal energy storage (TES) an ideal solution for many of these applications. Many TES technologies rely on latent energy storage, which utilizes the melting/solidification of phase change materials (PCM) to store energy. Typically, TES designs suffer from low power density due to their low inherent thermal conductivity. This limitation makes the deployment of TES in active applications difficult as the ease of access to energy is essential for effective use. Common routes for improving power density include high thermal conductivity additives or extended features such as fins that increase cost. This study presents an alternative approach to improving performance through increasing the overall surface area to volume ratio of the device, to increase the available area for convection to occur between the working fluid and PCM. In the study a commercial PCM was selected with a transition temperature ideal for space heating applications. The heat exchanger design utilizes a unique application of triply periodic minimal surfaces (TPMS) for macro-encapsulation of the PCM. The use of TPMS for heat exchangers has been growing in interest due to their high-surface area to volume ratios, which were previously unmanufacturable until the development of additive manufacturing. A modular system was designed and manufactured with a stereolithography resin printing system that is then backfilled with PCM. An experiment test set-up is designed to test the charge and discharge performance of the thermal storage using a conditioned air stream. The pressure drop of the design is tested across a variety of flow rates. When compared to existing experimental data within literature, there is excellent agreement based on the Reynolds number at similar hydraulic diameters. Several inlet temperatures are tested at consistent temperature differences from the phase change temperature for both charging and discharging. Additionally, the volumetric flow rate is varied for each temperature set point. It was found that increasing flow rate had diminishing returns in reducing the overall charge time of the TES. The temperature delta from the melting temperature was the primary contributor to the change in average heat flux with limited variation in average heat transfer rate between charging and discharging at similar inlet temperatures and flow rates. The TPMS heat exchanger design has a high air-side pressure drop but it provides high heat transfer rates. This helps maintain a high outlet temperature during discharge, which is important to thermal comfort applications. The design, manufacturing, and experimental characterization of the TES device will be presented as part of this study.

25 ENERGY STORAGE↗

DOE OSTI2025

Design, optimization, and validation of a triply periodic minimal surface based heat exchanger for extreme temperature applications

Heat exchanger (HX) innovation offers potential for significant improvements in energy efficiency for a host of applications including but not limited to aviation and power generation cycles. Triply Periodic Minimal Surfaces (TPMS) have received significant attention in recent years due to their incredibly high surface area density, which makes them very attractive from a heat transfer point of view. Recent efforts have largely focused on thermal-hydraulic characterization of the many available TPMS and the testing of small-scale HX prototypes. However, practical implementation remains largely unexplored, partially due to the extreme computational cost associated with accurately simulating these complex structures. In this work, we present the design, simulation, and optimization of a TPMS-HX for high temperature (900 °C) and pressure (25 MPa) applications. Detailed analysis of HX sub-sections is conducted to define the smallest repeatable section which may be used to characterize the thermal-hydraulic performance of the entire HX, enabling rapid design and iteration with significantly reduced computational cost. Compared to preliminary results for a water-to-water experiment, calibrated heat transfer and pressure drop predictions were within ±5 % and ±10 %, respectively. Optimization results show a 10x increase in volumetric power density over the initial design, which is verified against a parametric exhaustive search of the HX design space. Furthermore, it was found that reducing the unit cell hydraulic diameter cell plays the largest role in increasing heat transfer, increasing the surface area density and enabling a more compact and efficient HX.

42 ENGINEERING↗

DOE OSTI2026

Making Small-Volume Heat Pump Water Heaters Larger: A Design Framework for Integrated Phase Change Material Heat Exchangers

Those that use electricity for water heating, the majority use resistive elements rather than heat pump water heaters (HPWHs), the latter of which use 60-70% less energy than the former. One major barrier to wider HPWH adoption is the added equipment required, which prevents current 50-80-gallon tanks on the market from fitting into smaller utility closets sized for 30-40 gallons, such as those found in manufactured housing. Additionally, these smaller HPWHs tend to underperform relative to their larger counterparts. One solution that addresses both space and performance concerns is thermal energy storage, and in particular, phase change materials (PCMs). PCMs have been studied extensively in building envelope and HVAC systems, but remain a nascent technology in residential water heating. While water itself has a uniquely high energy storage capacity, PCMs have an even higher energy storage density, thus providing the potential to elevate the performance of 40-gallon HPWHs to that of 50-gallon or larger tanks. This research is part of a larger project that seeks to utilize thermal energy storage to enable decarbonized water heating in low-income communities. In this study, we outline the design process used to produce novel PCM heat exchangers for use in small-volume HPWH tanks, including the identification of design constraints and performance targets relevant to real-world applications. In order to ensure optimal PCM utilization and tank storage capacity, we focus here on co-maximizing surface area and PCM volume in the heat exchangers; therefore, this research targets triply periodic minimal surface (TPMS) lattices. TPMS lattices boast enhanced heat transfer capabilities compared to traditional heat exchanger geometries and offer highly tailorable designs; thus, they pair well with the growing field of additive manufacturing, or 3D printing. Starting with a suite of TPMS lattices, we demonstrate a systematic approach for narrowing down feasible designs that comply with identified constraints while meeting PCM performance objectives.

25 ENERGY STORAGE↗

NASA NTRS1992

Takeoff Performance Monitoring System display options

The development of displays for the Takeoff Performance Monitoring System (TPMS) is described with attention given to the three concepts prepared for commercial applications. The TPMS algorithm is described and related to the display requirements for pilots of two-engine airplanes. Head-up and -down displays are considered for displaying the simple advisory data which indicate whether the takeoff is a 'Go' or 'No-go' based on engine failure, acceleration error, and runway length. Six pilots are shown the three display options which include: (1) basic information; (2) basic data with 'Go/No-go' advisory flags; and (3) basic data, advisory flags, and an abort-warning symbol. The pilots tended to select the option with the most advisory data available, but the inconclusive preference study led to the concept of presenting all three configurations as possible display options for the TPMS.

Middleton, David B.↗

DOE OSTI2026

Design Considerations for Phase Change Material-Incorporated Heat Exchangers in Water Heating

In recent years, the buildings sector has seen major pushes towards decarbonization through innovations that promote deep electrification. 20% of an average household's energy use comes from water heating, and in the US, over half of all households still use gas water heaters. Of those that use electricity for water heating, the majority use resistive elements rather than heat pump water heaters (HPWHs), the latter of which use 60-70% less energy than the former. However, HPWHs tend to have larger dimensions, preventing current 50-80-gallon tanks on the market from fitting into smaller utility closets sized for 30-40 gallons, such as those found in manufactured housing. Additionally, these smaller HPWHs tend to underperform relative to their larger counterparts. One solution that addresses both space and performance concerns is thermal energy storage, and in particular, phase change materials (PCMs). This study outlines the design process used to produce novel PCM heat exchangers for use in small-volume HPWH tanks, including the identification of design constraints and performance targets relevant to real-world applications. To ensure optimal PCM utilization and tank storage capacity, this works seeks to co-maximize surface area and PCM volume; therefore, this research targets triply periodic minimal surface (TPMS) lattices, which boast enhanced heat transfer capabilities compared to traditional heat exchanger geometries. Starting with a suite of TPMS lattices, we demonstrate a systematic approach for narrowing down feasible designs that comply with identified constraints while meeting PCM performance objectives. Our current results indicate that tuning lattice properties can effectively produce geometries that provide enough energy storage to achieve a 50-gallon capacity out of a 40-gallon HPWH, even when placing the PCM heat exchanger inside the tank. Additionally, we demonstrate successful fabrication of lattices with these tuned properties.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

Modernization of Insulative Reusable Thermal Protection Systems (IRTPS)

Insulative thermal protection systems, such as Flexible Reusable Surface Insulation blankets and High Temperature Reusable Surface Insulation tiles, were developed for the Shuttle Orbiter to enable reuse of the vehicle for low-earth orbit missions. Since reusability is essential to many new industry launch and space vehicles, Shuttle-derived thermal protection materials (TPMs) are being sought for their flight proven performance. Alumina Enhanced Thermal Barrier (AETB) is the state-of-the-art tile material that was developed in the 90’s. AETB along with associated coatings, reaction cured glass (RCG) and Toughened Unipiece Fibrous Insulation (TUFI), are currently made by NASA using heritage raw materials derived from lifetime purchases. Finding viable replacements for raw materials that have changed in nature or are obsolete is important for continuation of these TPMs. In some cases, the use of modern raw materials has been shown to yield tile with reduced performance, most notably in mechanical properties. In this work, the production of AETB will be discussed to better understand the process-structure-property relationships and for allowing use of these modern alternatives. A small-scale tile casting system was developed for rapid and efficient exploration of the manufacturing variables such raw material selection and pre-processing, casting process parameters, and billet firing protocols. An optical transmission defect characterization technique was implemented to correlate process variables to structure. Comparisons between TUFI/RCG coated AETB derived from heritage and modern raw materials will be shown including AHF arc jet test results completed under a collaboration with Stratolaunch.

thermal protection materials↗

NASA NTRSDate not supplied

Mitigating Grazing Flow Impedance Eduction Errors in Additively Manufactured Porous Liners

Additively manufactured porous metamaterials, including triply periodic minimal surface (TPMS) cores, are promising candidates for aeroengine liners but often behave as extended-reacting treatments under grazing flow. Standard impedance eduction procedures assume locally-reacting behavior and can yield physically inconsistent results for such materials. This study evaluates internal partitions (thin solid walls inserted at regular intervals along the liner’s streamwise extent) as a means of suppressing internal streamwise propagation to improve eduction consistency. Six TPMS configurations were tested in the NASA Langley Grazing Flow Impedance Tube (GFIT) at partition spacings of 4′′, 2′′, and 1′′, as well as unpartitioned, and at Mach numbers up to 0.3. For most geometries, 2′′ partition spacing eliminated impedance discontinuities and substantially improved Prony correlation, though effectiveness varied with core topology. Partitions also altered the acoustic response of the liners: resistance increased, resonance frequencies shifted downward, and peak attenuation decreased while bandwidth broadened in some cases. Because partitions modify the liner itself, the educed impedance characterizes the partitioned system rather than the original unpartitioned core. These results establish partitioning as a practical pathway toward liners that are more compatible with standard eduction methods, while demonstrating that the intervention is itself an acoustic design change.

liners↗

DOE OSTI2022

Hierarchical triply periodic minimal surface structures as heat exchangers and reactors

The present disclosure relates to a transport mechanism apparatus for transporting at least one of a gas or a fluid. The transport mechanism may have an inlet, an outlet and a triply periodic minimal surface (TPMS) structure. The TPMS structure is formed in a layer-by-layer three dimensional (3D) printing operation to include cells propagating in three dimensions, where the cells include wall portions having openings, and where the cells form a plurality of flow paths throughout the transport mechanism from the inlet to the outlet, and where the cells form the inlet and the outlet.

Roy, Pratanu↗

DOE OSTI2022

Hydrodynamics of countercurrent flow in an additive-manufactured column with triply periodic minimal surfaces for carbon dioxide capture

Computational investigation of the countercurrent flows in an additively manufactured (AM) column packed with triply periodic minimal surface (TPMS) is challenging. Multiphase flow simulations using the volume of fluid (VOF) method can explain the column’s hydrodynamic characteristics, including interfacial area, liquid holdup, pressure drop, flow regime, etc. The interfacial area is a key factor dictating the mass transfer via the absorption process, and thereby the overall efficiency of the column. The impacts of a solvent's physical properties, liquid and gas loads, and contact angle on the hydrodynamics are extensively explored. The solvents include traditional solvent (monoethanolamine [MEA]) used in industry as well as a water-lean solvent (EEMPA) as prospective solvents for carbon capture. As expected, interfacial area and liquid holdup increase with increasing liquid loads (q L ). The EEMPA exhibits higher values for the interfacial area and liquid holdup compared to those for the MEA. The dry and wet pressure drops per unit length in the column at different gas loads (F G ) are calculated and further compared with the empirical correlations for traditional packings. At low gas loads, i.e., in the preloading regime, the predicted values of the wet and dry pressure drops match well with the corresponding values calculated from available correlations. The gas load has a marginal impact on the interfacial area at its lower value, but the higher value of F G (>2.18 $\sqrt{Pa}$) causes flooding in the column. The effect of varying contact angles on the interfacial area and liquid holdup in the preloading regime is also studied. Both interfacial area and liquid holdup decrease with the increase in the value of the contact angle. Altogether, the effect of the contact angle on interfacial area is more pronounced than other parameters influencing the interfacial area.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Cybersecurity Attacks in Vehicular Sensors

Today's modern vehicles contain anywhere from sixty to one-hundred sensors and exhibit the characteristics of Cyber-Physical-Systems (CPS). There is a high degree of coupling, cohesiveness, and interactions among vehicle's CPS components (e.g., sensors, devices, systems, systems-of-systems) across sensing, communication, and control layers. Cyber-attacks in the sensing or communication layers can compromise the security of the control layer. This paper provides a detailed review of potential cyber threats related to the sensing layer. Notably, the focus is mainly towards two categories of sensors: vehicle dynamics sensors (e.g., Tire Pressure Monitoring Systems (TPMS), magnetic encoders, and inertial sensors) and environment sensors (e.g., Light Detection and Ranging (LiDAR), ultrasonic, camera, Radio Detection and Ranging (Radar) systems, and Global Positioning System (GPS) units). Furthermore, the paper also offers perspectives through existing countermeasures from literature and stresses the need for data-driven cybersecurity solutions.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

HPC-Enabled Optimization of High Temperature Heat Exchangers (CRADA Final Report)

This project was a collaborative effort between Lawrence Livermore National Security, LLC (LLNS) as manager and operator of Lawrence Livermore National Laboratory (LLNL) and Materials Sciences, LLC, to develop a technology for design and optimization of heat exchangers using powerful desktop and laptop computers. The project was originally designated as a 12-month project, and consisted of 3# major tasks and the following 8# major deliverables: 1) CFD models of 3D heat exchangers based on existing and new geometry. 2) Validation against experimental data provided by MSC and published in the literature. 3) CFD models of 3D unit cells based on TPMS. 4) Surrogate models capable of delivering the gradients of the homogenized properties with respect to the parametrization. 5) 3D design methodology using TO algorithms. 6) Conventional reference and topology optimized designs. 7) 3D optimized designs stored in a 3D printer build format. 8) Verification of the improved performance. All of the deliverables for this project were successfully completed with two no-cost time extensions.

36 MATERIALS SCIENCE↗

DOE OSTI2026

HPC-Enabled Optimization of High Temperature Heat Exchangers (CRADA Final Report)

13 HYDRO ENERGY↗