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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A Comprehensive Review of Working Fluids for High-Temperature Heat Pumps: History, Selection, and Evaluation

High-temperature heat pumps (HTHPs) are essential for enhancing energy efficiency across various industrial applications, especially in terms of integrating with renewable energy sources and recovering waste heat. This article thoroughly investigates suitable working fluids for HTHPs, highlighting the evolution from traditional refrigerants to contemporary alternatives with low global warming potential (GWP). It proposes comprehensive selection criteria for these working fluids, pre-selects low-GWP working fluids, and outlines a screening methodology. The pre-selected low-GWP working fluids are evaluated for applications in three typical industrial scenarios involving HTHPs. Furthermore, this study demonstrates that regulatory compliance and environmental impacts significantly influence the development of next-generation refrigerants. The choice of working fluids is closely linked to the types of vapor compression cycles, tailored to the specific industrial applications for HTHPs. This study emphasizes areas for future research, including the development of innovative working fluids; integrated strategies that account for performance, safety, and regulatory standards; alignment of HTHP components; exploration of natural working fluids; and broadening the applications of existing working fluids.

Compression↗
DOE OSTI2022

Modeling of Supercritical CO2 Shell-and-Tube Heat Exchangers Under Extreme Conditions. Part I: Correlation Development

Abstract High-temperature supercritical CO2 Brayton cycles are promising possibilities for future stationary power generation and hybrid electric propulsion applications. Heat exchangers are critical components in supercritical CO2 thermal cycles and require accurate correlations and comprehensive performance modeling under extreme temperatures and pressures. In this paper (Part I), new Colburn and friction factor correlations are developed to quantify shell-side heat transfer and friction characteristics of flow within heat exchangers in the shell-and-tube configuration. Using experimental and computational fluid dynamics (CFD) data sets from existing literature, multivariate regression analysis is conducted to achieve correlations that capture the effect of multiple critical geometric parameters. These correlations offer superior accuracy and versatility as compared to previous studies and predict the thermohydraulic performance of about 90% of the existing experimental and CFD data within ±15%. Supplementary thermohydraulic performance data are acquired from CFD simulations with supercritical CO2 as working fluid to validate the developed correlations and demonstrate its capability to be applied to supercrtical CO2 heat exchangers.

Engineering↗
NASA NTRSDate not supplied

Single and Multi-Node Modeling of Direct, Submerged, and Self-Pressurization of A Cryogenic Propellant Tank Using Nodal Tools

The pressurization of cryogenic propellant tanks will always be an important process so long as cryogenic liquids are being considered as fuel sources or used for other in-space applications. Pressure control of the tank ullage is necessary for managing propellant flowrates to an engine or a receiver tank, and modeling of the process is used to predict the pressurant requirements and the amount of propellant boiloff. Direct ullage pressurization is the more traditional approach to tank pressurization, as the physics are straight-forward, and ample test (flight) data have been collected and analyzed over the past several decades. Submerged injection pressurization is an alternate method for tank pressurization and has been shown to reduce pressurant requirements, subcool the propellant, and reduce the risk of ullage collapse. Additionally, the pressurant gas entering the ullage is usually much colder when using the submerged pressurization approach, resulting in reduced propellant boiloff. These benefits are at the expense of vaporizing a small percentage of the propellent. Both tank pressurization methods are viable options for current and future space missions, and it is important to have the capability of analyzing the tank ullage conditions for both approaches. Our previous work has demonstrated the development of a Generalized Fluid System Simulation Program (GFSSP) model, which contains a thermodynamic equilibrium heat and mass transfer subroutine capable of effectively analyzing both direct and submerged pressurization systems [1-2]. This subroutine has most recently been enhanced to include the non-equilibrium effect of pressurant dissolution into the propellant. To date the ullage has always been represented as a single node, and although the simulated single-node temperatures have good comparison with the volume-averaged ullage temperatures computed from test data, the physics of the thermal stratification in the ullage were never captured, and adjustment factors in the model were required. The purpose of this paper is to introduce the development of a multi-node ullage model using GFSSP and to discuss the improvements of the simulated ullage temperature distribution and its resulting effects on ullage heat transfer processes. Test data from the Cryogenic Propellant Storage and Transfer Engineering Developmental Unit (CPST EDU) was used for model validation. For additional comparison, a Thermal Desktop (TD) model was also developed to analyze the CPST EDU direct ullage pressurization tests using both a single node and multi-node approach. The model includes the direct pressurant line, vent line, fill/drain line, and a TD FloCAD Compartment. The TD FloCAD Compartment is employed to represent the liquid and ullage as single volumes inside the tank, to include a liquid/vapor interface, and to generate network level objects such as lumps (analogous to nodes in GFSSP), paths, and ties between the fluid and thermal elements. An established heat load on the model tank was leveraged from a pre-existing higher-fidelity model correlated to CPST EDU test data.

pressurization↗
NASA NTRS1986

Advanced Gas Turbine (AGT) Technology Project

Engine testing, ceramic component fabrication and evaluation, component performance rig testing, and analytical studies comprised AGT 100 activities during the 1985 year. Ten experimental assemblies (builds) were evaluated using two engines. Accrued operating time was 120 hr of burning and 170 hr total, bringing cumulative total operating time to 395 hr, all devoid of major failures. Tests identified the generator seals as the primary working fluid leakage sources. Power transfer clutch operation was demonstrated. An alpha SiC gasifier rotor engine test resulted in blade tip failures. Recurring case vibration and shaft whip have limited gasifier shaft speeds to 84%. Ceramic components successfully engine tested now include the SiC scroll assembly, Si3N3 turbine rotor, combustor assembly, regenerator disk bulkhead, turbine vanes, piston rings, and couplings. A compressor shroud design change to reduce heat recirculation back to the inlet was executed. Ceramic components activity continues to focus on the development of state-of-the-art material strength characteristics in full-scale engine hardware. Fiber reinforced glass-ceramic composite turbine (inner) backplates were fabricated by Corning Glass Works. The BMAS/III material performed well in engine testing. Backplates of MAS material have not been engine tested.

Source record↗
DOE OSTI2021

Tunable exciton-polaritons emerging from WS 2 monolayer excitons in a photonic lattice at room temperature

Engineering non-linear hybrid light-matter states in tailored lattices is a central research strategy for the simulation of complex Hamiltonians. Excitons in atomically thin crystals are an ideal active medium for such purposes, since they couple strongly with light and bear the potential to harness giant non-linearities and interactions while presenting a simple sample-processing and room temperature operability. We demonstrate lattice polaritons, based on an open, high-quality optical cavity, with an imprinted photonic lattice strongly coupled to excitons in a WS 2 monolayer. We experimentally observe the emergence of the canonical band-structure of particles in a one-dimensional lattice at room temperature, and demonstrate frequency reconfigurability over a spectral window exceeding 85 meV, as well as the systematic variation of the nearest-neighbour coupling, reflected by a tunability in the bandwidth of the p-band polaritons by 7 meV. The technology presented in this work is a critical demonstration towards reconfigurable photonic emulators operated with non-linear photonic fluids, offering a simple experimental implementation and working at ambient conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

High throughput automated characterization of enamel microstructure using synchrotron tomography and optical flow imaging

The remarkable damage-tolerance of enamel has been attributed to its hierarchical microstructure and the organized bands of decussated rods. A thorough characterization of the microscale rod evolution within the enamel is needed to elucidate this complex structure. While prior efforts in this area have made use of single particle tracking to track a single rod evolution to various degrees of success, such a process can be both computationally and labor intensive, limited to the evolution path of a single rod, and is therefore prone to error from potentially tracking outliers. Particle image velocimetry (PIV) is a well-established algorithm to derive field information from image sequences for processes that are time-dependent, such as fluid flows and structural deformation. In this work, we demonstrate the use of PIV in extracting the full-field microstructural distribution of rods within the enamel. Further, enamel samples from a wild African lion were analyzed using high-energy synchrotron X-ray micro-tomography. Results from the PIV analysis provide sufficient full-field information to reconstruct the growth of individual rods that can potentially enable rapid analysis of complex microstructures from high resolution synchrotron datasets. Such information can serve as a template for designing damage-tolerant bioinspired structures for advanced manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Design of a 1 MWth Supercritical Carbon Dioxide Primary Heat Exchanger Test System

A new generation of Concentrating Solar Power (CSP) technologies is under development to provide dispatchable renewable power generation and reduce the levelized cost of electricity (LCOE) to 6 cents/kWh by leveraging heat transfer fluids (HTF) capable of operation at higher temperatures and coupling with higher efficiency power conversion cycles. The U.S. Department of Energy (DOE) has funded three pathways for Generation 3 CSP (Gen3CSP) technology development to leverage solid, liquid, and gaseous HTFs to transfer heat to a supercritical carbon dioxide (sCO 2 ) Brayton cycle. Here we present the design and off-design capabilities of a 1 MWth sCO 2 test system that can provide sCO 2 coolant to the primary heat exchangers (PHX) coupling the high-temperature HTFs to the sCO 2 working fluid of the power cycle. This system will demonstrate design, performance, lifetime, and operability at a scale relevant to commercial CSP. A dense-phase high pressure canned motor pump is used to supply up to 5.3 kg/s of sCO 2 flow to the primary heat exchanger at pressures up to 250 bar and temperatures up to 715 °C with ambient air as the ultimate heat sink. Key component requirements for this system are presented in this paper.

14 SOLAR ENERGY↗
NASA NTRS2023

Neural Radiance Fields for Shadow Removal and Relighting of Satellite Imagery

Multi-view stereo photogrammetric techniques have been conventionally utilized to generate Global Digital Elevation Models (GDEM) of planetary and lunar surfaces. However, these methods, relying on conventional feature detectors, are often subject to inaccuracies caused by changes in lighting conditions, including diffuse reflection and harsh shading. This has limited the ability of these methods to accurately reconstruct shadowed regions in orbital imagery, such as highly shaded urban areas and the permanently shadowed regions (PSRs) located in the lunar surface, which are critical targets for NASA's Artemis program. Neural Radiance Fields (NeRFs) offer a novel solution to these limitations by breaking away from traditional photogrammetric assumptions of ridged, opaque surfaces. NeRFs are capable of reconstructing 3D objects with variably transmissive properties, such as fluids, PSRs, and reflective surfaces. In this work, we demonstrate the robustness of NeRFs in generating high-fidelity 3D models of terrain from highly shaded orbital imagery acquired from small satellites in low earth orbit (LEO). Our results showcase the ability of NeRF to overcome the limitations of traditional photogrammetric methods and provide a promising solution for reconstructing complex scenes in challenging lighting conditions.

Caleb Ashmore Adams↗
NASA NTRS1999

Flight Testing of a Cryogenic Capillary Pumped Loop

Future space-based cryogenic systems will require enhanced integration flexibility, lower weight reduced parasitic penalties, better vibration isolation, and a variety of other improvements to meet performance goals. Additionally, there is an increasing need to locate cooling sources remotely from cooled components. In the past flexible conductive links were used and worked well in most cases. However, as the transport lengths increase, conductive couplings become heavier and less effective, and must be replaced by higher performance systems. One available option, which can meet many of these future requirements, is the cryogenic capillary pumped loop (CCPL). The development of the CCPL technology started in 1992, following the success of the room temperature CPLS. The extrapolation of CCPL technology to cryogenic temperatures offers many performance benefits, which are not currently within the reach of traditional heat pipes or conductive links. Specific advantages of the CCPL technology pertaining to cryocooler integration include: (1) greater capillary pumping pressure for improved ground testability; (2) improved mechanical isolation; (3) faster diode shutdown and lower reverse heat leaks; (4) tighter control of detector temperature; (5) variable or fixed conductance operation; and (6) ease of integration due to their flexibility. The applications of CCPL technology are numerous. Military and commercial applications include surveillance satellites, earth observing satellites, deep space observation systems, medical devices, and many other cryogenic systems. Over the past few years, several breadboard and prototype CCPLs have been built and ground tested. A prototype CCPL has demonstrated successful operation between 80K and 110K with heat loads between O.5W and 12W using nitrogen as the working fluid, and 35K and 40K with head loads of 0.25W to 3.5W using neon. In order to verify CCPL performance in a microgravity environment, a flight unit, CCPL-5, was tested onboard the Space Shuttle STS-95 in October of 1998 as part of the CRYOTSU Flight Experiment. This flight was the first in-space demonstration of the CCPL. The CCPL-5 utilized nitrogen as the working fluid and operated between 75K and 110K. Flight results indicated excellent performance of the CCPL-5 under zero-G environment The CCPL could start from a supercritical condition in all tests, and the loop operating temperature could be tightly controlled regardless of changes in the heat load and/or the sink temperature. In addition, the loop demonstrated successful operation with a heat load of 0.5W as well as with parasitic heat loads alone. There were no noticeable differences between zero-G and one-G operation.

Ku, Jentung↗
DOE OSTI2026

Organic Rankine Cycle Integration and Optimization for High Efficiency CHP Genset Systems (Final Technical Report)

This project successfully advanced the integration of Organic Rankine Cycle (ORC) technology with reciprocating engine–based combined heat and power (CHP) systems to improve electrical efficiency, total CHP efficiency, and grid-responsive operation. Over three budget periods, the work progressed from high-temperature ORC component development and thermodynamic model validation to next-generation system design, working fluid transition, and techno-economic analysis. Key technical accomplishments include development and validation of a thermodynamic model capable of accurately predicting ORC performance across an expanded temperature and pressure envelope; successful identification and validation of low-global-warming-potential (GWP) working fluids—most notably R1233zd(E)—as viable replacements for R245fa; and demonstration of scalable ORC architectures suitable for integration with 1–20 MW class reciprocating engines. These advances enable flexible CHP configurations that can increase electrical output while maintaining high overall utilization of available thermal energy. The project also produced a clean-sheet design for a next-generation ORC system targeting substantially higher power output per unit, supported by detailed component selection, heat exchanger evaluation, and system-level modeling. Techno-economic analyses indicate that ORC-enabled flexible CHP systems can meet or exceed Department of Energy (DOE) efficiency targets while providing value to both facility operators and the electric grid.. Late-stage testing of the largest next-generation ORC prototype identified limitations related to pump net positive suction head (NPSH) requirements and condenser flooding under certain operating conditions. Although these issues constrained full validation of that configuration within the project timeframe, they provided clear and actionable design guidance for future system refinements. Importantly, validated modeling, smaller-scale testing, and working fluid evaluations confirmed the technical viability of the overall approach. In aggregate, this project met its core objectives by establishing validated design tools, de-risking key ORC technologies for CHP applications, and defining a credible pathway toward commercialization of flexible, high-efficiency CHP systems. The results form a strong foundation for continued development and deployment beyond the conclusion of the DOE-funded effort.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1978

Performance investigations of liquid-metal heat pipes for space and terrestrial applications

The high heat transfer capacity of liquid-metal heat pipes is demonstrated in performance tests with mercury, potassium, sodium, and lithium working fluids and wick structures which serve to minimize liquid pressure losses and vapor/liquid interactions. Appropriate wicks for horizontal and vertical operation are described. It is shown that heat-transfer with these wicks is limited by vapor flow effects. Examples are given of particular effects associated with a long adiabatic section between evaporator and condenser and with a heat source of uniform temperature as opposed to a source of uniform power.

Kemme, J. E.↗
NASA NTRS1981

Flat-plate solar-array project. Experimental process system development unit for producing semiconductor-grade silicon using the silane-to-silicon process

The engineering design, fabrication, assembly, operation, economic analysis, and process support R and D for an Experimental Process System Development Unit (EPSDU) are reported. About 95% of purchased equipment is received and will be reshipped to the West Coast location. The Data Collection System is completed. In the area of melting/consolidation, to the system using silicon powder transfer, melting and shotting on a pseudocontinuous basis is demonstrated. It is proposed to continue the very promising fluid bed work.

Source record↗
NASA NTRS2001

Advecting Procedural Textures for 2D Flow Animation

This paper proposes the use of specially generated 3D procedural textures for visualizing steady state 2D flow fields. We use the flow field to advect and animate the texture over time. However, using standard texture advection techniques and arbitrary textures will introduce some undesirable effects such as: (a) expanding texture from a critical source point, (b) streaking pattern from the boundary of the flowfield, (c) crowding of advected textures near an attracting spiral or sink, and (d) absent or lack of textures in some regions of the flow. This paper proposes a number of strategies to solve these problems. We demonstrate how the technique works using both synthetic data and computational fluid dynamics data.

Kao, David↗
DOE OSTI2020

A space-time parallel algorithm with adaptive mesh refinement for computational fluid dynamics

This work describes a space-time parallel algorithm with space-time adaptive mesh refinement (AMR). AMR with subcycling is added to multigrid reduction-in-time (MGRIT) in order to provide solution efficient adaptive grids with a reduction in work performed on coarser grids. This algorithm is achieved by integrating two software libraries: XBraid (Parallel time integration with multigrid. https://computation.llnl.gov/projects/parallel-timeintegration-multigrid) and Chombo (Chombo software package for AMR applications—design document, 2014). The former is a parallel time integration library using multigrid and the latter is a massively parallel structured AMR library. Employing this adaptive space-time parallel algorithm is Chord (Comput Fluids 123:202–217, 2015), a computational fluid dynamics (CFD) application code for solving compressible fluid dynamics problems. For the same solution accuracy, speedups are demonstrated from the use of space-time parallelization over the time-sequential integration on Couette flow and Stokes’ second problem. On a transient Couette flow case, at least a 1.5× speedup is achieved, and with a time periodic problem, a speedup of up to 13.7× over the time-sequential case is obtained. In both cases, the speedup is achieved by adding processors and exploring additional parallelization in time. The numerical experiments show the algorithm is promising for CFD applications that can take advantage of the time parallelism. Future work will focus on improving the parallel performance and providing more tests with complex fluid dynamics to demonstrate the full potential of the algorithm.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1993

Insoluble coatings for Stirling engine heat pipe condenser surfaces

The work done by Thermacore, Inc., Lancaster, Pennsylvania, for the Phase 1, 1992 SBIR National Aeronautics and Space Administration Contract, 'Insoluble Coatings for Stirling Engine Heat Pipe Condenser Surfaces' is described. The work was performed between January 1992 and July 1992. Stirling heat engines are being developed for electrical power generation use on manned and unmanned earth orbital and planetary missions. Dish Stirling solar systems and nuclear reactor Stirling systems are two of the most promising applications of the Stirling engine electrical power generation technology. The sources of thermal energy used to drive the Stirling engine typically are non-uniform in temperature and heat flux. Liquid metal heat pipe receivers are used as thermal transformers and isothermalizers to deliver the thermal energy at a uniform high temperature to the heat input section of the Stirling engine. The use of a heat pipe receiver greatly enhances system efficiency and potential life span. One issue that is raised during the design phase of heat pipe receivers is the potential solubility corrosion of the Stirling engine heat input section by the liquid metal working fluid. This Phase 1 effort initiated a program to evaluate and demonstrate coatings, applied to nickel based Stirling engine heater head materials, that are practically 'insoluble' in sodium, potassium, and NaK. This program initiated a study of nickel aluminide as a coating and developed and demonstrated a heat pipe test vehicle that can be used to test candidate materials and coatings. Nickel 200 and nickel aluminide coated Nickel 200 were tested for 1000 hours at 800 C at a condensation heat flux of 25 W/sq cm. Subsequent analyses of the samples showed no visible sign of solubility corrosion of either coated or uncoated samples. The analysis technique, photomicrographs at 200X, has a resolution of better than 2.5 microns (.0001 in). The results indicate that the heat pipe environment is not directly comparable to liquid metal pumped loop data, that nickel aluminide is still a leading candidate for solubility corrosion protection, and that longer duration tests are required to reach a definitive conclusion whether coatings are required at all. Should further testing be required, the test vehicle and analytical tools were developed.

Dussinger, Peter M.↗
NASA NTRS1999

Control of Meridional Flow by a Non-Uniform Rotational Magnetic Field

The diffusive mass transfer of species during crystal growth in vertical ampoules is significantly affected by fluid flow in the liquid mother phase (melt). For electrically conductive melts, an elegant way of remotely inducing and controlling this flow is by utilizing a uniform rotational magnetic field (RMF) in the transverse direction. It induces an azimuthal flow which tends to homogenize the thermal and solutal fields. The rotating field also reduces the diffusion boundary layer, stabilizes temperature fluctuations, and promotes better overall crystal growth. For moderate strengths of the applied magnetic field (2-20 m Tesla) with frequencies of up to 400 Hz, the induced secondary meridional flow becomes significant. It typically consists of one roll at the bottom of the liquid column and a second roll (vortex) at the top. The flow along the centerline (ampoule axis) is directed from the growing solid (interface) towards the liquid (melt). In case of convex interfaces (e.g. in floating zone crystal growth) such flow behavior is beneficial since it suppresses diffusion at the center. However, for concave interfaces (e.g. vertical Bridgman crystal growth) such a flow tends to exacerbate the situation in making the interface shape more concave. It would be beneficial to have some control of this meridional flow- for example, a single recirculating cell with controllable direction and flow magnitude will make this technique even more attractive for crystal growth. Such flow control is a possibility if a non-uniform PNE field is utilized for this purpose. Although this idea has been proposed earlier, it has not been conclusively demonstrated so far. In this work, we derive the governing equations for the fluid dynamics for such a system and obtain solutions for a few important cases. Results from parallel experimental measurements of fluid flow in a mercury column subjected to non-uniform RMF will also be presented.

Mazuruk, Konstantin↗
DOE OSTI2025

Scalable Solution-Processed Electrolyte Membranes with Optimized Microstructure for High-Performance Protonic Ceramic Electrochemical Cells

Proton-conducting electrochemical cells (PCECs) are promising for efficient hydrogen production, but achieving dense, uniform, thin electrolyte layers remains a key challenge, particularly for scalable fabrication. Here, we present a solution-processed deposition approach with a mechanistically optimized slurry for uniform electrolyte formation. By tailoring particle size distribution, solid loading, and solvent/additive balance, we regulated wetting behavior and evaporation kinetics of the electrolyte slurry to promote homogeneous electrolyte particle packing. These features facilitate tight grain boundary contact and early stage neck growth during sintering, eliminating residual porosity, and improving mechanical integrity. The resulting ∼15 μm thick electrolyte shows high density, strong electrode adhesion, and stable interfaces outperforming the previously reported spray-based fabricated electrolyte by about 31% at 600 °C in FC mode. Single cells deliver 0.962 W cm –2 at 600 °C in fuel cell mode and 1.31 A cm –2 at 1.3 V in electrolysis mode, maintaining robust performance over 100 h with negligible degradation (≤0.02% h –1 ) in each mode. Scale-up to 2.5 cm diameter substrates confirmed reproducible densification and geometric stability. This work demonstrates a cost-effective, scalable route where control over particle-fluid interactions and drying dynamics enables a superior electrolyte microstructure and high PCEC performance.

dense microstructure↗
DOE OSTI2021

Engineering Challenges of Solution and Slurry-Phase Chemical Hydrogen Storage Materials for Automotive Fuel Cell Applications

In this work, we present the research findings of the DOE-funded Hydrogen Storage Engineering Center of Excellence (HSECoE) related to liquid-phase and slurry-phase chemical hydrogen storage media and their potential as future hydrogen storage media for automotive applications. Chemical hydrogen storage media other than neat liquid compositions will prove difficult to meet the DOE system level targets. Solid- and slurry-phase chemical hydrogen storage media requiring off-board regeneration are impractical and highly unlikely to be implemented for automotive applications because of the formidable task of developing solid- or slurry-phase transport systems that are commercially reliable and economical throughout the entire life cycle of the fuel. Additionally, the regeneration cost and efficiency of chemical hydrogen storage media is currently the single most prohibitive barrier to implementing chemical hydrogen storage media. Ideally, neat liquid-phase chemical hydrogen storage media with net-usable gravimetric hydrogen capacities of greater than 7.8 wt% are projected to meet the 2017 DOE system level gravimetric and volumetric targets. The research presented herein is a collection of research findings that do not in and of themselves warrant a dedicated manuscript. However, the collection of results do, in fact, highlight the engineering challenges and short-comings in scaling up and demonstrating fluid-phase ammonia borane and alane compositions that all future materials researchers working in hydrogen storage should be aware of.

25 ENERGY STORAGE↗