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DOE OSTI2025

Risk assessment of wellbore leakage during underground hydrogen storage

The expansion of renewable energy sources would require large-scale energy storage options to overcome the intermittent nature of these sources. Underground hydrogen storage (UHS) in depleted hydrocarbon reservoirs offers a scalable and practical energy storage solution. These reservoirs are chosen for their availability and large capacity, but the unique properties of hydrogen raise concerns about potential leakage pathways, particularly through wellbores. In this study, we develop and apply, for the first time, reduced-order models (ROMs) specifically designed for efficient leakage risk prediction in UHS systems operating in depleted hydrocarbon reservoirs. Using 3,000 high-fidelity simulation scenarios, we examine the influence of 11 key parameters, including reservoir and aquifer depths, wellbore permeability and porosity, initial saturations of water, oil and gas fractions (hydrogen, light, intermediate, and heavy hydrocarbons), reservoir pressure multiplier, and the aquifer-to-reservoir volume ratio, to simulate leakage behavior over a 1,000-year timescale. We train ROMs using a two-step classification-regression approach, achieving R 2 values exceeding 99 % across all targets. These ROMs effectively capture the leakage evolution and identify critical controls of leakage, guiding the design of mitigation strategies. Results indicate that gas leakage occurs in about 27 % of scenarios as early as five years post-operation, reaching volumes of up to 106 ft3. Oil leakage is less frequent (~17 %) and typically begins decades later. Our findings also show that hydrogen often migrates first, owing to its smaller molecular size and higher buoyancy, followed by heavier hydrocarbons. Over time, these heavier components contribute significantly to the total leaked volume, reinforcing the need for targeted monitoring and remediation strategies. Our analysis highlights that deeper storage reservoirs, shallower aquifers, and low-permeability wellbores significantly reduce leakage risks. In conclusion, this work offers a robust framework for risk-informed UHS deployment, supporting energy security through reliable large-scale hydrogen storage while safeguarding environmental integrity.

08 HYDROGEN↗

DOE OSTI2023

Mitigating Electronic Conduction in Ceria‐Based Electrolytes via External Structure Design

Doped ceria electrolytes are the state of the art low‐temperature solid oxide electrolytes because of their high ionic conductivity and good material compatibility. However, cerium tends to reduce once exposed to reducing environments, leading to an increase in electronic conduction and a decrease in efficiency. Here, the leakage current is mitigated in ceria‐based electrolytes by controlling the defect chemistry through an engineered cathode side microstructure. This functional layer effectively addresses the problematic electronic conduction issue in ceria‐based electrolytes without adding significant ohmic resistance and increases the ionic transference number to over 0.93 in a thin 20 µm ceria‐based electrolyte at 500 °C, compared to a of 0.8 for an unmodified one. Based on this design, solid oxide fuel cells (SOFCs) are further demonstrated with the remarkable peak power density of 550 mW at 500 °C and excellent stability for over 2000 h. This approach enables a potential breakthrough in the development of ceria‐based low‐temperature solid oxide electrolytes.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Multilaminate Energy Storage Films from Entropy‐Driven Self‐Assembled Supramolecular Nanocomposites

Abstract Composite materials comprising polymers and inorganic nanoparticles (NPs) are promising for energy storage applications, though challenges in controlling NP dispersion often result in performance bottlenecks. Realizing nanocomposites with controlled NP locations and distributions within polymer microdomains is highly desirable for improving energy storage capabilities but is a persistent challenge, impeding the in‐depth understanding of the structure–performance relationship. In this study, a facile entropy‐driven self‐assembly approach is employed to fabricate block copolymer‐based supramolecular nanocomposite films with highly ordered lamellar structures, which are then used in electrostatic film capacitors. The oriented interfacial barriers and well‐distributed inorganic NPs within the self‐assembled multilaminate nanocomposites effectively suppress leakage current and mitigate the risk of breakdown, showing superior dielectric strength compared to their disordered counterparts. Consequently, the lamellar nanocomposite films with optimized composition exhibit high energy efficiency (>90% at 650 MV m −1 ), along with remarkable energy density and power density. Moreover, finite element simulations and statistical modeling have provided theoretical insights into the impact of the lamellar structure on electrical conduction, electric field distribution, and electrical tree propagation. This work marks a significant advancement in the design of organic–inorganic hybrids for energy storage, establishing a well‐defined correlation between microstructure and performance.

Li, He↗

DOE OSTI2021

Monitoring of helium gas leakage from canister storing spent nuclear fuel: Radiological consequences and management

Chloride-induced stress corrosion cracking (CISCC) of canisters has been identified as a potential degradation mechanism requiring ageing management — especially in a marine air environment. Methods for monitoring helium gas leakage from canisters have been developed on the basis of a phenomenon that the bottom temperature of the canister increases as the top temperature of the canister decreases when helium gas leaks during storage. In this paper, we consider the radiological consequences of CISCC based on two scenarios of helium gas leakage and propose effective management that includes a timeline for monitoring and mitigation. Monitoring helium gas leakage by measuring the difference in temperature between canister surfaces in the dry cask storage of spent fuel (SF) can detect leakage before SF undergoes oxidation as a result of air ingress and before country-specific regulatory limits of off-site doses are exceeded, thereby enabling mitigatory action.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

DISARM: Target Electronic Device Informed Mitigation of Software Runtime Side-Channel Vulnerabilities

Program runtime/timing attacks exploit variations in a program’s execution times to extract sensitive information from the program (e.g. encryption keys, sensitive variable data, intellectual property). State-of-the-art solutions to runtime side-channel attacks attempt to balance the execution time of the sensitive code for different control flow paths to eliminate the timing leakage. However, during the mitigation process, most techniques do not consider the underlying hardware/device on which the target program is supposed to run on. This can lead to over-fixing (unnecessary extra operations), under-fixing (not solving the imbalance properly), and even failures. Here, we propose DISARM, a joint hardware-software methodology (unlike any existing solution) for mitigating runtime side-channel vulnerabilities that utilizes timing values from real embedded devices to generate targeted software fixes. We implement DISARM to support C/C++/Java source codes and validate it across 22 standard benchmarks. DISARM outperforms state-of-the-art solutions such as PENDULUM and DifFuzzaR in terms of execution time overhead, code size overhead, and correctness on five different embedded/edge devices.

Timing/runtime side-channel↗

DOE OSTI2026

Hardware Aware Mitigation of Timing Side-Channel Vulnerabilities in Critical Infrastructure Software

Program runtime/timing attacks exploit variations in a program’s execution times to extract sensitive information from the program (e.g. encryption keys, sensitive variable data, intellectual property). State-of-the-art solutions to runtime sidechannel attacks attempt to balance the execution time of the sensitive code for different control flow paths to eliminate the timing leakage. However, during the mitigation process, most techniques do not consider the underlying hardware/device on which the target program is supposed to run on. This can lead to over-fixing (unnecessary extra operations), under-fixing (not solving the imbalance properly), and even failures. We propose DISARM, a joint hardware-software methodology (unlike any existing solution) for mitigating runtime side-channel vulnerabilities that utilizes timing values from real embedded devices to generate targeted software fixes. We implement DISARM to support C/C++/Java source codes and validate it across 22 standard benchmarks. DISARM outperforms state-of-the-art solutions such as PENDULUM and DifFuzzAR in terms of execution time overhead (up to −46%), code size overhead (up to −10%), and correctness (no failures) on five different embedded/edge devices.

Suha, Tasneem [University of Maine]↗

NASA NTRS1996

High temperature braided rope seals for static sealing applications

Achieving efficiency and performance goals of advanced aircraft and industrial systems are leading designers to implement high temperature materials such as ceramics and intermetallics. Generally these advanced materials are applied selectively in the highest temperature sections of the engine system including the combustor and high pressure turbine, amongst others. Thermal strains that result in attaching the low expansion-rate components to high expansion rate superalloy structures can cause significant life reduction in the components. Seals are being designed to both seal and to serve as compliant mounts allowing for relative thermal growths between high temperature but brittle primary structures and the surrounding support structures. Designers require high temperature, low-leakage, compliant seals to mitigate thermal stresses and control parasitic and cooling airflow between structures. NASA is developing high temperature braided rope seals in a variety of configurations to help solve these problems. This paper will describe the types of seals being developed, describe unique test techniques used to assess seal performance, and present leakage flow data under representative pressure, temperature and scrubbing conditions. Feasibility of the braided rope seals for both an industrial tube seal and a turbine vane seal application is also demonstrated.

Adams, Michael L.↗

DOE OSTI2022

High Voltage Regrown GaN P-N Diodes Enabled by Defect and Doping Control

This project studied and implemented methods to form GaN p-n diodes using selective area regrowth to achieve selective area doping. Successful selective area doping of GaN p-n diodes is an enabling factor to realize more advanced devices such as vertical transistors. The general challenge to selective area regrowth of GaN is that the primary etch method, inductively coupled plasma (ICP), damages the crystal and causes high leakage when didoes are formed by regrowth on the etched surface. Our approach used low damage etch methods following ICP etch to remove crystal damage and reduced leakage in the regrown diode. This project demonstrated 1.6 kV etched-and-regrown GaN p-n diodes using planar (non-selective) regrowth and 840 V etched-and-regrown p-n diodes using selective area regrown. Enabling factors were use of a low-damage reactive ion etch (RIE) to remove damage caused by the primary ICP etch combined with a multi-step junction terminal extension (JTE) process. Deep level defect investigation quantitatively correlated a deep level near the middle of the GaN band gap with ICP etch-induced leakage that was greatly mitigated by using a slow, low damage RIE process. This research is economically feasible for commercialization because the processes used in this project, including substrate type and source, epitaxial crystal growth and fabrication techniques are all standard to the GaN semiconductor industry. The fundamental understanding and foundational ability to produce kV-class GaN p-n diodes through etch-and-regrowth provides a path to realize high power, high efficiency GaN power switches that can significantly outperform commercial devices for next-generation electrical power conversion and transmission systems.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Fracture Network Quantification for Enhanced Reservoir Characterization in CO2 Storage Sites

Presentation slides on “Fracture Network Quantification for Enhanced Reservoir Characterization in CO2 Storage Sites” for the CCUS 2025 conference held in Houston, Texas March 3-5, 2025. Accurate reservoir characterization is fundamental for the safe and efficient operation of carbon capture, utilization, and storage (CCUS) projects. This process is not only critical during initial site selection but also plays a key role in continuously updating reservoir geomodels throughout injection operations to effectively manage subsurface storage sites. Our primary objective is to develop a comprehensive understanding of fracture networks within CO2 injection reservoirs, which are critical for predicting the behavior of injected fluids, ensuring storage integrity post-injection, and mitigating risks such as leakage or induced seismicity.

artifical intelligence / machine learning (AI/ML)↗

DOE OSTI2021

Axion searches with two superconducting radio-frequency cavities

We propose an experimental setup to search for Axion-like particles (ALPs) using two superconducting radio-frequency cavities. In this light-shining-through-wall setup the axion is sourced by two modes with large fields and nonzero $_E^→$∙$_B^→$ in an emitter cavity. In a nearby identical cavity only one of these modes, the spectator, is populated while the other is a quiet signal mode. Axions can up-convert off the spectator mode into signal photons. We discuss the physics reach of this setup finding potential to explore new ALP parameter space. Enhanced sensitivity can be achieved if high-level modes can be used, thanks to improved phase matching between the excited modes and the generated axion field. We also discuss the potential leakage noise effects and their mitigation, which is aided by O(GHz) separation between the spectator and signal frequencies.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

NASA NTRS1997

Development of Tailorable Electrically Conductive Thermal Control Material Systems

The optical characteristics of surfaces on spacecraft are fundamental parameters in controlling its temperature. Passive thermal control coatings with designed solar absorptance and infrared emittance properties have been developed and have been in use for some time. In this total space environment, the coating must be stable and maintain its desired optical properties as well as mechanical properties for the course of the mission lifetime. The mission lifetimes are increasing and in our quest to save weight, newer substrates are being integrated which limit electrical grounding schemes. All of this has added to already existing concerns about spacecraft charging and related spacecraft failures or operational failures. The concern is even greater for thermal control surfaces that are very large. One way of alleviating such concerns is to design new thermal control material systems (TCMS) that can help to mitigate charging via providing charge leakage paths. The objective of this program was to develop two types of passive electrically conductive TCMS. The first was a highly absorbing/emitting black surface and the second was a low (alpha(sub s)/epsilon(sub N)) type white surface. The surface resistance goals for the black absorber was 10(exp 4) to 10(exp 9) Omega/square, and for the white surfaces it was 10(exp 6) to 10(exp 10) Omega/square. Several material system concepts were suggested and evaluated for space environment stability and electrical performance characterization. Our efforts in designing and evaluating these material systems have resulted in several developments. New concepts, pigments and binders have been developed to provide new engineering quality TCMS. Some of these have already found application on space hardware, some are waiting to be recognized by thermal designers, and some require further detailed studies to become state-of-the-art for future space hardware and space structures. Our studies on baseline state-of-the-art materials and conductive concepts have resulted in several important findings that are of interest to all thermal designers and systems integrators.

Deshpande, M. S.↗

NASA NTRS1998

Development of Tailorable Electrically Conductive Thermal Control Material Systems

Deshpande, M. S.↗

DOE OSTI2021

New Modulation and Impact of Transformer Leakage Inductance on Current-Source Solid-State Transformer

This article presents a novel modulation scheme for device voltage stress mitigation and comprehensive analysis of the impact of transformer leakage inductance in a current-source solid-state transformer (SST). Different from dual active bridge (DAB) SST, the operation of the current-source SST is similar to that of a flyback converter. The device bridge on only one side of the transformer is active to store energy into or release energy from the magnetizing inductance which acts as a current-source dc link. Such flyback operation with reverse-blocking switches can lead to additional device voltage stress and incomplete zero-voltage switching (ZVS) on the current-source soft-switching solid-state transformer (S4T) under conventional modulation. A new modulation scheme is proposed to address this issue. Moreover, different from the DAB, the leakage inductance of the medium-frequency transformer (MFT) in the S4T is a parasitic element similar to that in a matrix SST and can cause additional device voltage stress. Though the resonant capacitors, originally added to achieve ZVS, can absorb and recycle the leakage energy in the S4T, these capacitors need to be increased with larger leakage inductances to limit the voltage stress. However, large resonant capacitors can result in more lost duty cycles and reduced efficiency. The impact of such leakage inductance on device voltage stress is analyzed comprehensively, which is critical to guide future research and design of the S4T. Experimental results from S4T prototypes for DC-DC, multiport AC-DC, and AC-AC conversion with 1:1 and 4:1 MFT comprehensively verify the proposed concepts. Lastly, a case study of a three-phase AC-AC S4T over a power range from 1 kVA to 100 kVA each module reveals that the MFT leakage inductance should be less than 1% of the magnetizing inductance for safe operation.

14 SOLAR ENERGY↗

NASA NTRS2017

Forest Carbon Emissions from Cropland Expansion in the Brazilian Cerrado Biome

Land use, land use change, and forestry accounted for two-thirds of Brazil's greenhouse gas emissions profile in 2005. Amazon deforestation has declined by more than 80% over the past decade, yet Brazil's forests extend beyond the Amazon biome. Rapid expansion of cropland in the neighboring Cerrado biome has the potential to undermine climate mitigation efforts if emissions from dry forest and woodland conversion negate some of the benefits of avoided Amazon deforestation. Here, we used satellite data on cropland expansion, forest cover, and vegetation carbon stocks to estimate annual gross forest carbon emissions from cropland expansion in the Cerrado biome. Nearly half of the Cerrado met Brazil's definition of forest cover in 2000 (greater than or equal to 0.5 ha with greater than or equal to 10% canopy cover). In areas of established crop production, conversion of both forest and non-forest Cerrado formations for cropland declined during 2003-2013. However, forest carbon emissions from cropland expansion increased over the past decade in Matopiba, a new frontier of agricultural production that includes portions of Maranhao, Tocantins, Piau, and Bahia states. Gross carbon emissions from cropland expansion in the Cerrado averaged 16.28 Tg C yr (exp -1) between 2003 and 2013, with forest-to-cropland conversion accounting for 29% of emissions. The fraction of forest carbon emissions from Matopiba was much higher; between 2010-2013, large-scale cropland conversion in Matopiba contributed 45% of total Cerrado forest carbon emissions. Carbon emissions from Cerrado-tocropland transitions offset 5-7% of the avoided emissions from reduced Amazon deforestation rates during 2011-2013. Comprehensive national estimates of forest carbon fluxes, including all biomes, are critical to detect cross-biome leakage within countries and achieve climate mitigation targets to reduce emissions from land use, land use change, and forestry.

remote sensing↗

NASA NTRS2024

Evaluation of Cleaning Methods for Dust Mitigation of Lunar Docking and Hatch Seals

Low-leakage seals are an enabling technology for future lunar surface systems, and they must be kept clean to ensure that crews have sufficient breathable air for extended lunar surface missions. Previous testing on representative state-of-the-art seals showed that while seals can tolerate some level of lunar simulant dust contamination, dust can degrade seal performance to a point at which seal leak rates exceed maximum allowable values. The ability to clean simulant from seals had not been thoroughly studied, and the effectiveness and potential complications of using different cleaning methods for lunar seals were not well understood. To address this knowledge gap, researchers at the NASA Glenn Research Center executed a multiphase study to better understand and mitigate seal dust-exposure risks. The focus of this report is on the second phase of that study, in which tests were conducted to evaluate the viability of seal cleaning methods for use in the lunar environment. Multiple methods for cleaning seals contaminated with lunar simulant were assessed for cleaning effectiveness and viability for use in the lunar environment. Leak tests were performed on seals after they were cleaned to determine whether leak rates could be brought back to acceptable levels, and cleaned seals were examined to determine whether their surfaces had been damaged by the cleaning processes. This phase of the study also investigated changes in the seals’ adhesion forces as a result of contamination and cleaning.

Dust Mitigation↗

DOE OSTI2023

Enabling site-specific well leakage risk estimation during geologic carbon sequestration using a modular deep-learning-based wellbore leakage model

Geologic carbon sequestration (GCS) is a promising technology for mitigating net carbon emissions and growing climate concern by storing CO 2 in reservoirs. Oil and gas brownfields are an attractive option for CO 2 storage, but these sites have many historical wellbores from petroleum production and can be a potential leakage pathway for CO 2 or formation brine. Therefore, risk management of GCS operations requires an assessment of potential well leakage. Due to the high uncertainty of the system, stochastic approaches are ideal for quantifying the range of risk behaviors, but they must be computationally efficient in the face of complex physics. Here, we develop a new physics-centric deep learning wellbore model to predict the leakage of CO 2 and brine through leaky wellbores. Multi-physics numerical simulations were used to generate data sets, and physics-informed features were introduced. Neural networks were optimized with an automated searching algorithm. Feature analysis quantifies the impact of each feature on model prediction and confirms the role of physics-inspired parameters. The model shows high predictive performance across a wide range of geologic and injection conditions and well attributes. In conclusion, a case study illustrates how the model is applied to assess well leakage in GCS operations.

58 GEOSCIENCES↗

DOE OSTI2021

On-Device Lead Detention for Perovskite Solar Cells

As the power conversion efficiency (PCE) of perovskite solar cells (PSCs) have reached above 25.5%, the commercialization of PSCs appears to be imminent due to its lower fabrication cost, simpler manufacturing processes, and larger processing area over Si-based solar cells that dominate the current photovoltaic (PV) market. While many efforts have focused on tackling the stability and scalability issues with promising advances, the potential lead (Pb) toxicity issue has remained a concern of PSCs. Unlike the metallic Pb, the Pb 2+ in perovskite generally exhibit high solubility in water. However, Pb 2+ has so far appeared to be a necessary component in all high-efficiency PSCs. Handful methods have been explored to mitigate the potential Pb2+ leaking issue, which can be generally categorized as physical encapsulation and our pioneering chemical absorption method, which was extended by others later. Since device damage is inevitable in outdoor conditions, physical encapsulation alone is not sufficient to mitigate the long-term risk of leakage of soluble Pb 2+ to the environment under severe weather conditions. As a result, the chemical absorption approach has recently attracted significant attention as a more effective solution to confine the potential lead leakage. Hence, it is of great value to develop durable and highly efficient Pb-absorbing components that can be conveniently mounted onto the standard PSC stack as an add-on accessory in line with the encapsulation of PSCs instead of modifying the standard device fabrication and/or device configuration.

14 SOLAR ENERGY↗

NASA NTRS2013

Self-Healing Nanocomposites for Reusable Composite Cryotanks

Composite cryotanks, or composite overwrapped pressure vessels (COPVs), offer advantages over currently used aluminum-lithium cryotanks, particularly with respect to weight savings. Future NASA missions are expected to use COPVs in spaceflight propellant tanks to store fuels, oxidizers, and other liquids for launch and space exploration vehicles. However, reliability, reparability, and reusability of the COPVs are still being addressed, especially in cryogenic temperature applications; this has limited the adoption of COPVs in reusable vehicle designs. The major problem with composites is the inherent brittleness of the epoxy matrix, which is prone to microcrack formation, either from exposure to cryogenic conditions or from impact from different sources. If not prevented, the microcracks increase gas permeation and leakage. Accordingly, materials innovations are needed to mitigate microcrack damage, and prevent damage in the first place, in composite cryotanks. The self-healing technology being developed is capable of healing the microcracks through the use of a novel engineered nanocomposite, where a uniquely designed nanoparticle additive is incorporated into the epoxy matrix. In particular, this results in an enhancement in the burst pressure after cryogenic cycling of the nanocomposite COPVs, relative to the control COPVs. Incorporating a novel, self-healing, epoxy-based resin into the manufacture of COPVs allows repeatable self-healing of microcracks to be performed through the simple application of a low-temperature heat source. This permits COPVs to be reparable and reusable with a high degree of reliability, as microcracks will be remediated. The unique phase-separated morphology that was imparted during COPV manufacture allows for multiple self-healing cycles. Unlike single-target approaches where one material property is often improved at the expense of another, robustness has been introduced to a COPV by a combination of a modified resin and nanoparticle additives. Unique nanoparticles were used that have been surface-functionalized to be compatible with the resin. Both organic and inorganic components toughen the matrix and result in a more impact-resistant COPV. In one resin system containing an inorganic nanomaterial additive, a significant improvement in burst performance was observed after the COPV was cryo-impact-damaged and then self-healed, with a greater than 10% improvement in burst pressure after the self-healing process was performed. Initial cross-sectional analysis via microscopy showed good resin infiltration of the carbon fibers and without voids. To further enhance the capability between the nanomaterial additives and the resin, a surface modification was successfully performed. A second specialty epoxy resin was prepared using a surface modified nanomaterial additive, and COPVs were fabricated. Steps were taken to improve the mechanical properties of the COPVs by using a low-viscosity resin system that contained a different curing agent. This lower viscosity improves the processing of the COPV, and preliminary results show that the burst pressure of these new vessels is 20 to 25% higher than that of the original. The self-healing concept demonstrated in this research and development effort represents a platform technology, and the self-healing property is neither restricted to the particular epoxy system used here, nor to the COPV application. Self-healing is a direct result of a unique phase separated morphology created via the resin and is aided by the nanoparticles. The self-healing function can be introduced to other customer-specific resin systems in coating, bulk, or composite applications provided that the unique phase separated morphology can be enabled in those systems.

Eberly, Daniel↗