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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Electrostatic powder spreading for metal powder bed fusion applications

Typical powder bed fusion processes spread each layer of powder by pushing it across the build area with a spreader bar or roller. While simple, these methods require good flowing powder and do not have the ability to place more than one powder type per layer. This naturally limits the ability to incorporate more than one material onto each powder layer in powder bed additive manufacturing processes. Here we demonstrate electrostatic powder spreading, a method to deposit a powder layer without mechanical contact with the previous layers. Electrostatic powder spreading (ESPS) uses an electric field formed between a powder container and a counter electrode to move powder particles from the container to the powder bed. We show that the rate at which powder is deposited can be controlled by adjusting the strength of the electric field. Correspondingly, the deposited layer thickness is controlled by the strength of the electric field and the recoating speed. To demonstrate the feasibility of ESPS for laser powder bed fusion powder spreading, nearly fully dense (> 99.8%) coupons were built in a commercial L-PBF machine using the ESPS setup. Finally, we achieve 2D patterning of a single layer by using an array of electrodes and switching the applied electric field on and off. ESPS represents a method to produce an arbitrary patterned multi-material powder bed without complicated powder removal steps and easy implementation into existing L-PBF machines. Furthermore, ESPS presents an opportunity to build parts with 3D gradients in material properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Machine Learning-Based PV Reserve Determination Strategy for Frequency Control on the WECC System

Frequency control from photovoltaic (PV) power plants has great potential to address the frequency response challenge of the power system with high penetrations of renewable generation. Using model-based approaches to determine the optimal PV headroom reserve, however, requires significant online computation and is intractable for an interconnection level system. This paper proposes a machine learning based strategy, that is suitable for real-time operation, to determine the optimal PV reserve for frequency control. The proposed machine learning algorithm is trained and tested on 1,987 offline simulations of a 60% renewable penetration Western Electricity Coordinating Council (WECC) system. Furthermore, the proposed reserve determination strategy is applied on a realistic 1-day operation profile of the WECC system and demonstrates a savings of more than 40% PV headroom compared to a conservative approach. It is evident that the proposed strategy can efficiently and effectively determine the optimal PV frequency control reserve for realistic interconnection systems.

frequency control↗
DOE OSTI2026

Quantitative Analysis and Prediction of Thermal Runaway Metrics of High-Nickel Oxide Cathodes by Machine Learning Models

The pursuit of higher energy density in lithium-ion batteries has made high-nickel (Ni) layered oxides leading cathode candidates for next-generation electric vehicles. However, their poor thermal stability, particularly at Ni contents ≥ 90%, increases the risk of cathode-initiated thermal runaway. Furthermore, we present a data-driven framework combining linear and nonlinear machine learning models to predict key thermal runaway descriptors from a high-throughput differential scanning calorimetry database. With cathode composition and state of charge (SOC) as input features, the ensemble model accurately predicts peak temperature, heat release, and peak heat flow. SHAP analysis identifies Ni content and SOC as the dominant factors controlling thermal runaway temperature, while SOC primarily governs heat release and peak heat flow. Al, Mg, and Mn improve thermal stability by strengthening metal–oxygen bonding and delaying structural transformation, whereas B mainly reduces heat release through surface passivation. Validation with a new cathode composition confirms accurate prediction of SOC-dependent thermal runaway behavior and critical SOC.

25 ENERGY STORAGE↗
DOE OSTI2023

Radiation, optical, power flow, and electrical diagnostics at the Z facility: Layout and techniques utilized to operate in the harsh environment

The Z machine is a current driver producing up to 30 MA in 100 ns that utilizes a wide range of diagnostics to assess accelerator performance and target behavior conduct experiments that use the Z target as a source of radiation or high pressures. Here, we review the existing suite of diagnostic systems, including their locations and primary configurations. The diagnostics are grouped in the following categories: pulsed power diagnostics, x-ray power and energy, x-ray spectroscopy, x-ray imaging (including backlighting, power flow, and velocimetry), and nuclear detectors (including neutron activation). We will also briefly summarize the primary imaging detectors we use at Z: image plates, x-ray and visible film, microchannel plates, and the ultrafast x-ray imager. The Z shot produces a harsh environment that interferes with diagnostic operation and data retrieval. We term these detrimental processes “threats” of which only partial quantifications and precise sources are known. Finally, we summarize the threats and describe techniques utilized in many of the systems to reduce noise and backgrounds.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Comparing energy and water use of aqueous and gas-based metalworking fluids

Gas-based metalworking fluids (MWFs) have been proposed as alternative coolants and lubricants in machining operations to mitigate concerns surrounding water use and pollution, industrial hygiene, occupational health, and performance limitations associated with water-based (aqueous) MWFs that are ubiquitously used in the metals manufacturing industry. This study compares the primary energy and water use associated with the consumptive use, delivery, and disposal of aqueous MWFs with three gas-based MWFs in the literature-minimum quantity lubricant-in-compressed air (MQL), liquid/gaseous N-2, and liquid/supercritical CO2. The comparison accounts for reported differences in machining performance in peer-reviewed experimental studies across several machining processes and materials. The analysis shows that despite the reported improvement in tool life with N-2 and CO2-based MWFs, the electricity- and water-intensive separation and purification processes for N-2 and CO2 lead to their higher primary energy and water use per volume of material machined relative to water-based MWFs. Although MQL is found to have lower primary energy use, significant consumptive water use associated with the vegetable oil commonly used with this MWF leads to higher overall water use than aqueous MWF, which is operated in a recirculative system. Gas-based MWFs thus shift the water use upstream of the manufacturing plant. Primary energy and water use of gas-based MWFs could be reduced by focusing on achieving higher material removal rates and throughput compared to aqueous MWF instead of solely targeting improvements in tool life. Additionally, the consumptive use of CO2 and N-2 MWFs could be minimized by optimizing their flow rates and delivery to precisely meet the cooling and lubrication needs of specific machining processes instead of flooding the tool and workpiece with these gases. This article met the requirements for a gold-gold JIE data openness badge described at http://jie.click/badges.

cutting fluids↗
DOE OSTI2022

Physiochemical Machine Learning Models Predict Operational Lifetimes of CH3NH3PbI3 Perovskite Solar Cells

Halide perovskites are promising photovoltaic (PV) materials with the potential to lower the cost of electricity and greatly expand the penetration of PV if they can demonstrate long-term stability under illumination in the presence of moisture and oxygen. The solar cell service lifetime as quantified by the T80 (the time required for the power conversion efficiency to drop to 80% of its starting value) is a useful metric to assess stability. The T80 for utility, commercial, or residential PV systems needs to be several decades in order to yield low-cost electricity, and thus it is not practical to directly measure the T80. It would be useful if T80 could be predicted from the initial dynamics of a solar cell’s performance, but until now no models have been developed to forecast T80. In this work, we report the development of machine learning models to predict T80 of ITO/NiOx/CH3NH3PbI3/C60/BCP/Ag solar cells operating at maximum power point under 1-sun equivalent photon flux in air at varying temperatures and relative humidities. Efficiency losses are driven by short-circuit current and fill factor, indicating that chemical decomposition of the perovskite is a major contributor to degradation. Spatial patterns evident from in situ dark field optical microscopy suggest that the electric field gradient at device edges plays a significant role in perovskite decomposition, along with photochemical reactions with O2 and H2O. Models are trained using a menu of features from three distinct categories: (i) features based on measurements of the initial rates of change of device parameters, (ii) features based on the ambient conditions during operation (temperature, & partial pressure of H2O), and (iii) features based on underlying physics and chemistry. We show that a theory-based physiochemical feature derived from a model of the chemical reaction kinetics of the rate of degradation of the CH3NH3PbI3 is particularly valuable for prediction. This physiochemical feature was selected as the first or second most dominant feature in the best performing models. With a dataset consisting of 45 accelerated degradation experiments with T80 that range over a factor of 30, the model predicts T80 with an accuracy of about 40% (|predicted T80 - observed T80| / observed T80) on samples not used in training. This hybrid ML approach should be effective when applied to other compositions, device architectures, and advanced packaging schemes.

14 SOLAR ENERGY↗
DOE OSTI2022

Physiochemical Machine Learning Models Predict Operational Lifetimes of CH3NH3PbI3 Perovskite Solar Cells

Halide perovskites are promising photovoltaic (PV) materials with the potential to lower the cost of electricity and greatly expand the penetration of PV if they can demonstrate long-term stability under illumination in the presence of moisture and oxygen. The solar cell service lifetime as quantified by the T80 (the time required for the power conversion efficiency to drop to 80% of its starting value) is a useful metric to assess stability. The T80 for utility, commercial, or residential PV systems needs to be several decades in order to yield low-cost electricity, and thus it is not practical to directly measure the T80. It would be useful if T80 could be predicted from the initial dynamics of a solar cell’s performance, but until now no models have been developed to forecast T80. In this work, we report the development of machine learning models to predict T80 of ITO/NiOx/CH3NH3PbI3/C60/BCP/Ag solar cells operating at maximum power point under 1-sun equivalent photon flux in air at varying temperatures and relative humidities. Efficiency losses are driven by short-circuit current and fill factor, indicating that chemical decomposition of the perovskite is a major contributor to degradation. Spatial patterns evident from in situ dark field optical microscopy suggest that the electric field gradient at device edges plays a significant role in perovskite decomposition, along with photochemical reactions with O2 and H2O. Models are trained using a menu of features from three distinct categories: (i) features based on measurements of the initial rates of change of device parameters, (ii) features based on the ambient conditions during operation (temperature, & partial pressure of H2O), and (iii) features based on underlying physics and chemistry. We show that a theory-based physiochemical feature derived from a model of the chemical reaction kinetics of the rate of degradation of the CH3NH3PbI3 is particularly valuable for prediction. This physiochemical feature was selected as the first or second most dominant feature in the best performing models. With a dataset consisting of 45 accelerated degradation experiments with T80 that range over a factor of 30, the model predicts T80 with an accuracy of about 40% (|predicted T80 - observed T80| / observed T80) on samples not used in training. This hybrid ML approach should be effective when applied to other compositions, device architectures, and advanced packaging schemes.

14 SOLAR ENERGY↗
DOE OSTI2021

High-resolution hourly surrogate modeling framework for physics-based large-scale building stock modeling

Surrogate modeling can play a key role in reducing high computational burdens for large-scale physics-based modeling and uncertainty quantification. With the rapid development of large-scale building stock energy modeling, surrogate modeling has also begun to be widely applied in this field; however, most existing surrogate models lack hourly time resolution for regional-scale modeling, which is essential for understanding building demand profiles and grid impacts. Further, there is generally a lack of necessary data and feature engineering frameworks specific to building modeling for efficiently managing large datasets and complex computations. Furthermore, this paper proposes a modeling framework for large-scale (city-/region-scale), high-resolution, high-fidelity surrogate building stock energy models. Our developed framework consists of six modules: (1) building stock energy modeling (ComStock TM and ResStock TM ), (2) data engineering for large simulation data, (3) high performance computing workflow, (4) feature engineering, (5) machine learning model development, and (6) model performance evaluation. Two case studies apply the developed framework in both residential and commercial building stock analysis to demonstrate its computational efficiency and surrogate modeling accuracies. Results show that surrogate models, when efficiently trained using the HPC workflow module, reach a high level of modeling accuracy for two case studies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Parameterization of generic positive sequence models to represent behavior of inverter based resources in low short circuit scenarios

The connection of large inverter based resources (IBR) in transmission systems is often located geographically and electrically far away from load centers. This, coupled with the displacement of synchronous machine plants, results in a reduction of the network short circuit strength at the point of connection. Under these conditions, state-of-the-art positive sequence simulation platforms and models can have difficulties maintaining numerical stability and/or providing an accurate representation of IBR plant dynamic behavior. As a result, computationally heavy time domain electromagnetic transient (EMT) simulations may be required to evaluate these systems. In this paper, a recently developed improved generic positive sequence model is parameterized to provide a representation of IBR behavior in low short circuit networks. Further, comparisons against generic and detailed EMT models demonstrate the suitability of the improved positive sequence model to study practical stability issues experienced with presently in-service plants. Such a model can provide some of the accuracy of an EMT representation with a much lower computational burden. The performance of the positive sequence model is validated against the behavior shown by both open white box and closed black box EMT domain models from around the world.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Amplitude- and frequency-dependent activation of layer II/III neurons by intracortical microstimulation

Intracortical microstimulation (ICMS) has been used for the development of brain machine interfaces. However, further understanding about the spatiotemporal responses of neurons to different electrical stimulation parameters is necessary to inform the design of optimal therapies. In this study, we employed in vivo electrophysiological recording, two-photon calcium imaging, and electric field simulation to evaluate the acute effect of ICMS on layer II/III neurons. Our results show that stimulation frequency non-linearly modulates neuronal responses, whereas the magnitude of responses is linearly correlated to the electric field strength and stimulation amplitude before reaching a steady state. Temporal dynamics of neurons’ responses depends more on stimulation frequency and their distance to the stimulation electrode. In addition, amplitude-dependent post-stimulation suppression was observed within ~500 μm of the stimulation electrode, as evidenced by both calcium imaging and local field potentials. These findings provide insights for selecting stimulation parameters to achieve desirable spatiotemporal specificity of ICMS.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Lab’s Z-machine efforts advance stockpile stewardship in multi-org collaboration

For the past 15 years, Los Alamos (LANL) employees have played a major role in plutonium experiments using the Z-machine — a device at Sandia National Laboratories (SNL) that uses high magnetic fields, electrical currents, and X-rays to help scientists understand how materials behave under extreme temperatures and pressures. High-energy density physics, or the study of matter under extreme conditions, is a key component of certifying the nation’s nuclear weapons stockpile.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Solid Phase Processing of Lead-Free Brass with Carbon Additives

Currently, “lead-free” brass alloys (like C27450/C27451/C6930), used extensively in drinking water fixtures and automotive, electrical, and electronic applications contain maximum 0.25% lead to maintain mechanical performance and machinability. Adding graphite to brass as an alternative to lead, using casting, powder metallurgy, and extrusion methods, has been explored previously. However, all these methods have proven to be energy-, time-, and resource-intensive, while not enabling performance equivalent to that of C36000 brass. In this project, we developed a one-step approach using friction extrusion and ShAPE to make lead-free brass/graphite components such as wires, rods and tubes with mechanical performance equivalent to commercial lead-free brass alloys. Manufacturing temperatures were maintained ~550-730 °C with feed rates ranging between 4 – 25 mm/min. Results show larger grains at the center of the rods and wires with smaller grains developing at the edges. Graphite particles were sheared in the direction of extrusion with higher strains observed towards the edges. Hardness of the brass/graphite samples was over 25% higher than that of the corresponding brass-only samples (rods and wires), also friction extruded. Our results show that the sub-micron graphite plays an important role in limiting process temperature and restraining grain growth during friction extrusion, thus reducing grain size in composites.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Assembly and Testing of Scintillator Tile Modules for the CMS High-Granularity Calorimeter Upgrade

The High-Granularity Calorimeter (HGCAL), part of the upgrade to the Compact Muon Solenoid (CMS) experiment, employs silicon and scintillator tile modules in the endcaps to maintain detector performance during the High-Luminosity Large Hadron Collider (HL-LHC) era, scheduled to operate from 2030 to 2040. The upgraded calorimeter will provide highly segmented three-dimensional imaging, energy measurements, and precise timing for particle shower reconstruction. Approximately half of the HGCal plastic scintillator tile modules (1,834 total) will be assembled at Fermilab using an automated pick-and-place (PnP) machine. Following assembly, each tile module undergoes quality control (QC) procedures such as electrical validation, thermal testing, and physics validation using cosmic rays. This poster/talk presents the QC procedures and results from the tile module production in 2026, demonstrating the performance and quality of the assembled tile modules.

Bazimya, Jean Luc [Grambling State U.]↗
DOE OSTI2024

Machine learning-guided design of direct methanol fuel cells with a platinum group metal-free cathode

Direct methanol fuel cells (DMFCs) offer a promising solution for clean electricity generation, particularly in small electronics and remote auxiliary power units. However, optimizing their efficiency and performance is challenging due to the complex interactions between various factors. Here, we present a novel approach that integrates experiments with machine learning to model and predict the performance of these fuel cells using atomically dispersed platinum group metal (PGM)-free catalysts at the cathode. Further, our machine learning models, trained on diverse input parameters, allow for the comprehensive optimization of DMFC performance prior to fabrication and testing. Through extensive experimental validation, we demonstrate that this data-driven approach accurately predicts key performance metrics, such as maximum power output and polarization curves. By combining our models with interpretable game-theory methods, we provide deep insights into the factors governing fuel cell performance, ultimately paving the way for the design of scalable and efficient DMFC technologies.

25 ENERGY STORAGE↗
DOE OSTI2024

Accurate machine-learning predictions of coercivity in high-performance permanent magnets

Increased demand for high-performance permanent magnets in the electric vehicle and wind-turbine industries has prompted the search for cost-effective alternatives. Discovering magnetic materials with the desired intrinsic and extrinsic permanent magnet properties presents a significant challenge to researchers because of issues with the global supply of rare-earth elements, material stability, and a low maximum magnetic energy product BH max . While first-principles density functional theory (DFT) predicts materials’ magnetic moments, magnetocrystalline anisotropy constants, and exchange interactions, it cannot compute extrinsic properties such as coercivity (H c ). Although it is possible to calculate H c theoretically with micromagnetic simulations, the predicted value is larger than the experiment by almost an order of magnitude due to the Brown paradox. To circumvent these issues, we employ machine-learning (ML) methods on an extensive database obtained from experiments, DFT calculations, and micromagnetic modeling. The use of a large experimental dataset enables realistic H c predictions for materials such as Ce-doped Nd 2 ⁢Fe 14 ⁢B, comparing favorably against micromagnetically simulated coercivities. Remarkably, our ML model accurately identifies uniaxial magneto-crystalline anisotropy as the primary contributor to H c . With DFT calculations, we predict the Nd-site-dependent magnetic anisotropy behavior in Nd 2 ⁢Fe 14 ⁢B, confirming that Nd 4⁢g sites mainly contribute to uniaxial magnetocrystalline anisotropy, and also calculate the Curie temperature (T c ). Finally, both calculated results are in good agreement with the experiments. The coupled experimental dataset and ML modeling with DFT input predict H c with far greater accuracy and speed than was previously possible using micromagnetic modeling. Further, we reverse engineer the grain-boundary and intergrain exchange coupling with micromagnetic simulations by employing the ML predictions.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Electric Field’s Dueling Effects through Dehydration and Ion Separation in Driving NaCl Nucleation at Charged Nanoconfined Interfaces

Investigating nucleation in charged nanoconfined environments under electric fields is crucial for many scientific and engineering applications. Here we study the nucleation of NaCl from aqueous solution near charged surfaces using machine-learning-augmented enhanced sampling molecular dynamics simulations. Our simulations successfully drive phase transitions between the liquid and solid phases of NaCl. The solid phase is stabilized under electric fields, particularly at an intermediate surface charge density. We examine which physical characteristics drive the nucleation of NaCl from aqueous solutions and find that the removal of solvent water from Cl– at the solid precursor surface plays a more critical role than the accumulation of ions. Our simulations reveal the competing effects of electric fields on nucleation processes: they facilitate the removal of water, promoting nucleation, but also promote the separation of ion pairs, thereby hindering nucleation. Here, this work provides a framework for studying nucleation processes in nanoconfined environments under electric fields and provides physical insights for the design of electrochemistry materials.

Electric fields↗
DOE OSTI2025

Uniform Field Electrode Generator

SAND2025-03788O Uniform Field Electrode Generator is a user-friendly tool designed to create uniform electric field electrodes, essential for high voltage applications. By generating electrodes with precise dimensions, it ensures a consistent electric field across their surfaces. This software is particularly beneficial for researchers and engineers working on projects like closing switches and studying power flow in advanced systems, such as the Z machine. Its unique approach simplifies the design process, making it accessible for users without technical expertise, while enhancing the efficiency and effectiveness of their electrical applications. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Mason, Tyler [Sandia National Lab. (SNL-CA), Liver↗
DOE OSTI2023

AN OVERVIEW OF THE DESIGN AND PERFORMANCE TESTING OF A 275 BAR INTEGRALLY GEARED SUPERCRITICAL CO2 COMPRESSOR FOR POWER GENERATION

An integrally geared compressor-expander (compander) for supercritical CO2 (sCO2) was developed to convert thermal energy to electricity. With operating pressures of 275 bar, this turbomachine represents the state of the art in integrally geared machine architecture, hitting compressor inlet densities of 600 kg/m3 and discharge pressures of 275 bar. The product development was funded by the Department of Energy’s Energy Efficiency and Renewable Energy Office under EE0007114 to advance the state of the art in concentrated solar power applications; however, the technology itself is agnostic to heat source, and is predicted to achieve a thermal-to-electric conversion efficiency of 50% for any indirect heat source capable of providing turbine inlet temperatures of 700°C or greater. While the program encompassed the design and testing for the compressor and turbine elements, this paper will focus on the compressor design and operation. The paper will begin with an introduction to the cycle design and analysis of an indirectly heated integrally geared sCO2 compander, a discussion of the mechanical and aerodynamic design of the compressor that is a two stage radial compressor operating subcritically at 27,512 rpm, and will then proceed to describe the test facility and measured data to characterize the performance and robustness of the machine. The paper will conclude with a discussion on lessons learned throughout the course of commissioning and testing. Practical aspects of testing a compressor operating near the dome including complications relating to obtaining an accurate compressor flow map, efficiency calculations, flow unsteadiness, and associated measurement uncertainties will be discussed.

wilkes, jason↗