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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 OSTI2024

Self-healing carbon fiber/epoxy laminates with particulate interlayers of a low-melting-point alloy

In order to prolong the service life of fiber-reinforced polymer composites, the implementation of self-healing ability with the micro-encapsulated healing agent has been extensively studied. However, such microcapsule-based self-healing composites typically suffer from degraded mechanical properties due to the liquid-phase inclusions, thereby limiting their proliferation. Here, in this study, a low-melting-point alloy is utilized as the particulate inclusions of carbon fiber/epoxy laminated composites. Field's Metal particles (melting point: 62 °C) are distributed between woven carbon fiber preforms followed by the resin impregnation to realize laminated composites with a Field's Metal-enhanced interlayer(s). The resulting laminated composites demonstrate the autonomic repair of interlaminar failure with a 40 % of healing efficiency. Most of all, the mechanical properties of these self-healing laminated composites are comparable to the conventional laminated composites attributed to the rigid inclusions that can be compressed to increase the fiber volume. Since the Field's Metal particle inclusions can bestow polymer composites with self-healing ability and the potential increase in mechanical properties, Field's Metal-enhanced fiber-reinforced polymer composites are expected to unlock the practical utility of self-healing composites.

A. polymer-matrix composites (PMCs)↗
DOE OSTI2025

Benchmarking image processing techniques for porosity measurement in polymer additive manufacturing: Review and experimental analysis

An image processing workflow is proposed for porosity measurement in polymer additive manufacturing. Various techniques, including global and local thresholding, region growing, and K-means clustering, were applied to microscopic images of carbon fiber reinforced acrylonitrile butadiene styrene (CF-ABS) and benchmarked for their ability to accurately measure porosity. Global methods included Otsu, minimum error, iterative, and entropy-based thresholding, while local methods included Niblack, Bernsen, Sauvola, and Bradley-Roth algorithms. Artificial uneven illumination was introduced to test local adaptive thresholds. Results showed significant differences in porosity values across methods. Otsu, region growing, and K-means clustering excelled under uniform illumination, while Sauvola and Bradley-Roth performed better with uneven illumination. Comparison with X-ray computed tomography (XCT) revealed slightly lower porosity values (2.55 %) than optimized methods (2.73–2.79 %) due to XCT's lower resolution excluding smaller pores. While XCT offers finer pore detection, it limits sample volume and underestimates porosity due to spatial variation. Validation using artificial grayscale images with 5 % porosity confirmed that Otsu, Bradley-Roth, region growing, and Sauvola algorithms produced accurate results. Although tested on a single material system, these methods can be adapted to others with optimization. In conclusion, given XCT's high computational and time costs, this study highlights suitable image processing techniques as cost-effective alternatives for porosity analysis in polymer composites.

Additive manufacturing↗
DOE OSTI2026

FLiBe compatibility of fusion-relevant materials

There is current interest in a 2LiF-BeF2 (FLiBe) molten salt blanket for fusion applications, however, very little compatibility data are available for fusion relevant materials. Initial static capsule testing results for 500 h at 550°-750 °C are presented for V-4Cr-4Ti, Fe-8Cr-2W (alloy F82H) compared to type 316H stainless steel and monolithic SiC as a surrogate for SiC/SiC composites. In addition, sintered Be12Ti specimens with varying additions of Be (0–20%) and a Be2C specimen were exposed with F82H coupons at 650 °C in individual Mo capsules. The V-4Cr-4Ti and SiC specimens exposed at 650 °C had small mass changes. Steel specimens showed increasing mass losses with increasing exposure temperature. However, when Be12Ti-Be specimens were included in a capsule with an F82H coupon, increasing F82H mass gains were observed with increasing Be content due to the formation of a Fe-Be surface layer. No layer and no mass gain were observed for the F82H specimen tested with Be2C.

Pint, Bruce [Oak Ridge National Laboratory (ORNL) ↗
DOE OSTI2026

Synergistic ruthenium single-atom and nanoparticles in nickel as cooperative catalysts for the alkaline hydrogen evolution reaction

Efficient hydrogen evolution reaction (HER) catalysts that reduce the use of noble metals and can be synthesized on a large scale are essential for advancing anion exchange membrane water electrolyzers (AEMWEs) toward commercialization. Herein, we present a composite catalyst in which Ru nanoparticles coexist with Ru single-atom alloys (SAAs) dispersed within Ni nanoparticles (Ru-SAA/Ni), creating a highly active HER electrocatalyst. Using a one-pot and scalable synthesis method, we can tune the material composition from SAA, i.e. materials containing atomically dispersed Ru atoms (with ≤0.4 at% Ru) to composite structures in which SAAs coexist with Ru NPs. Comprehensive characterization using XPS, XAS, and TEM confirms Ru-SAA formation at a low Ru content and composite structures at higher contents. Electrochemical evaluations conducted in a three-electrode setup reveal that Ru-SAA/Ni composites achieve HER performance on par with that of Pt/C. Computational insights suggest that water dissociation is significantly faster at the Ru/Ni interface compared with that on extended surfaces. These active sites are thermodynamically as active as basal planes, preventing the excessive accumulation of reaction intermediates (H*, OH*). All these results highlight the synergistic interaction between Ru SAAs and Ru nanoparticles and their potential for large-scale applications with minimal use of precious metals. Finally, the materials are processed and tested in AEMWEs, achieving 1.85 V at 0.5 A cm −2 with a total noble metal loading of only 0.1 mg cm −2 .

Khalil, Gaëlle [Université de Paris (France)]↗
DOE OSTI2025

Design and Analysis of a Mutual Inductance Level Sensor for Liquid Metals

Here, this article describes the design and analysis of an electromagnetic level sensor for use in high-temperature liquid metal systems. The mutual inductance level sensor (MILS) described in this work was fabricated using two single-conductor mineral insulated cables wrapped in a bifilar fashion around a stainless steel tube core and was housed in an isolating thimble that preserved the pressure boundary of the test vessel. Two sensor variations were fabricated that differ only in active length, 1016 and 1778 mm. Experimental data were collected using the 1016-mm sensor (MILS-MKII-040) that demonstrated a sensitivity of 9.2 μ V/mm in a room temperature testing stand that used solid aluminum as a surrogate for liquid metal. Experimental data were collected using the 1778-mm sensor (MILS-MKII-070) that demonstrated a sensitivity of 6.9 μ V/mm in the high-temperature (300 ° C) liquid sodium environment at the mechanisms engineering test loop (METL) of Argonne National Laboratory. The sensor performance was found to be repeatable over the course of several months, with roughly ±1% deviation from nominal output. Finite element models were developed in COMSOL Multiphysics that fully describe each test setup, and the models were validated using experimental data. The validated COMSOL models were used to perform an array of analyses that examined the performance of the sensor in differing environments. Maximizing the coil diameter inside the isolating thimble was found to maximize the signal and sensitivity of the sensor. An optimal operating frequency was found near 1000 Hz using both experimental data and COMSOL. The influence of a metallic thimble surrounding the sensor and a metallic sensor core was quantified and found to be negligible at the optimal operating frequency. The sensitivity of the sensor was quantified when monitoring the level of additional liquid metals. These include lead, lead-bismuth eutectic (LBE), sodium-potassium alloy (NaK), and lithium (in addition to sodium). The sensitivities were quantified using liquid metal properties at 350 ° C and 650 ° C. The geometry of the test stand model, all material properties used in the model, and the results are presented in a manner that allows the reader can replicate the model and perform additional analyses.

COMSOL↗
DOE OSTI2024

The impact of temperature, chlorides and sulfate-reducing bacteria on the corrosion of steel in soil

Here, this investigation aimed to study the corrosion performance of low-carbon steel in a soil environment at different temperatures. The steel specimens in the soil were treated at three temperatures: 5, 25 and 60°C. The specimens were embedded in chloride-free soil for 21 days, and then 3.5% (by weight) sodium chloride (NaCl) was added to the soil. The specimens were then kept in the chloride-contaminated soil for 54 days. The results of electrochemical experiments showed superior corrosion performance of the specimens at 60°C, which had the lowest corrosion activity, followed by the specimens at 5 and 25°C. The slow nature of the kinetics of the corrosion reactions at 5°C compared with that at ambient temperature was the reason for this improvement at 5°C. The lower number of microorganisms, including sulfate-reducing bacteria, in the soil at 60°C compared with that at the other temperatures was attributed to the lower corrosion activity of steel in the soil at 60°C compared with the corrosion activity of steel in the soil at other temperatures.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Scanning Mobility Particle Sizer (SMPS) Instrument Handbook

The Model 3936 Scanning Mobility Particle Spectrometer (SMPS) measures the size distribution of aerosols ranging from 10 nm up to 1000 nm. The SMPS uses a bipolar aerosol charger to keep particles within a known charge distribution. Charged particles are classified according to their electrical mobility, using a long-column differential mobility analyzer (DMA). Particle concentration is measured with a condensation particle counter (CPC). The SMPS is well-suited for applications including: nanoparticle research, atmospheric aerosol studies, pollution studies, smog chamber evaluations, engine exhaust and combustion studies, materials synthesis, filter efficiency testing, nucleation/condensation studies, and rapidly changing aerosol systems.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Idaho National Laboratory Water Assessment

Established in 1949, Idaho National Laboratory (INL) is part of the U.S. Department of Energy’s (DOE) complex of national laboratories. INL performs work in each of the strategic goal areas of the department: energy, national security, science, and environment, and is the nation’s center for nuclear energy research and development. Located in southeastern Idaho, its physical footprint includes 569,180 acres of federally owned land. A water balance for the fiscal year (FY) 2022 year was conducted for INL to identify major water using equipment and calculate the end-use categories. FY 2022 was selected as the evaluation year per the DOE Sustainability Performance Office. This report provides an analysis of facilities on the INL Site operated by Battelle Energy Alliance, LLC (BEA). This water balance report focused on the Advanced Test Reactor (ATR) Complex, Materials and Fuels Complex, Idaho Falls campus, and Central Facilities Area campuses, which consumed 98% of the 540,611 thousand gallons (kGal) of water used by INL in FY 2022. The resulting water balance identified the use categories for 75.3% of the FY 2022 water consumption.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Gear Test Assembly – Experimental Testing and Analysis of Gears and Bearings – FY2024

The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The focus of GTA has been to test larger radial spur gear sets machined from Inconel 718 along with a variety of bearing components that are to be used in the fuel handling machines built for use in pool-type sodium fast reactors. The testing in GTA also informs the design and material choices for the full-scale Gripper Test Assembly (GrTA) being developed by Argonne.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

CSEWG Meeting Minutes

There were many improvements and additions to ENDF/B-VIII.1. We tested four key moderator materials: Be, HF, FLiBe, and graphite. Be-metal moderated critical assemblies of HEU only see 26 pcm difference. Sd library adds new physics to the TSL which improves the agreement with the benchmark. Other changes besides the TSL impact the benchmark: 235U and 9Be. Free gas change affects library heavily, hundreds of pcm in wrong way – need to look at FG libraries. F and Cl TSLs added to 8.1. A 3k pcm disagreement was seen without new TSL. Adding 8.1 + TSL reduces pcm disagreement A LOT.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2024

Measure the effect of molten halide salt exposure on creep rupture lifetime

Recent resurgence in the research and commercial interests in molten salt reactors (MSRs) as a viable advanced reactor concept to achieve the short- and long-term climate goals has resulted in ongoing efforts to demonstrate their commercial potential. These are relying on a combination of the extensive legacy knowledge from the molten salt reactor experiment (MSRE) and relatively recent data on materials compatibility of structural materials of interest such as 316H in molten salts environments. However, there is a critical lack of data on the mechanical behavior of alloys of interest for MSRS such as 316H, 617 and 709 in molten fluoride (FLiNaK or FLiBe) or chloride (NaCl-MgCl 2 ) salts. Limited legacy data from the molten salt reactor experiment (MSRE) program showed a significant reduction in creep rupture strength of a Ni-base alloy (Ni-15Cr-7Fe wt.%) in the molten fluoride NaF-ZrF4-UF4 (50-46-4 mol.%) salt. With ongoing efforts to commercialize different molten salt reactor concepts, the industry can considerably benefit from quantitative information on the impact of molten halide salts on the engineering properties such as creep and fatigue strength of materials of interest. Creep tests for 316H were conducted with fluoride (FLiNaK) and chloride (NaCl-MgCl 2 ) salts tat 650°C/150 MPa while alloys 709 and 617 were tested with FLiNaK at 700C/158 MPa and 750C.146 MPa respectively. Baseline tests were conducted in air to assess the impact of the molten salts on the creep behavior.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Reducing Mass of Steel Auto Bodies using Thin Advanced High Strength Steel with Carbon-Fiber Reinforced Epoxy

Diversitak, a company based in Detroit, MI, has developed a proprietary, low specific gravity, carbon fiber reinforced epoxy (CFRE) under U.S. patent number 9,963,58832. Preliminary testing on this new material conducted in collaboration with ArcelorMittal Steel Company proved out the CFRE concept. A thin layer of this CFRE was applied to a stamped sheet of steel with residual stamping oils from a mill, in a time corresponding to automotive processing (e.g., ~15 seconds), and processed following automotive e-coat procedures (phosphating + 175–200°C heating), to complete the curing. No problems with adherence or performance were noted. While the CFRE does add weight to a thin gauge steel panel, it weighs much less than what is displaced by using thicker conventional mild steel gauges. The application of the coating showed a significant increased dent resistance, oil canning resistance, and part stiffness.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Advanced Mooring Lines for Marine Energy Workshop – Summary Report

This report summarizes the outcomes of the virtual Advanced Mooring Lines for Marine Energy Workshop. The workshop convened experts from industry, academia, and national laboratories to identify key challenges associated with the deployment of synthetic mooring lines for marine energy applications. Discussions focused on four technical areas—materials, failure and degradation, testing, and modeling. Despite the significant promise of leveraging synthetic mooring systems for marine energy applications, discussion highlighted broader research and development needed to address the lack of validated long-term performance data, insufficient structural health monitoring frameworks, limited large-scale testing capabilities, and gaps in predictive modeling. Overall, the workshop emphasized the importance of coordinated research and development efforts to advance reliable, durable, and cost-effective synthetic mooring solutions for marine energy applications.

16 TIDAL AND WAVE POWER↗
DOE OSTI2026

Overview of IMPACT Data Acquisition System and Data Reduction Process

This report documents the development of the data acquisition system (DAS) and data reduction methodologies for the Irradiated Material Property Accelerated Characterization Test (IMPACT) experiment at the Advanced Test Reactor (ATR). The IMPACT experiment is designed to enable in-pile measurement of thermal conductivity in metallic nuclear fuels, specifically U-10Zr, using an instrumented thermal conductivity probe. The DAS supports both passive temperature monitoring and active thermal interrogation of the probe through controlled AC and DC excitation. Significant modifications to laboratory-scale systems were required to accommodate the higher resistance paths associated with the in-pile application. Custom electronics and relay-controlled measurement sequencing were developed to enable the measurement and sufficient power delivery to the sensing region. A reduced-order, axisymmetric thermal model based on the thermal quadrupoles method is presented to support data interpretation. This model enables efficient evaluation of transient heat transfer behavior and facilitates solution of the inverse problem required to extract thermal properties from measured signals. Multiple boundary condition formulations are discussed to address varying experimental time scales and geometries. Additionally, machine learning techniques are introduced to support data reduction and improve confidence in inverse solutions. Convolutional neural networks are applied to identify the presence of gas gaps and other evolving geometric features that significantly impact thermal response during irradiation. These efforts contribute to the broader integration of digital twin frameworks and real-time modeling capabilities within the Advanced Fuels Campaign.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2025

SPC-70804 Rev 1 Zircar ZAL-45 Alumina Standoff Plates for Use in MARVEL

Idaho National Laboratory (INL) is developing a microreactor to produce electrical power utilizing a small nuclear core and Stirling engines under the Microreactor Application Research Validation and Evaluation (MARVEL) program. This procurement specification defines the requirements for fabrication of the MARVEL ZAL-45 standoff plates manufactured by Zircar. The design requires eight (8) ceramic standoff plates; however, the requested quantity shall be twelve to account for required testing after receipt of materials. Any conflict between this specification and referenced Codes and Standards, or any supplementary specifications in the procurement documents requires written clarification from the Contractor prior to proceeding with any work. Any deviation from the procurement documents requires approval by the Contractor with the change request process.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2024

Bayesian optimization scheme for the design of a nanofibrous high power target

High Power Targetry (HPT) R&D is critical in the context of increasing beam intensity and energy for next generation accelerators. Many target concepts and novel materials are being developed and tested for their ability to withstand extreme beam environments; the HPT R&D Group at Fermilab is developing an electrospun nanofiber material for this purpose. The performance of these nanofiber targets is sensitive to their construction parameters, such as the packing density of the fibers. Lowering the density improves the survival of the target, but reduces the secondary particle yield. Optimizing the lifetime and production efficiency of the target poses an interesting design problem, and in this paper we study the applicability of Bayesian optimization to its solution. We first describe how to encode the nanofiber target design problem as the optimization of an objective function, and how to evaluate that function with computer simulations. We then explain the optimization loop setup. Thereafter, we present the optimal design parameters suggested by the algorithm, and close with discussions of limitations and future refinements.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Bayesian Optimization Scheme for the Design of a Nanofibrous High Power Target

High Power Targetry (HPT) R\&D is critical in the context of increasing beam intensity and energy for next generation accelerators. Many target concepts and novel materials are being developed and tested for their ability to withstand extreme beam environments; the HPT R\&D Group at Fermilab is developing an electrospun nanofiber material for this purpose. The performance of these nanofiber targets is sensitive to their construction parameters, such as the packing density of the fibers. Lowering the density improves the survival of the target, but reduces the secondary particle yield. Optimizing the lifetime and production efficiency of the target poses an interesting design problem, and in this paper we study the applicability of Bayesian optimization to its solution. We first describe how to encode the nanofiber target design problem as the optimization of an objective function, and how to evaluate that function with computer simulations. We then explain the optimization loop setup. Thereafter, we present the optimal design parameters suggested by the algorithm, and close with discussions of limitations and future refinements.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Atomate2: modular workflows for materials science

High-throughput density functional theory (DFT) calculations have become a vital element of computational materials science, enabling materials screening, property database generation, and training of “universal” machine learning models. While several software frameworks have emerged to support these computational efforts, new developments such as machine learned force fields have increased demands for more flexible and programmable workflow solutions. This manuscript introduces atomate2, a comprehensive evolution of our original atomate framework, designed to address existing limitations in computational materials research infrastructure. Key features include the support for multiple electronic structure packages and interoperability between them, along with generalizable workflows that can be written in an abstract form irrespective of the DFT package or machine learning force field used within them. Our hope is that atomate2's improved usability and extensibility can reduce technical barriers for high-throughput research workflows and facilitate the rapid adoption of emerging methods in computational material science.

97 MATHEMATICS AND COMPUTING↗