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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Demonstration of Utility Managed Smart Charging for Multiple Benefit Streams (Final Report)

In the summer of 2020, the U.S. Department of Energy (DOE) awarded funding to Exelon’s Maryland utilities—Baltimore Gas and Electric (BGE), Delmarva Power & Light (DPL), and Potomac Electric Power Company (Pepco)—to implement the Smart Charge Management (SCM) pilot. This initiative aimed to design and implement managed electric vehicle (EV) charging strategies, evaluate the grid impacts of EV charging, and assess the utilities' ability to control EV load based on real-time grid conditions. The SCM pilot explored four aspects for continued improvement: (1) cybersecurity and managed charging functionality testing of two vendor platforms—WeaveGrid (telematics-based) and Shell Recharge Solutions (network-based)—which pursued charge scheduling and optimization through distinct approaches; (2) an analysis by Argonne National Laboratory (ANL) modeling team of three potential SCM enrollment scenarios within BGE and Pepco service territories over the next decade to assess future scalability; (3) employing customer engagement strategies, including surveys and a responsive pricing approach; and (4) the launch and implementation of pilots in Exelon’s Maryland territories in collaboration with WeaveGrid.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Direct vitrification of HLW: evaluation of candidate source tanks

The initial objective of the present work was to review Hanford HLW compositions to identify HLW streams that are good candidates for the HLW direct feed vitrification option. Another objective was to develop and identify HLW glass compositions and glass forming additive blends for vitrification of two HLW streams identified from the review that could be treated with little or no washing or other pretreatment and would be, therefore, good direct feed candidates. The HLW glass compositions and additive blends were developed to maintain high waste loadings, high processing rates, and acceptable product glass properties. This was accomplished through a combination of crucible-scale and DM100 melter system tests.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

ATF Cladding Mechanical Properties Report: Capability Demonstration

This report documents mechanical testing capability demonstration activities performed in fiscal year (FY)2025 at Oak Ridge National Laboratory(ORNL)on chromium-coated (Cr-coated) and uncoated advanced zirconium alloy claddings irradiated in the High Flux Isotope Reactor (HFIR) to approximately 4 displacements per atom (dpa), corresponding to ~13GWd/t burnup. Specimens were prepared in axial tension (ATT) and ring tension (RTT) geometries, and passive silicon carbide(SiC)thermometry (TM) was employed to determine irradiation temperatures, which averaged 38–43 °C below the 330 °C design target. Mechanical testing at ambient temperature demonstrated the expected irradiation-induced hardening, with yield strength(YS)and ultimate tensile strength(UTS)values increasing substantially relative to unirradiated counterparts. However, this strengthening was accompanied by a reduction in ductility, as indicated by lower uniform and total elongations(UE and TE). Both coated and uncoated claddings exhibited similar mechanical response, though Cr-coated specimens showed surface cracking perpendicular to the loading direction, attributable to the hardness mismatch between the coating and substrate. Fracture in all cases remained ductile, and no coating spallation was observed following HFIR irradiation. Complementary efforts were directed toward the fabrication of test specimens from commercially irradiated cladding (rod 47I, ~31.1 GWd/t average burnup). Axial sectioning and computer numerical control(CNC)machining successfully produced ATT geometries suitable for benchmarking against HFIR-irradiated specimens. This capability enables direct comparison of cladding behavior between test reactor and commercial reactor environments, thereby supporting the validation of HFIR as a surrogate irradiation platform for accident tolerant fuel (ATF) development. Once HFIR irradiations are completed in FY26,the relevant comparison tests will be completed. Collectively, the FY 2025 PIE campaign has provided mechanical performance data for irradiated advanced claddings The demonstrated capabilities support the framework for mechanical testing and further evaluations in subsequent years. These efforts will represent an important contribution toward the licensing and deployment of Cr-coated zirconium alloy cladding as a near-term ATF solution.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Zero-CO Residential Natural Gas Furnace

Residential natural gas furnaces are widely used in the US homes. Manufacturers dedicate significant design and testing resources to meet requirements of design standards. One area of these standards is controlling flue gas carbon monoxide (CO) emissions. To more effectively reduce CO emissions at the flue, we developed a novel catalyst-assisted approach that integrated a low Pt/Rh loading acidic gas reduction (AGR) catalyst with three-way catalyst (TWC) or diesel oxidation catalyst (DOC) components. Compact catalysts were fabricated and assembled into tubular components, which can be seamlessly incorporated into the primary heat exchanger of a representative commercially available condensing furnace. The retrofitted furnace was demonstrated and tested following ANSI/ASHRAE Standard 103-2017. Experimental results showed that both AGR/TWC and AGR/DOC configurations achieved near-zero CO emissions under steady-state and cold-start conditions, compared with up to 500 ppm at a cold start and 17 ppm in a steady state in the OEM furnace. The catalyst-assisted furnaces also exhibited an annual fuel utilization efficiency improvement of more than 1.5% relative to the baseline unit, with a manageable pressure drop of 2.0−2.5 in. of water column. These results demonstrate that the catalyst-assisted approach can effectively eliminate CO emissions and improve energy efficiency. The technology has broad applicability for residential and commercial gas-fired heating systems.

Gao, Zhiming [ORNL] (ORCID:0000000271397995)↗
DOE OSTI2025

In-Field Testing of Components for Feedback and Control of the ITER Disruption Mitigation System

Here, the shattered pellet injection (SPI) method has been chosen as the disruption mitigation system (DMS) for ITER. To protect the device from plasma disruptions that cause damaging heat and electromagnetic loads, SPI is used to inject high-Z material into the plasma. The process of SPI utilizes cryogenic cooling to form solid pellets. Pellets are accelerated down a barrel and into an angled surface, causing the pellet to shatter prior to entering the tokamak chamber. For the DMS to function reliably, the 27 separate shattered pellet injectors planned for ITER must rely on many components to provide accurate feedback data and for control functions. Each component in the DMS is exposed to an elevated background magnetic field depending on its placement and proximity to the plasma chamber. A Helmholtz coil test stand that is operated at Oak Ridge National Laboratory was utilized to test the components in relevant background field levels to assess component performance. This paper details the test design and results for in-field component operation for a variety of components. This list includes the following components: two different network switches for camera connectivity, a VAT fast shutter valve intended to reduce the flow of SPI propellant gas into the torus, a solenoid control valve intended for use in the pellet formation process, pressure/vacuum switches to be used for feedback and control, a printed circuit board piezo pressure sensor to be used to measure breech pressure, and various relays for the high-voltage pulsed power supply used to drive the SPI propellant valve.

Disruption mitigation↗
DOE OSTI2026

LAF-Net: A Deep Residual and Cross-Attention Framework for Day-Ahead Load Forecasting: Preprint

Accurate day-ahead load forecasting is essential for reliable power system operations and market efficiency. System operators such as the Midcontinent Independent System Operator (MISO) rely on forecasts from multiple vendors, yet combining them effectively remains a persistent challenge due to vendor-specific biases. This paper presents a novel LSTM-Attention Fusion Network with Error Representation (LAF-Net) that enhances day-ahead hourly load forecasting through deep residual learning and multi-modal cross-attention. The proposed model builds a historical error memory from past vendor performance and dynamically queries it with future hour context to generate adaptive, hour-specific trust weights for each vendor. A bounded residual correction further refines forecasts by mitigating systematic and temporally localized errors. Tested on real MISO LBA data with multi-vendor forecasts, LAF-Net consistently outperforms the best vendor baseline across all 38 LBAs, achieving more than a 40% reduction in system-level mean absolute error (MAE) during peak load hours relative to the best vendor baseline.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Effect of pore fluid chemistry on the mechanical behavior of a divalent compacted bentonite, an experimental and constitutive study

Ongoing research in isolating high-level nuclear waste and spent fuel has highlighted compacted bentonite as a suitable material for engineered barrier systems in deep geological repositories due to its extraordinary swelling and retention properties. This research focuses on the chemo-mechanical behavior of compacted bentonite exposed to different pore fluids with different concentrations and loading conditions. The study involves swelling pressure and compressibility experiments along with mineralogy analysis employing X-ray diffraction (XRD) and Cation exchange. The tests were conducted on BCV (a Mg/Ca- bentonite) compacted at a dry density of 1.48 ± .02 Mg/m 3 . An advanced chemical-mechanical constitutive model for unsaturated highly expansive clays was adopted to simulate the material response and better understand its behavior. The model is able to account for the main phenomena at both macro and microstructural levels and the interactions between them. The model successfully replicated experimental observations. The XRD analyses support the macroscopic observation, indicating that salinity impacts crystalline swelling as demonstrated by the reduction of basal spacing from 19.27 Å to 15.68 Å when the osmotic suction increases from 0 MPa to 33 MPa. The results suggested that the osmotic pressure generated by the concentration in the pore fluids promotes a reduction in swelling pressures, swelling strains, and crystalline swelling of clay minerals. Also, it affects the pre-consolidation stress and the compressibility of the compacted samples. In conclusion, it was also observed that both solution type and solution concentration impact the clay swelling pressure.

Chemo-mechanical constitutive model↗
DOE OSTI2024

Instrumentation for the Investigation of Pitch Bearing Design and Reliability

Recently, there has been an increasing level of industry interest in pitch system and pitch bearing reliability. Pitch bearings are used in wind turbines to connect the blade root to the hub. Some populations of pitch bearings have demonstrated a 12% failure rate in 20 years. As rotor diameters continue to increase for tall land-based and offshore wind turbines, pitch bearings are becoming even larger in diameter, which can make them vulnerable to deflections and consequent stress concentrations. There is an increased need to more accurately study pitch bearing deformations, misalignment, load distributions, and contact stresses. A significant body of work has investigated fatigue lives and wear characteristics of pitch bearings on ground-based test rigs. NREL has also recently begun a research program related to pitch bearing reliability, recognizing its growing importance for wind turbines. The purpose of this paper is to describe a set of instrumentation that was recently installed on a 1.5 MW wind turbine at the NREL Flatirons Campus and provide an example data set. To the authors' knowledge, this will be the first publicly available pitch bearing data collection campaign on an operational wind turbine.

17 WIND ENERGY↗
DOE OSTI2024

Summary of FY2024 Experimental Results to Support Development of New Inelastic Material Models and Validation of Section III, Division 5, Class A Design Rules

To address the data gap crucial for updating existing viscoplastic constitutive material models for the Class A materials in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME, 2023) for inelastic design analysis, Oak Ridge National Laboratory (ORNL) conducted experimental studies on Alloy 800H and Alloy 617 across a range of temperatures up to their maximum temperature limits in Section III, Division 5. The studies aim to characterize the materials' deformation behavior under both strain-controlled mechanical cyclic loading and thermal cycling conditions. This report summarizes ORNL's FY 2024 experimental findings on Alloy 800H and Alloy 617, focusing on pure fatigue tests, cyclic stress-strain curves, thermomechanical fatigue experiments, and verification of the high temperature cyclic damage summation design rules.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Expansion of the Fuel Motion Monitoring System

The Idaho National Laboratory (INL) Transient Reactor Test Facility (TREAT) Fuel Motion Monitoring System (FMMS) is a diagnostic tool used to visualize the movement and location of fuel within the nuclear reactor during transient experiments. TREAT is designed to test the behavior of nuclear fuel under accident conditions, such as a rapid power increase. The TREAT FMMS, also referred to as the “hodoscope” because of the system’s massive steel collimator component, is located on the North beam port of the reactor. While the FMMS system is capable of incorporating a total of 360 sensors, initial refurbishment efforts resulted in a array of 96 fast neutron detectors. This initial array was configured to provide a narrow (2 channels) full-length view of experiment vessels with an extended 4-channel–wide region in the center of the array capable of providing a full view of all initially planned experiments. Planning and efforts to expand the FMMS array began immediately following the restart of TREAT. An additional 96 detectors were evaluated, characterized, and prepared for installation at TREAT during the summer of 2018. Unfortunately, funding reductions forced the project towards a 5-year hiatus. In October of 2023 funding from the Department of Energy’s Nuclear Science User Facilities enabled the expansion to recommence. This report serves to document the activities performed to expand the FMMS detector array to 192 channels in order to provide a broader view of the larger and more sophisticated test capsules currently planned for future irradiation in the TREAT reactor. This expansion also included doubling the data acquisition capability, addressing the new heat load on the system, and synchronizing the time for all digital components.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

High waste loading glass formulation development for high-P HLW

The primary objective of the work described herein was to develop and identify HLW glass compositions and glass forming additive blends that achieve high waste loadings and processing rates for high phosphorus HLW streams while maintaining acceptable glass properties. This was accomplished through a combination of crucible-scale tests, vertical gradient furnace tests, and confirmation tests on the DM100 melter system.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

A hierarchical framework for aggregating grid-interactive buildings with thermal and battery energy storage

The behind-the-meter (BTM) thermal and battery energy storage can help improve energy efficiency, reduce energy costs, and enhance energy resilience, particularly in rural areas and for disadvantaged communities. Aggregating numerous BTM energy storage systems can act as a price influencer with a significant source of load shifting and peak demand reduction. An integrated and scalable control mechanism is required to effectively utilize energy storage systems and flexible building loads to maximize the economic benefits, considering various distribution system constraints. Here, this paper presents an innovative hierarchical coordination framework for energy storage and flexible load in buildings, considering various factors such as electricity prices, thermal comfort, and distribution system modeling and constraints. At the upper level, a distribution system operator optimizes the power flow to minimize its power procurement costs from the electricity wholesale market, while at the lower level, aggregators determine the optimal dispatch of battery and thermal energy storage systems in multiple buildings on behalf of end-users to minimize operating costs according to the power prices. These problems are solved using a game-theoretic approach through negotiations between the distribution system operator and aggregators as a bi-level decision model. Simulation case studies have been performed for a test distribution network with a number of building end-users using energy storage systems to quantify the performance of aggregators. The results demonstrate that the proposed strategy can reduce peak load for a reliable electricity distribution network while saving electricity bills for customers.

25 ENERGY STORAGE↗
DOE OSTI2024

Validation Exercise of a Coarse Finite Element Model of Laser Welds

The objective of this project is to validate low-fidelity models of 304L to 304L stainless steel partial-penetration laser welds for thin sheets. Low-fidelity means that the weld is represented by coarsely meshed element blocks. Here, the hexahedral element size is approx imately half the weld penetration depth. The material behavior of the block is represented by a J2 plasticity model with a Voce hardening function. The source of the data used in this work is an extensive experimental study conducted by Sharlotte Kramer (1528) and published in 2015. Figure 1 shows a cross-section of the weld of interest. The nominal thickness of the sheets is 0.063 in. while the target penetration depth of the weld is in the range of 0.028 to 0.032 in., extending about half the sheet thickness. Uniaxial tension tests provided data for calibration of base material and weld models. Results of two validation geometries were also provided. The principal validation geometry is shown in Fig. 2. It consists of a plate specimen with in-plane dimensions 6 in × 2.875 in loaded in tension. A circular plug with a 1.5 in. diameter was cut from the center of the plate and then welded in place. The details of the welding schedule are given. An important assumption is that the welds in the calibration and validation specimens have similar geometric and material properties as those in the validation tests. The task was to first calibrate models for the base material and the welds and then simulate the validation tests until the point of weld first failure.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Geophysical Signatures of Crack Network Coalescence in Rocks at Multiple Length Scales

The main goal of the research project was to identify the geophysical signatures of fracture growth in natural rocks by utilizing novel geophysical techniques. The research objectives were to (a) investigate the potential for geophysical methods to determine when cracks initiate, the types and locations of propagated cracks, and the coalescence of networks of cracks in natural rocks at multiple scales, (b) determine how damage at the microscale evolved into damage at the macroscale and then link the microscopic and macroscopic observations, (c) quantify crack coalescence in rocks under realistic stress conditions using coupled mechanical-geophysical-optical visualization, and (d) identify the precursors in geophysical signals to crack coalescence. The following research thrusts were explored to achieve the research objectives: (1) uniaxial compression testing of rock specimens with and without a set of pre‐existing flaws and (2) triaxial compression testing of natural rock specimens. These thrusts allowed for exploring fracturing in rocks under realistic in situ environments and at multiple scales. This project provided educational opportunities for nine graduate and undergraduate students and resulted in 27 peer-reviewed publications. This first research thrust focused on investigating the micromechanics of fractures in rocks through uniaxial compression testing combined with advanced geophysical and imaging techniques, specifically acoustic emission (AE) monitoring, ultrasonic imaging, and 2-dimensional Digital Image Correlation (2D-DIC). By examining damage processes under time-independent and time-dependent loading conditions, insights into damage localization, crack initiation, and fracturing mechanisms were gained. It was observed that the AE signals and the strain-based measurements directly reflect the state of damage in the rock specimen and could be used to identify the cracking levels, such as the crack initiation (CI) and crack damage (CD), and the mode of deformation. A novel calibration apparatus was developed to enhance the accuracy of AE sensors, allowing for the estimation of key parameters such as magnitude, source dimension, stress drop, and radiated seismic energy associated with the fractures. The findings highlighted significant variations in the temporal evolution of AE source parameters during the primary, secondary, and tertiary stages of creep, identifying tensile cracking as the primary deformation mode. The second research thrust focused on enhancing the understanding of fracturing processes in natural rocks through triaxial compression testing, real-time AE monitoring, and ultrasonic monitoring. We investigated the impact of various factors such as fracture propagation regimes, injection parameters, rock types, and pre-existing conditions on the hydraulic fracture (HF) behavior using scaled true-triaxially loaded specimens of Barre granite and Lyons sandstone. Custom sensor housing facilitated concurrent active and passive monitoring to analyze hydro-mechanical responses and microseismicity associated with different HF scenarios. A coupled investigation of passive microseismicity and active signal attributes permitted a detailed comprehension of the various HF processes (aseismic deformation, fracture initiation and propagation, fluid permeation, and leak-off) and their dependence on the specific rock type. The findings of this research demonstrated the effectiveness of AE monitoring techniques in providing valuable insights into the impact of various factors on the behavior and dynamics of HF processes. The advancements in monitoring techniques, offering a more thorough and precise approach, represent a significant step towards optimizing HF practices and ensuring sustainable resource extraction.

58 GEOSCIENCES↗
DOE OSTI2026

Mechanism-Informed Breakdown: Understanding Degradation by Controlling Voltage-Hold Patterns in Proton Exchange Membrane Water Electrolyzers

Low catalyst loadings pose challenges to performance stability in proton exchange membrane (PEM) water electrolysis over extended operation. To study the impact of degradation mechanisms and voltage loss rates, different stress tests are applied to membrane electrode assemblies. Potential cycling conditions were observed to induce higher degrees of iridium (Ir) oxide crystallization, ionomer degradation, and catalyst layer (CL) thinning, which likely contributed to higher kinetic loss rates. On the other hand, while Ir migrating into the PEM (Ir band) generally impairs performance, the interconnected and more uniform Ir band formed under a constant 2 V hold may allow for Ir at the catalyst/membrane interface to remain electronically connected and kinetically accessible, as well as indicate greater Ir site access during the applied stressor. The 2 V hold also demonstrates improved kinetic durability through a lower Tafel slope, faster polarization kinetics, and reduced charge transfer resistance. In contrast, potential cycling caused the migration of disconnected Ir agglomerates into the membrane bulk and created a steady increase in charge transfer resistance, a more dramatic decrease in capacitance (46.7% loss), and significant damage to the surrounding ionomer, indicating a decline in both the quality and quantity of active sites in the anode CL. This work underscores the distinct degradation pathways associated with load holds versus cycling, highlighting the role of catalyst-ionomer interactions in kinetic performance and long-term stability. These insights can inform operational strategies for PEM electrolyzers powered by intermittent energy sources, aiming to minimize efficiency losses over extended operation.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Main Shaft Bending Moment Analysis for a Gamesa G97 2-MW Wind Turbine

In a collaborative project between Siemens Gamesa Renewable Energy and the National Renewable Energy Laboratory (NREL), a cost-effective method to measure dynamic main shaft torque and the influence of non-torque loads was applied to the gearbox of the Gamesa G97 2-megawatt (MW) wind turbine at the NREL Flatirons Campus and verified through a field test campaign that took place in 2023. The method involved the installation of fiber-optic sensors on the ring gear of the gearbox. Additionally, traditional strain gauges and a rotary encoder were installed on the main shaft to measure mechanical torque and orthogonal bending moments. We compare the measured total main shaft bending moments from the field test campaign to those predicted by an updated OpenFAST model of the G97 wind turbine for similar environmental conditions. We also assessed the sensitivity of the predicted bending moment to varying levels of turbulence intensity, shear exponent, and yaw error.

17 WIND ENERGY↗
DOE OSTI2026

Prime Time for Model-Predictive Control? Assessing the Technical and Market Readiness of Advanced Controls in Buildings

Despite three decades of extensive research and field testing that have consistently validated the benefits of Model Predictive Control (MPC) in building applications, the technology has seen limited market adoption. This paper evaluates the readiness of MPC for widespread deployment, showcases recent demonstrations and field tests across diverse building types, including residential, small commercial, large commercial, and campus settings. Our results demonstrate that MPC can optimize system operations to achieve load shifting, minimize curtailment of on-site generation, and reduce energy costs by up to 80 %, while maintaining or improving occupant comfort. We also show that MPC can effectively control large assets, such as MW-sized thermal storage systems, and respond to dynamic pricing signals. However, achieving scale remains difficult due to labor-intensive workflows, reliance on a “PhD-in-the-loop” for MPC design and maintenance, susceptibility to fragile data infrastructure, and persistent workforce education and acceptance barriers. To bridge this gap, we outline a transition from bespoke, labor intensive prototypes toward streamlined, segment-targeted deployment strategies that leverage model templates, semantic tools, and generative AI. By automating control configuration and reducing engineering effort, these recommendations provide a pathway for transforming successful research demonstrations into scalable, market ready solutions for MPC-based controls.

Pritoni, Marco↗
DOE OSTI2024

Fabrication and testing of the transition section between modules of a wakefield accelerator

The fabrication process is presented for a typical transition section located between each cylindrical corrugated waveguide structure comprising the wakefield accelerator module. The transition section includes couplers for extracting the 180 GHz TM 01 accelerating mode and separate couplers for extracting the 190 GHz HE 11 dipole mode, both modes induced by the electron bunch traversing the cylindrical corrugated waveguide structure. Extraction of the high-power accelerating mode reduces the heat load due to the subterahertz wave power dissipation within the corrugated accelerating structure. Extraction of the low-power dipole mode serves the purpose of detecting the electron bunch transverse oscillations within the wakefield accelerator and identifying the onset of beam breakup instability. Comprehensive testing of the fully functional transition section with an electron beam was done at the Accelerator Test Facility in Brookhaven National Laboratory which verified the functionality of the transition section. Published by the American Physical Society 2024

43 PARTICLE ACCELERATORS↗