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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Moving from Information Assurance to Functional Assurance with Engineered Controls

Cyber threats to operational technology demand more than traditional IT defenses—they require full-spectrum mission assurance. Cyber-Informed Engineering (CIE) is an approach that embeds engineered controls into system design to ensure critical functions remain safe and reliable, even under attack. Unlike conventional cybersecurity tools, engineered controls act directly on physical processes to prevent unacceptable outcomes such as equipment damage or mission failure. This session will outline the CIE framework and share examples of consequence-based design that deliver true resilience, not just fail-safe behaviors. Attendees will learn how to integrate these principles into the engineering lifecycle to support resilient-by-design architectures and inform emerging standards. This talk sets the stage for the panel discussion on advancing CIE across sectors as digital and physical systems converge.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Reducing Methane Emissions with an Engine Fuel Reformer

Southwest Research Institute (SwRI) designed and demonstrated a compact, plasma-based fuel reformer designed to reduce methane leaks from natural-gas engines used in pipeline compression and industrial power applications. The system uses pulsed electrical discharges to convert a small portion of methane (CH4) into hydrogen (H2) and light hydrocarbons, promoting more complete combustion and reducing unburned methane in the exhaust. The reformer was evaluated through bench-scale testing, high-flow facility testing, and engine-integration testing on representative low-speed and high-speed natural-gas engines. Measured methane-leak reductions ranged from 1 to 27 percent, depending on engine type and operating condition, while reformer energy consumption remained below one percent of total engine output. Design refinements addressed thermal and electrical challenges, resulting in reliable operation with minimal impact on engine control systems. The project achieved all performance objectives within budget and schedule, produced a patentable pulsed-power system design, and established a scalable, energy-efficient pathway for mitigating methane leaks from existing natural-gas engine infrastructure.

03 NATURAL GAS↗
DOE OSTI2021

Towards a Robust Sampling Approach: A Computational Review and Design

As pointed out in several other works, the estimation of the reliability of the electrical grid can not be conducted without the estimation of the stochastic phenomena of electicity demand and electricity production by variable renewable sources. Therefore, sampling procedures have become integral in the design of engineering structures and analysis. Commonly referred to as Monte Carlo uncertainty analysis or integration, the general objective of these procedures is to establish specifics about the uncertainty of an output characteristic of such an engineering system, given uncertainty about its input characteristics. These sampling procedures are applied in a context in which establishing such specifics cannot be performed through other means. Variance-reduction techniques are designed to lessen the variability among estimators to estimate statistics of those output uncertainties. Importance-sampling techniques, on the other hand, are designed to reduce the number of samples needed to estimate a particular statistic—e.g., a tail probability. The combination of these approaches can reduce the computational burden considerably for a particular estimator and statistic. Importance sampling—geared and designed as it is toward improving a particular estimator—suffers, unfortunately, from the unintended consequence of reducing the performance of other estimators in terms of their variance. The objective of this paper is to offer an alternative sampling procedure where this variance does not grow unacceptably large for a suite of estimators. Moreover, it is anticipated that, with additional knowledge of how an engineering output characteristic responds to its input characteristics, tuning parameters of the input’s sampling procedure can be set to improve the output characteristic’s estimation. This work proves the effectiveness of the suggested alternative approach. Such positive outcome will lead to a decrease of the computational burden of performing stochastic optimization of integrated energy systems (e.g., components dispatch, and portfolio composition). In particular, capturing the contribution to the overall system cost of rare and unlikely events and patterns of the electricity demand and production will become less computationally expensive. This is due to the fact that the approach demonstrated here will allow the sampling of those rare occurrences more frequently without misrepresenting their probabilistic impacts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Linking Plant and Microbial Traits to Soil Carbon for Reliable and Resilient Bioenergy Systems

Bioenergy systems in the United States offer a dual opportunity to supply renewable feedstocks while enhancing ecosystem services such as hydrologic regulation, erosion control, and soil carbon (C) storage. National assessments highlight the potential to grow perennial energy crops to improve soil function and ecosystem resilience. Realizing this potential requires understanding the ecological mechanisms that govern how C is added, transformed, and stabilized in soils. Plant traits determine the quantity, depth, and chemistry of organic inputs, while microbial processes—including carbon use efficiency, necromass formation, and trophic interactions—mediate their transformation and partitioning among soil carbon pools. These biological pathways are shaped by soil physical and chemical properties, including aggregation, texture, and mineralogy, and by environmental drivers such as temperature, moisture, and disturbance, leading to context-dependent outcomes across landscapes. Management practices that diversify feedstocks, minimize disturbance, and maintain soil cover can promote both biomass production and C retention, while microbial amendments and rhizosphere engineering offer emerging, but often context-dependent, tools to optimize plant–microbe interactions. Trade-offs between biomass yield and soil carbon storage may arise when systems favor rapid aboveground productivity at the expense of belowground inputs and microbial processing, underscoring the importance of trait combinations that support both functions. Advances in monitoring, reporting, and verification—spanning precision agriculture, remote sensing, and biosensing—are improving predictive capacity through microbial-explicit process models and model–experiment (ModEx) frameworks. By connecting soil, plant, and microbial processes with advances in modeling and biosensing, this review outlines research priorities focused on trait-based parameterization and ModEx integration. These priorities will support the design of bioenergy systems that are both reliable and resilient, enhancing renewable energy production and ecosystem sustainability.

bioenergy systems↗
DOE OSTI2020

Parametric Design Study of a Power Electronics Package

The lifetime of a power electronics package is, to a large extent, determined by the reliability of its bonded interfaces under major loading conditions in an operational environment. Based on the application-level requirements of the package, bonded interface material is selected based on the results obtained from accelerated tests such as thermal cycling and power cycling. In addition to evaluating the reliability through accelerated tests, it is important to consider the impact of other component layers on the thermomechanical performance of the interface material, both from a material and geometric perspective. The co-efficient of thermal expansion (CTE) mismatch introduced by the use of different materials within a package and its structural design plays a critical role in determining the interface material reliability. In this paper, we present the results of a parametric modeling study of a power electronics package under thermal cycling in which the materials and geometric design of the different component layers were varied with respect to a baseline design to understand their impact on the reliability of the interface material. We chose the volume-averaged strain energy density per cycle computed at the corner region of the interface material as the metric for the reliability comparisons. Our results indicate that in addition to the CTE mismatch, the stiffness of individual component layers has a major impact on reliability. Among the different baseplates that we studied, aluminum silicon-carbide baseplates offered superior reliability over their copper and aluminum counterparts. We also found that the magnitude of the impact of stiffness variation—amongst the adjacent layers—on the reliability of the solder joint is dependent on the inherent CTE mismatch between the layers.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Transformational Solid Oxide Fuel Cell (SOFC) Technology

This project was conducted under the Co-operative Agreement No. DE-FE0027584 with the US Department Energy to developed advanced Solid Oxide Fuel Cell (SOFC) Technologies. The overall objective of this project was to advance SOFC technology at the cell and stack level to enhance cell robustness and durability, increase performance, and reduce balance-of-plant (BOP) requirements. By reducing system complexity combined with the increases in power density and efficiency, the ultimate goal of the project was to increased reliability and to reduce capital and operating costs of installed systems. The project was focused on pathways that will reduce the cost of the SOFC cell and stack, including the following areas: Robust, redox tolerant cell technology Lower cost cell manufacturing through advances in cell design, which will reduce the amount of material, energy and time used in the fabrication of SOFCs High performance, low temperature electrolyte based on improvement of established materials Innovative SOFC stack architecture which truly integrates Balance of Plant functionality into the stack level design Thermal management of the fuel cell stack for increased durability and expanded window of operation Novel stack design amenable for use in sub-MW to multi-MW-scale power plants and having low replacement cost The incorporation of balance-of-plant (BOP) equipment into the stack platform increased the economic viability of smaller scale systems. The project objectives were met by a multi-prong approach, including new cell design complemented with modifications to existing cell technology, as well as a new stack design incorporating components typically included in the BOP, such as heat exchangers, oxidizer, fuel reformers, and recycle systems. The project culminated with demonstration of a stack test validating the viability of the cell and stack improvements. A cost model was also developed to estimate costs for the advanced stack technology at high volume manufacturing levels. The net outcome of the project is SOFC cell and stack technology with costs significantly below current DOE targets without compromising and, in some cases, improving on the performance and degradation rate demonstrated with the current state-of-the-art stack design. The results of this project advanced the reliability, robustness, and endurance of low-cost SOFC technology that ultimately are ready to be deployed in coal power systems with greater than 60 percent efficiency (based on higher heating value of fuel) and the capability for ≥97% CO 2 capture at a cost-of-electricity that is approximately 40 percent below presently available Integrated Gasification Combined Cycle systems.

03 NATURAL GAS↗
DOE OSTI2023

Multiphysics simulations of Self-Regulating performance of an optimized molten metal fuel microreactor design

Advanced microreactors are expected to play an indispensable role in reliable energy solutions for civilian/ military applications in off-grid regions and space applications such as power supplies for Lunar and Mars bases. An innovative fast neutron spectrum heat pipe microreactor (HP-MR) concept was recently proposed with two unique features: molten U-Mn fuel and heat pipes as the heat removal mechanism. The microreactor was designed to be self-regulated, solely relying on reactivity feedbacks from fuel temperature. The reactor design has been further optimized to provide sufficient engineering safety margin and effective heat removal. In this study, the self-regulating performance of the optimized molten metal fuel microreactor was investigated by multi-physics simulations (neutronics, heat-transfer and heat pipe modeling) based on the MOOSE MultiApps system. In conclusion, the responses of the reactor to a series of transient scenarios were simulated to demonstrate the exceptional and inherent safety features of the novel microreactor concept.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Control Co-Design Studies for a 22 MW Semisubmersible Floating Wind Turbine Platform

We present a control co-design software framework that can be used to optimize floating wind turbines and their controllers. Because this framework has many options for design variables, constraints, and merit figures, along with modeling fidelity levels, we seek to demonstrate best practices for using the tool while designing a floating platform for the new 22 MW offshore reference wind turbine developed within the International Energy Agency Wind Technology Commercialization Programme 55 on Reference Wind Turbines and Farms. During these studies, we evaluate the use of different simulation fidelity levels, the effect of using different load cases for controller tuning, and the difference between sequential and simultaneous control co-design solutions. Based on these efforts, we suggest using an algorithm that performs an initial search of the design space before optimization. We find that solving smaller optimization problems, in a sequential manner, leads to more reliable outcomes in fewer iterations than larger, simultaneous control co-design solutions. However a simultaneous CCD solution produces a platform with a 2% lower mass than the sequential CCD outcome.

17 WIND ENERGY↗
DOE OSTI2026

Design and Validation of a Cryogenic Dilatometer

This project focuses on the design and development of a cryogenic dilatometer capable of measuring the thermal expansion of materials at extremely low temperatures. Understanding how materials change dimension with temperature is critical for applications involving cryogenic environments, particularly laminated systems housing superconducting magnets, where small dimensional changes can significantly affect performance and reliability. To address this, a dilatometer system was designed to operate within a liquid nitrogen environment while accurately measuring displacements caused by thermal contraction. The purpose of this device is to determine the coefficient of thermal expansion (CTE) of a material. The design process involved defining functional requirements, developing mechanical and thermal concepts for the measurement apparatus, selecting appropriate materials compatible with cryogenic temperatures, and integrating sensors capable of detecting small dimensional changes. The resulting system aims to provide a practical and repeatable method for evaluating material thermal expansion at cryogenic temperatures, supporting research into composite use in superconducting applications that require accurate characterization of material behavior in low-temperature environments.

Schmitt, Nicholas [Northern Illinois U.]↗
DOE OSTI2024

Measurement of Wind Loading on Heliostats at the Crescent Dunes Power Plant: An Overview

The cost of solar collectors constitutes almost one third of the total cost of a CSP plant. One of the ongoing challenges in the design of these collectors is wind loading on mirrors, support structures, and drives. A particular challenge is dynamic wind loading, caused by the turbulent wind flow. To date, the design of solar collector structures has relied on wind tunnel experiments and numerical simulations that do not entirely capture the dynamic effects observed at scale. The CSP industry has shown increased interest in validating the idealized assumptions with measurements obtained in operational settings to improve wind load assumptions and increase reliability and cost-efficiency of the collector design. Further, performance models need realistic assumptions about wind loading and its impact on optical performance. In a parabolic trough field campaign, NREL successfully collected a wealth of long-term, high-resolution wind and loads data [2], that are publicly available and that can be used for the above-mentioned purposes. Heliostats are impacted differently by wind than parabolic troughs, due to their different shape, size, and field layout. To study the impact of wind and turbulence on heliostats, we initiated another field campaign in an operational power- tower plant, Crescent Dunes, in Nevada, USA. In this work, we present an overview of the measurements, first results, and potential implications of wind driven loads on Heliostats.

concentrated solar power↗
DOE OSTI2025

Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines

Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗
DOE OSTI2022

Thermodynamic modeling of MDEA(aq)-NH 3 (aq)-K 2 CO 3 (aq)-CO 2 (aq) using the Extended UNIQUAC model

Here, the development of advanced processes for carbon dioxide capture requires reliable thermodynamic models to ensure accurate process design. This work presents an optimized parameter set of the Extended UNIQUAC model for advanced mixed solvent solutions containing CO 2 -MDEA-NH 3 -K 2 CO 3 in water. The model was parameterized using vapor–liquid equilibrium, pure component saturation pressure, excess enthalpy, heat of absorption, molar heat capacity, apparent molar heat capacity, and solid–liquid equilibrium. These thermal and equilibrium properties cover temperatures between 253.6 K to 600 K and pressures up to 75.6 bar. The current model represents an extension of previous versions that were suitable for modeling aqueous NH 3 and K 2 CO 3 solutions. This parametrization accounts for molecular interactions between MDEA and these two components, which allows for the design of advanced capture processes. This paper demonstrates that the new model parameters are valid within the range of operational conditions typically found in CO 2 capture processes.

42 ENGINEERING↗
DOE OSTI2020

Thermionic microwave gun for terahertz and synchrotron light sources

Conventional thermionic microwave and radiofrequency (RF) guns can offer high average beam current, which is important for synchrotron light and terahertz (THz) radiation source facilities, as well as for industrial applications. For example, the Advanced Photon Source at Argonne National Laboratory is a national synchrotron radiation light source research facility that utilizes thermionic RF guns. Yet, these existing thermionic guns are bulky, difficult to handle and install, easily detuned, very sensitive to thermal expansion, and are due for a major upgrade and replacement. Here, we present the design of a new, more stable and reliable gun with optimized electromagnetic performance, improved thermal engineering and a more robust cathode mounting technique, which is a critical step to improve the performance of existing and future light sources, industrial accelerators, and electron beam-driven terahertz sources. We will also present a fabricated gun prototype and show results of high-power and beam tests.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

A hardware-in-the-loop (HIL) testbed for cyber-physical energy systems in smart commercial buildings

In recent years, there has been a growing trend toward the development of smart buildings that rely on cyber-physical systems (CPS) to optimize occupant comfort, safety, and energy efficiency. To ensure the reliable and efficient operation of CPS with designed control strategies, it is important to evaluate their performance under various scenarios before deploying them in the real world. This is where a Hardware-in-the-loop (HIL) testbed designed for studying sensor and control-related studies in smart buildings can be highly valuable. With the growing threat of cyber-attacks and physical faults targeting smart buildings, it is essential to ensure the security of building operations. A HIL testbed can emulate cyber-attack and physical fault scenarios, allowing researchers to develop and test threat detection and mitigation algorithms. This enables researchers to identify potential issues and optimize the algorithms in a safe and controlled environment before they are deployed in real-world settings, reducing the risk of failures that can negatively impact occupant comfort, safety, and energy efficiency. Therefore, this paper developed a HIL testbed designed for cyber-physical energy systems (e.g. buildings automation system (BAS)) in smart commercial buildings. The HIL testbed is comprised of a real-time building and Heating, Ventilation, and Air-Conditioning (HVAC) emulator using Modelica-based dynamic models, a set of BAS controllers, and a BAS computer server. The data generation capability of the HIL testbed is demonstrated by tracking normal and faulty operating data in the BAS, as well as monitoring detailed network traffic in the local BAS network. Here, this study further demonstrates the HIL testbed’s capability by conducting case studies on real-time physical fault and cyber-attack experiments using a Department of Energy (DOE) prototype commercial building. It is anticipated that the fully functional HIL testbed will be utilized for a variety of sensor and control-related studies, including but not limited to testing, developing, validating of different HVAC control strategies, fault detection & diagnosis, energy monitoring and analysis, cyber security study, etc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Mechanistic modeling of lifetime distribution of SiC/SiC composite claddings

Silicon carbide (SiC) fiber-reinforced SiC matrix (SiC/SiC) composites have emerged as a new material candidate for fuel claddings in light water reactors. Recent studies showed that the load capacity of SiC/SiC materials exhibits a considerable statistical variation. Therefore, reliability analysis plays a critical role in design of SiC/SiC composite claddings. Here, this paper presents a probabilistic model for the lifetime distribution of SiC/SiC composites. The model is anchored by a multiaxial stress-based failure criterion and subcritical damage accumulation mechanism. Based on the kinetics of subcritical damage growth, the lifetime distribution of a laboratory test specimen for any given loading history can be calculated. A finite weakest-link model is used to extrapolate the lifetime distribution of test specimens to full-length claddings. It is shown that the damage accumulation mechanism has a strong influence on the lifetime distribution of the cladding. This finding highlights the importance of understanding the static fatigue behavior of SiC/SiC composites. The present analysis also demonstrates an intricate length effect on the failure probability of the cladding, which is expected to play a crucial role in design extrapolation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Experimental and Computational Investigation of Integrated Internal and Film Cooling Designs Incorporating a Thermal Barrier Coating

Abstract Few studies in the open literature have studied the effect of thermal barrier coatings (TBC) when used in combination with shaped hole film cooling and enhanced internal cooling techniques. The current study presents Reynolds-averaged Navier–Stokes (RANS) conjugate heat transfer simulations that identify trends in cooling design performance as well as experimental measurements of overall effectiveness using a flat-plate matched-Biot number model with a simulated TBC layer of 0.42D thickness, where D is the film cooling hole diameter. Coolant is fed to the film cooling holes in a co-flow configuration, and the results of both the smooth and rib-turbulated channels are compared. At a constant coolant flow rate, enhanced internal cooling was found to provide a 44% increase in spatially-averaged overall effectiveness, $\bar{\bar{\phi}}$, without a TBC. The results show that the addition of a TBC can raise $\bar{\bar{\phi}}$ on a film-cooled component surface by 47%. The optimum velocity ratio was found to decrease with the addition of enhanced cooling techniques and a TBC as the film provided minimal benefit at the expense of reduced internal cooling. While the computational results closely identified trends in overall system performance without a TBC, the model over-predicted effectiveness on the metal–TBC interface. The results of this study will inform turbine component design as material science advances increase the reliability of the TBC.

Engineering↗
DOE OSTI2021

Joint LLNL & SNL Material Compatibility Study Commences

The fundamental goal of the W80-4 Life Extension Program (LEP) is the design and production of a safe and reliable system. Ensuring long-term viability and chemical compatibility of the materials in the warhead is paramount to its success. To that end, the material and aging compatibility team, which includes researchers from Lawrence Livermore and Sandia National Laboratories (SNL), has launched the LEP’s most comprehensive compatibility test to date.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Feasibility Study of NSLS-II Sextupole BBA Measurement

In storage ring light sources, beam-based alignment (BBA) which adjusts the BPM centers to the quadrupole magnet centers is a common practice to maintain the machine performance. For more reliable and convenient BBA process, in the design of the storage ring, BPMs are located as close as possible to the quadrupoles. The most common method is scanning the position of the beam at the BPM (equivalently at the adjacent quadrupole) and find the position where the quadrupole strength change does not give change in the closed orbit. In the simulation of the feasibility test, we choose parameters, tune, orbit and phase advance and measure their variations depending on the sextupole offsets. Also, together with the real configuration of family, we simulate the individual power supply case for the comparisons. In this note, the simulation processes and the results are presented.

43 PARTICLE ACCELERATORS↗