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DOE OSTI2025

EVSE Characterization: V2G EVSE Comparison

As part of the U.S. Department of Energy EVs@Scale consortium Next-Generation Profiles project, results and analysis from the characterization of high-power conductive and wireless charging infrastructure are presented. This characterization is conducted over a wide range of direct current (DC) current and DC voltage operation for nominal test conditions and off-nominal test conditions. Test plans and procedures were developed to define the test configurations and requirements, measurement parameters, and test procedures used throughout testing. Results from a 2024 study conducted on electric vehicle supply equipment (EVSE) characterization by the Idaho National Laboratory (INL) include two bi-directional vehicle-to-grid (V2G) capable EVSEs. These EVSE are referred to as V2G-EVSE9 and V2G-EVSE10. Laboratory testing is conducted at nominal test conditions to characterize the power transfer capabilities, efficiency, power factor, and other power quality metrics of the two DC EVSEs capable of V2G bi-directional power transfer. Results from testing show the performance is consistent for V2G-EVSE9 and V2G-EVSE10 when comparing charging to discharging performance, except for V2G-EVSE10 for power transfer when operating above 70% of the rated DC current. V2G-EVSE10 efficiency is >98% while charging and <91% while discharging at the same operating conditions, near maximum-rated current, at 300VDC. In contrast, V2G-EVSE9 results are consistent for charging and discharging. This EVSE is nearly 96% efficient while charging or discharging when operating over 50% of rated AC power. V2G EVSE performance is also characterized during off-nominal AC grid conditions involving AC voltage deviation (426 VAC to 518 VAC), AC frequency deviation of +2% (58.8 Hz to 61.2 Hz), and AC voltage harmonics injection. Many test conditions have little-to-no impact on performance characteristics of the two EVSEs; however, there are a few notable findings with significant power transfer capability impacts. AC voltage harmonics injection resulted in negative impacts on power quality attributes for both EVSEs, but with no impact on power transfer capability. Off-nominal AC voltage and frequency conditions resulted in unstable or lack of power transfer capability for both EVSEs. V2G-EVSE9 is unable to transfer power when AC voltage is >300V L-N. V2G-EVSE10 is unable to transfer power when AC frequency deviation exceeds +0.8%. V2G energy management system transient response and latency are quantified during laboratory testing. V2G-EVSE9 and V2G-EVSE10 utilize cloud-based V2G energy management systems that command the power transfer level between the EVSE and EV. The latency and response characteristics of the entire systems (web-based user interface, V2G energy management system, cellular communications, and EVSE response) are quantified through laboratory testing for V2G-EVSE9 and V2G-EVSE10. V2G-EVSE9 latency ranges from 0.8 to 1.8 seconds, whereas V2G-EVSE10 latency ranges from 3.4 to 8.8 seconds. The ramp rate to a change in power transfer request also differs between the two EVSEs. V2G-EVSE10 ramp rate ranges from 50% to -250% of rated AC power per second, whereas V2G-EVSE9 rate ranges from 95% to -95% of rated AC power per second. At the highest rate of change in power transfer, V2G-EVSE10 can change from full charge power to full discharge power in less than one second. The V2G EVSE characterization presented in this report provides valuable insights and results for use by numerous entities. This includes modeling and simulation organizations, decision makers, fleet planning, industry stakeholders, and many others involved with the development and deployment of electrified transportation technologies. Additional high-power DC chargers, bidirectional chargers, and inductive power transfer EVSE characterization results are anticipated from additional EVSE brands and models, which will be detailed in future publications in support of the U.S. Department of Energy EVs@Scale consortium Next-Gen Profiles project.

25 ENERGY STORAGE↗

DOE OSTI2024

Wrought FeCrAl alloy (C26M) cladding behavior and burst under simulated loss-of-coolant accident conditions

Cladding burst experiments for FeCrAl cladding were performed in the Severe Accident Test Station facility at Oak Ridge National Laboratory. These experiments were simulated using the BISON fuel performance code to better understand the cladding plastic behavior and failure under simulated loss-of-coolant accident conditions. 3D cladding surface boundary conditions were generated using composite axial and azimuthal profiles from experiment thermocouple data. To improve the simulation analysis capabilities in BISON for cladding burst behavior, new thermal creep, plasticity, and failure stress models specific to C26M, a wrought FeCrAl alloy, were developed and implemented. Initial cladding burst results indicated a general underprediction in the failure temperature of the six cladding burst simulations versus the observed failure temperatures. Close investigation of the experiment timing versus the underlying tensile test data revealed that, compared with the tensile specimens, the cladding tubes did not experience the same long holding time at high temperatures. New tensile tests were performed at high temperatures using a temperature ramp similar to the simulated loss-of-coolant accident experiments. These new tensile curves showed an approximately 80% increase in the ultimate tensile strength of the C26M alloy, indicating that a holding time of 10 min at 700 °C and 800 °C allows annealing to change the material microstructure. Using the updated tensile properties, the burst temperatures and stresses from the simulations showed remarkable agreement with the experimental results. This study was then extended by varying the initial pressure to highlight the burst temperature difference between standard Zircaloy-4 and C26M cladding under equivalent conditions. The results show that C26M has a burst temperature that is approximately 70–130 K greater than that of Zircaloy-4. In conclusion, these modeling predictions can be further improved by collecting high-temperature tensile data for C26M beyond the temperature ranges used in this work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Metal–Oxide Interface Sites Created Using Atomic Layer Deposition and Tested for CO Oxidation

The performance of catalysts made out of Pt supported on TiO 2 thin films grown on SBA-15 (a silica mesoporous material) by atomic layer deposition (ALD) was characterized systematically by combining in situ infrared absorption spectroscopy (IR) with other techniques including electron microscopy and adsorption−desorption isothermal measurements. The titania films in the resulting high-surface-area catalysts were evenly distributed throughout the inner surface of the SBA-15 mesopores, and their thickness could be controlled at a submonolayer level, with 3 to 4 TiO 2 ALD cycles needed for the complete coverage of the silica sites. The titania films could be deposited either before or after adding the metal (Pt), which was dispersed in the form of small nanoparticles (NPs) approximately 4−6 nm in diameter, in order to exert some control on the density and nature of the Pt/TiO 2 interface sites. One important lesson deriving from this work is that such an order of deposition leads to significantly different catalysts in spite of the fact that most of their structural properties are similar. If the Pt is deposited on the titania films, the resulting metal NPs are slightly smaller than those grown on silica and display CO adsorption sites with lower surface Pt coordination numbers. On the other hand, when TiO 2 is deposited on the Pt/SBA-15 starting material, some titania grows on the metal and partially blocks its surface while also creating new interface sites where CO binds more weakly and displays lower C−O stretching frequencies. In terms of catalytic performance, the results from in situ IR CO site titration and kinetic measurements combined suggest a mechanism where CO first adsorbs on Pt atop sites and then migrates to Pt/TiO 2 interface sites, where oxidation takes place. Both types of sites appear to be similar in all the catalysts tested, but catalytic performance could be optimized by tuning their surface densities. Maximum catalytic activity was obtained when the TiO2 films were deposited first and with TiO 2 coverages of at least half a monolayer, that is, after at least 2 ALD cycles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

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

Resumption of SFR Overpower Testing and Post-Transient Examination of the THOR-C-2 Irradiation Test

Transient overpower testing for fuel safety research and development has resumed at Idaho National Laboratory. The THOR-C-2 commissioning test has been performed and post-transient examination has been performed revealing the intended failure near the top of the fuel zone. This paves the way for future testing on previously irradiated fuels that will support fuel development and qualification.

advanced reactors↗

DOE OSTI2024

The ASSIST trial: Acute effects of manipulating strength exercise volume on insulin sensitivity in obese adults: A protocol for a randomized controlled, crossover, clinical trial

Type 2 diabetes mellitus is a disease in which insulin action is impaired, and an acute bout of strength exercise can improve insulin sensitivity. Current guidelines for strength exercise prescription suggest that 8 to 30 sets could be performed, although it is not known how variations in exercise volume impact insulin sensitivity. Additionally, this means an almost 4-fold difference in time commitment, which might directly impact an individual’s motivation and perceived capacity to exercise. This study will assess the acute effects of high- and low-volume strength exercise sessions on insulin sensitivity. After being thoroughly familiarized, 14 obese individuals of both sexes (>40 year old) will undergo 3 random experimental sessions, with a minimum 4-day washout period between them: a high-volume session (7 exercises, 3 sets per exercise, 21 total sets); a low-volume session (7 exercises, 1 set per exercise, 7 total sets); and a control session, where no exercise will be performed. Psychological assessments (feeling, enjoyment, and self-efficacy) will be performed after the sessions. All sessions will be held at night, and the next morning, an oral glucose tolerance test will be performed in a local laboratory, from which indexes of insulin sensitivity will be derived. We believe this study will aid in strength exercise prescription for individuals who claim not to have time to exercise or who perceive high-volume strength exercise intimidating to adhere to. This trial was prospectively registered.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2024

Resumption of SFR Overpower Testing and Post-Transient Examination of the THOR-C-2 Irradiation Test

Transient overpower testing for fuel safety research and development has resumed at Idaho National Laboratory. The THOR-C-2 commissioning test has been performed and post-transient examination has been performed revealing the intended creep rupture failure near the top of the fuel zone. This paves the way for future testing on previously irradiated fuels that will support fuel development and qualification.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Ducted Fuel Injection And Cooled Spray Technologies For Particulate Control In Heavy-duty Diesel Engines (Final Report)

Cooled Spray (CS) and Ducted Fuel Injection (DFI) are in-cylinder technologies for diesel engines that can reduce particulate matter and soot emissions and data has been published showing that these technologies can reduce soot emissions by 75-100% for some engines at some operating conditions. However, little is known about scaling the devices for engine size. Additionally, the performance of either technology over the engine duty cycle has not been explored. This project addresses both of these points through single-cylinder engine investigations. The objectives of this project are to provide details about dimensional scaling of these devices and to demonstrate 75% PM reduction over a range of operating conditions on a single-cylinder engine. Two engines were used for this project: a 125mm bore optically accessible engine at Sandia National Laboratories and a 168mm bore metal engine at Southwest Research Institute. The optical engine was used to study the performance of DFI and CS inserts for a large injector orifice diameter injector that is characteristic of a locomotive engine and to perform scaling studies for DFI. The metal engine was used to perform scaling and alignment studies for CS and to evaluate the technology for both EGR and non-EGR engines over the engine operating map. Modifications were required for both engines to accept the prototype inserts being tested. The optical engine required a new fuel injector, cylinder head and piston so that tests could be run at the pressures and engine speeds required. Additionally, a novel rotating stage was designed for the optical engine to simplify alignment of the modules. The metal engine required a modified cylinder head to accept CS inserts and a modified piston to provide additional space around the fuel injector for the CS inserts. Tests on the optical engine showed that DFI reduces PM emissions for both small injector orifices (0.170mm diameter) and large injector orifices (0.290mm). For high load testing, the DFI modules were not as effective as at low load testing, but it was acknowledged that minimal geometric optimization was performed and more improvements may be possible. Comparing DFI to CS and conventional diesel combustion (CDC), DFI performed better than CS or CDC. The CS geometries used in these studies may not be ideal for that engine and additional modifications likely would improve performance. Tests on the metal engine showed PM reductions as high has 80% at some operating conditions with duty-cycle PM reductions of ~50% for EGR and non-EGR configurations. The CS testing on the metal engine showed that chamfering of the fuel passage inlet either through hydro-erosion or mechanical grinding provided significant improvements in the PM reduction capabilities of the insert. Additionally, alignment sensitivities were explored and the data show that the tolerance to misalignment is approximately 0.05 to 0.1mm for the inserts that were studied here. Air-fuel ratio was shown to be important in the effectiveness of the CS inserts. In several tests, it was shown that the CS inserts are more effective at reducing the PM for high-AFR operating conditions compared to low AFR conditions. In summary, multiple designs were evaluated on both engines. It was found that for the conditions and configurations studied here, a fuel passage diameter of ~2.5mm performed best overall. Significant duty-cycle PM reductions are possible using these technologies and sensitivities to AFR, alignment fuel passage diameter and inlet fuel passage shaping were explored and are reported here. More PM reduction may be possible with improved geometric design and attention to alignment practices.

02 PETROLEUM↗

DOE OSTI2024

Compositional Variation Tests on DuraMelter 100 with LAW Sub-Envelope C1 Feed (LAWC22 Glass) in Support of the LAW Pilot Melter (Final Report)

This report provides the results from tests that were performed on a DM100 system with LAW Sub-Envelope Cl and Al feeds in support of the subsequent Pilot Melter tests. The principal objectives of the DM100 tests were to determine the processing characteristics as the simulated melter feed transitioned from the LAW Sub-Envelope Cl to the Sub-Envelope Al composition and to determine the effect of bubbling rate on production rate.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

UL 1741SC Conformance Development, Evaluation, and Proposal [Slides]

V2G AC is a type of grid interconnection by mobile battery that transforms an EV into a DER with the potential to stabilize the grid and lower costs for electricity. UL 1741SC is a critical new standard to enable grid interconnection of V2G AC-capable vehicles, by defining requirements for V2G AC-intended EVSEs as a gatekeeper between the grid and the EV to support grid safety, such as through redundant voltage trip (namely oversight). EVSE manufacturers need a clear set of conformance test cases and criteria by which to evaluate their equipment and confirm the compliance with UL 1741SC, so that the EVSEs performs as intended for the grid safety. Hence, NLR identified necessary conformance tests and performed the tests identified to understand the maturity.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

PARET/ANL (V.7.7) Verification and Validation Report

This report documents the software testing which has been performed for the PARET/ANL version 7.7 software. The software testing is based on code capabilities identified by research reactor analysts as frequently used in their safety analyses. The verification and validation procedures have been performed and documented to address the steady-state capabilities of the software, as described in Chapter 2, and the transient capabilities, as described in Chapter 3. Testing based on the comparison between PARET/ANL calculations and analytical solutions, hand calculations, or other code calculations of the test cases confirms that all the identified capabilities of the software were implemented correctly. In addition, results from code comparisons against SPERT-I and SPERT-IV experiments for various flow rates are reported for the peak power, energy release and cladding surface temperature. The comparisons showed overall good agreement for the peak power and conservative predictions of the cladding surface temperature

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

PARET/ANL v7.7 Verification and Validation Report

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Research, Development and Demonstration of Advanced Vehicle Technologies in Clean Motor Fuels (CRADA Final Report)

NREL/DOE has been funding research, development, and demonstration (RD&D) projects to facilitate the deployment of alternative fuels into the marketplace in order to achieve three objectives: 1) enhance the reduction of mobile source emissions in California and the U.S.; 2) increase U.S. competitiveness and economic prosperity; and 3) preserve the environment through the reduction of emissions and toxins from the motor vehicle population. The Lewis-Presley Air Quality Management Act requires the South Coast Air Quality Management District to establish a program to encourage participation in projects to increase the utilization of clean-burning fuels. The parties seek to collaborate on a joint RD&D project to perform a field test on a small vehicle fleet operating on Fischer-Tropsch synthetic diesel fuel. Recently the 106th U.S. Congress designated "gas-to-liquid" (GTL) transportation fuels that are produced from domestic products as alternative fuels under the Energy Policy Act of 1992 (EPACT). Niche markets could develop quickly for these fuel products, perhaps especially for the use of Fischer-Tropsch synthetic fuels in centrally fueled vehicle fleets in California. NREL and its project partners from the U.S. Department of Energy and West Virginia University have recently conducted what we believe to be the first-ever controlled tests of Fischer-Tropsch synthetic fuels in heavy vehicles. These tests have shown that Fischer-Tropsch fuels can be substituted in unmodified trucks and buses without any detectable loss in drivability and performance. Compared to a California diesel fuel baseline, neat Shell Fischer-Tropsch fuel emitted about 12% lower NOx and 24% lower particulate matter over a five-mile driving route while maintaining the same fuel economy on an energy equivalent basis. Whereas these exhaust emissions reductions from these previous studies have been impressive, far greater exhaust emissions reductions can be achieved if the vehicles are retrofitted with emissions control technologies that are enabled by Fischer-Tropsch fuels. For this program, a test fleet would be selected and retrofitted with continuously regenerating traps (CRT’s) or diesel particulate filters (DPF's). The University of West Virginia, under a separate subcontract to SCAQMD will have the responsibility to test and measure the emissions from the test fleet of vehicles.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Draft Impacts: Modeling and Lab Validation (CRADA Final Report)

Chimney draft is a significant source of variability in real-world wood heater performance, yet laboratory tests conducted for certification do not capture this variability. Because draft varies with climate, chimney height, and home conditions, a heater that performs well in the lab can perform quite differently when installed in a home. Until now, wood heater manufacturers and installers have lacked the tools needed to anticipate how draft will vary across real installations or to advise on corrective measures when draft is too low or too high. The goal of this project was to develop and validate an open-source draft prediction tool for cordwood heater chimney systems. Over 18 months, Lawrence Berkeley National Laboratory (LBNL) and the Hearth, Patio & Barbecue Association (HPBA) collaborated to build a physics-based, Python tool that predicts how chimney draft evolves during operation, from ignition through steady burning. HPBA convened a stakeholder group of manufacturers and venting experts who provided feedback throughout development. LBNL validated the tool against laboratory measurements from a catalytic and a non-catalytic cordwood heater operated across a range of chimney heights and room-pressure conditions.

42 ENGINEERING↗

DOE OSTI2025

Design and Flow Considerations of Additively Manufactured, Internal Cooling Geometries for Small Industrial Gas Turbines

Additive manufacturing is now a mainstream technology and can be utilized to rapidly develop and test turbine airfoil cooling networks. This paper reports on an ongoing effort to integrate advanced internal cooling architectures in a realistic blade profile for test in a high-speed cascade. Airfoil cooling schemes were developed using reduced order modeling and computer aided design. However, the additive manufacturing impacts on cooling channel flow performance were unknown. Test articles consisting of typical cooling features and networks were derived from the designs and flow proved to identify additive manufacturing impacts on performance and develop guidelines to mitigate these impacts.

additive manufacturing↗

DOE OSTI2026

The NREL Sensor Laboratory Detection of Hydrogen Emissions

The development of a functional hydrogen detection system is a multifaceted process that integrates hardware, deployments strategies, and analytics which can be supported by the NREL Sensor Laboratory: 1. Support of the design, validation and optimization of sensing prototypes; 2. Guide optimized sensing element development, including control electronics; 3. Laboratory testing to validate/optimize metrological performance (measurement range, detection limit, etc.); 4. Provide test sites for field deployments representative of real-world scenarios with controlled hydrogen releases; 5. Develop sensor placement and operation guidance; 6. Provide guidance on electronics to accommodate facility integration; 7. Electrical safety designs to allow for operation within restricted zones; 8. Integration into facility monitoring and control systems; 9. Guide incorporation of cyber security elements to protect facilities from malicious attacks; 10. Modeling and application of advanced analytics to detect and quantify emissions; 11. Higher Order dispersion models to guide sensor placement for reliable detection; 12. Advanced analytics for improved metrological performances, and to inform inverse modeling; 13. Market support and commercialization (national and international markets); 14. Commercial deployments in H2@SCALE markets (e.g., HUBs and other large-scale hydrogen markets); and 15. Leverage off international collaborations/partnerships (e.g., NREL is on the advisory board for the European initiative "pre-Normative Research on Hydrogen Releases Assessment"-NHyRA).

08 HYDROGEN↗

DOE OSTI2025

Initial assessment of alternative carbon fiber geometries for design of cost-effective compressive performance: Size effect studies

Carbon fiber provides opportunity to reduce weight in structural composites, including wind turbine blades, due to the material's superior specific stiffness and specific strength compared to alternatives. Despite these advantages, cost and compressive performance are considered weaknesses for carbon fiber products available today. Studies to produce low-cost carbon fiber alternatives, including the use of textile-derived precursor systems, have shown progress and merit through the DOE/ORNL low-cost carbon fiber initiatives. Here, this work focuses on enabling increases in compressive strength through design of the carbon fiber geometry, applicable to both textile and conventional precursor systems, while also providing opportunities to reduce carbon fiber processing costs. Fiber-resin interface and fiber alignment are among the most frequently cited factors controlling composite compressive performance. However, it is believed that there is opportunity in traditionally unexplored routes to increasing compressive strength through alteration of the carbon fiber geometry by increasing the fiber area moment of inertia and/or the fiber perimeter and interfacial area. This paper presents initial results from manufacturing carbon fiber materials to assess the impacts of carbon fiber size on tested composite compressive performance with projected neutral or even beneficial impact on fiber and composite manufacturing economics. Carbon fiber systems with increasing size illustrate a favorable correlation for compressive performance greater than predicted from a micromechanical failure model. The manufacturing and mechanical test results support the hypothesis of this work that alterations to fiber geometry can be used to produce improvements of the compressive strength of carbon fiber reinforced polymers and provide incentive for related work in designing alternative shapes to further enhance compressive performance.

42 ENGINEERING↗

DOE OSTI2025

First Results from a Nb3Sn-Coated 1.5-Cell 650 MHz SRF Cavity for Cryogen-Free Industrial Accelerators

First Results from a Nb3Sn-Coated 1.5-Cell 650 MHz SRF Cavity for Cryogen-Free Industrial Accelerators ABSTRACT = Fermilab is advancing the development of a compact, high-power electron beam accelerator using superconducting radio frequency (SRF) technology as a non-radioactive alternative to traditional radiological sources. The current design targets continuous-wave (CW) operation at \SI{1.6}{MeV} and \SI{20}{kW}. To ensure suitability for industrial environments, the system is being designed for cryogen-free operation, driving the adoption of a novel Nb$_3$Sn-coated 1.5-cell SRF cavity operating at \SI{650}{MHz}. This contribution reports on the fabrication, surface preparation, and Nb$_3$Sn coating process of the cavity, as well as first results from vertical test stand (VTS) measurements performed in a liquid helium bath. These initial tests mark a key milestone toward demonstrating the viability of conduction-cooled Nb$_3$Sn SRF cavities for industrial-scale deployment.

Tagdulang, N. [Fermilab]↗