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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Statement of Work: Toward AI-driven additive manufacturing for metal-ceramic composite structures

The project scope is to investigate the compatibility of various ceramic and metal powder composite feedstock development, implement AI algorithms for in-situ monitoring and parameter optimization of binder jet 3D printing to achieve reliable and robust metal/ceramic and/or ceramic/ceramic composite components, and create a generative design framework for heterogeneous composite structures incorporating metals and ceramic-based materials to achieve specific mechanical properties. Funded is the effort and travel by the faculty advisor at University of California Berkeley in support of the work of their students and the related collaborative research and development effort.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

FuSED Users Manual, 5.24

The Fusion of Simulation, Experiment, and Data (FuSED) team provides a set of tools for solving inverse problems in structural dynamics and thermal physics, and also sensor placement optimization via Optimal Experimental Design (OED). These methods are used for designing experiments, model calibration, and verification/validation analysis of systems. This document provides a user’s guide to the input for the three apps that are supported for these methods. Details of input specifications, output options, and optimization parameters are included.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

High-Throughput Characterization Tools/Algorithms To Outline Porosity Variability in AM Samples as a Function of Processing Conditions

This report documents the development and deployment of advanced algorithms and tools that enable high-throughput characterization for metal additive manufacturing (AM), with a particular focus on process parameter optimization and material/part qualification for nuclear applications. While the method ologies presented support diverse characterization techniques, the majority of the work is centered on AI-driven algorithms for X-ray computed tomography (XCT) to accelerate defect detection and materials analysis at scale.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development of a high fidelity CFD model for solvent evaporation and transport in porous structure during battery electrode drying

An efficient battery manufacturing process is the key to the mass production of Electric Vehicles (EV), in which drying is one of the most energy-intensive steps significantly influencing the battery cell performance. An accurate 3D CFD model for drying is essential for predicting the drying mechanism and optimizing its parameters. By optimizing the drying process, it is possible to reduce energy consumption and cost during battery manufacturing, minimize binder loading and maximize active material loading to achieve superior electrochemical performances and facilitate wider and faster public adoption of EV. This project aims to optimize the drying process during electrode manufacturing by leveraging high-fidelity, porous electrode simulations for solvent evaporation. By optimizing this process, we seek to reduce energy consumption during battery manufacturing, while minimizing binder loading and maximizing active material loading, with the overall goal of enhancing electrical vehicle performance.

Horner, Jeffrey Scott [Sandia National Laboratorie↗
DOE OSTI2020

The Convolutional Multiple Whole Profile (CMWP) Fitting Method, a Global Optimization Procedure for Microstructure Determination

The analysis of line broadening in X-ray and neutron diffraction patterns using profile functions constructed on the basis of well-established physical principles and TEM observations of lattice defects has proven to be a powerful tool for characterizing microstructures in crystalline materials. These principles are applied in the convolutional multiple-whole-profile (CMWP) procedure to determine dislocation densities, crystallite size, stacking fault and twin boundary densities, and intergranular strains. The different lattice defect contributions to line broadening are separated by considering the hkl dependence of strain anisotropy, planar defect broadening and peak shifts, and the defect dependent profile shapes. The Levenberg–Marquardt (LM) peak fitting procedure can be used successfully to determine crystal defect types and densities as long as the diffraction patterns are relatively simple. However, in more complicated cases like hexagonal materials or multiple-phase patterns, using the LM procedure alone may cause uncertainties. Here, we extended the CMWP procedure by including a Monte Carlo statistical method where the LM and a Monte Carlo algorithm were combined in an alternating manner. The updated CMWP procedure eliminated uncertainties and provided global optimized parameters of the microstructure in good correlation with electron microscopy methods.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Oxygen Reduction at PtNi Alloys in Direct Methanol Fuel Cells—Electrode Development and Characterization

Catalyst layers made from novel catalysts must be fabricated in a way that the catalyst can function to its full potential. To characterize a PtNi alloy catalyst for use in the cathode of Direct Methanol Fuel Cells (DMFCs), the effects of the manufacturing technique, ink composition, layer composition, and catalyst loading were here studied in order to reach the maximum performance potential of the catalyst. For a more detailed understanding, beyond the DMFCs performance measurements, we look at the electrochemically active surface area of the catalyst and charge-transfer resistance, as well as the layer quality and ink properties, and relate them to the aspects stated above. As a result, we make catalyst layers with optimized parameters by ultrasonic spray coating that shows the high performance of the catalyst even when containing less Pt than commercial products. Using this approach, we can adjust the catalyst layers to the requirements of DMFCs, hydrogen fuel cells, or polymer electrolyte membrane electrolysis cells.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Study of the Printability, Microstructures, and Mechanical Performances of Laser Powder Bed Fusion Built Haynes 230

The nickel-based superalloy, Haynes 230 (H230), is widely used in high-temperature applications, e.g., heat exchangers, because of its excellent high-temperature mechanical properties and corrosion resistance. As of today, H230 is not yet in common use for 3D printing, i.e., metal additive manufacturing (AM), primarily because of its hot cracking tendency under fast solidification. The ability to additively fabricate components in H230 attracts many applications that require the additional advantages leveraged by adopting AM, e.g., higher design complexity and faster prototyping. In this study, we fabricated nearly fully dense H230 in a laser powder bed fusion (L-PBF) process through parameter optimization. The efforts revealed the optimal process space which could guide future fabrication of H230 in various metal powder bed fusion processes. The metallurgical analysis identified the cracking problem, which was resolved by increasing the pre-heat temperature from 80 °C to 200 °C. A finite element simulation suggested that the pre-heat temperature has limited impacts on the maximum stress experienced by each location during solidification. Additionally, the crack morphology and the microstructural features imply that solidification and liquation cracking are the more probable mechanisms. Both the room temperature tensile test and the creep tests under two conditions, (a) 760 °C and 100 MPa and (b) 816 °C and 121 MPa, confirmed that the AM H230 has properties comparable to its wrought counterpart. The fractography showed that the heat treatment (anneal at 1200 °C for 2 h, followed by water quench) balances the strength and the ductility, while the printing defects did not appreciably accelerate part failure.

14 SOLAR ENERGY↗
DOE OSTI2024

Unraveling Electronic and Vibrational Coherences Following a Charge Transfer Process in a Photosystem II Reaction Center

A reaction center is a unique biological system that performs the initial charge separation within a Photosystem II (PSII) multiunit enzyme, which eventually drives the catalytic water-splitting in plants and algae. The possible role of quantum coherences coinciding with the energy and charge transfer processes in PSII reaction center is one of the active areas of research. Here, we study these quantum coherences by using a numerically exact method on an excitonic dimer model, including linear vibronic coupling and employing optimal parameters from experimental two-dimensional coherent spectroscopic measurements. This enables us to precisely capture the excitonic interaction between pigments and the dissipation of the energy from electronic and charge-transfer (CT) states to the protein environment. We employ the time nonlocal (TNL) quantum master equation to calculate the population dynamics, which yields numerically reliable results. The calculated results show that, due to the strong dissipation, the lifetime of electronic coherence is too short to have direct participation in the charge transfer processes. However, there are long-lived vibrational coherences present in the system at frequencies close to the excitionic energy gap. These are strongly coupled with the electronic coherences, which makes the detection of the electronic coherences with conventional techniques very challenging. Additionally, we unravel the strong excitonic interaction of radical pair (PD1 and PD2) in the reaction center, which results in a long-lived electronic coherence of >100 fs, even at room temperature. Our work provide important physical insight to the charge separation process in PSII reaction center, which may be helpful for better understanding of photophysical processes in other natural and artificial light-harvesting systems.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Systematically tracking the hourly progression of large wildfires using GOES satellite observations

Abstract. In the western United States, prolonged drought, a warming climate, and historical fuel buildup have contributed to larger and more intense wildfires as well as to longer fire seasons. As these costly wildfires become more common, new tools and methods are essential for improving our understanding of the evolution of fires and how extreme weather conditions, including heat waves, windstorms, droughts, and varying levels of active-fire suppression, influence fire spread. Here, we develop the Geostationary Operational Environmental Satellites (GOES)-Observed Fire Event Representation (GOFER) algorithm to derive the hourly fire progression of large wildfires and create a product of hourly fire perimeters, active-fire lines, and fire spread rates. Using GOES-East and GOES-West geostationary satellite detections of active fires, we test the GOFER algorithm on 28 large wildfires in California from 2019 to 2021. The GOFER algorithm includes parameter optimizations for defining the burned-to-unburned boundary and correcting for the parallax effect from elevated terrain. We evaluate GOFER perimeters using 12 h data from the Visible Infrared Imaging Radiometer Suite (VIIRS)-derived Fire Event Data Suite (FEDS) and final fire perimeters from the California's Fire and Resource Assessment Program (FRAP). Although the GOES imagery used to derive GOFER has a coarser resolution (2 km at the Equator), the final fire perimeters from GOFER correspond reasonably well to those obtained from FRAP, with a mean Intersection-over-Union (IoU) of 0.77, in comparison to 0.83 between FEDS and FRAP; the IoU indicates the area of overlap over the area of the union relative to the reference perimeters, in which 0 is no agreement and 1 is perfect agreement. GOFER fills a key temporal gap present in other fire tracking products that rely on low-Earth-orbit imagery, where perimeters are available at intervals of 12 h or longer or at ad hoc intervals from aircraft overflights. This is particularly relevant when a fire spreads rapidly, such as at maximum hourly spread rates of over 5 km h−1. Our GOFER algorithm for deriving the hourly fire progression using GOES can be applied to large wildfires across North and South America and reveals considerable variability in the rates of fire spread on diurnal timescales. The resulting GOFER product has a broad set of potential applications, including the development of predictive models for fire spread and the improvement of atmospheric transport models for surface smoke estimates. The resulting GOFER product has a broad set of potential applications, including the development of predictive models for fire spread and the improvement of atmospheric transport models for surface smoke estimates (https://doi.org/10.5281/zenodo.8327264, Liu et al., 2023).

Geology↗
DOE OSTI2022

The impact of hurricane disturbances on a tropical forest: implementing a palm plant functional type and hurricane disturbance module in ED2-HuDi V1.0

Hurricanes commonly disturb and damage tropical forests. Hurricane frequency and intensity are predicted to change under the changing climate. The short-term impacts of hurricane disturbances to tropical forests have been widely studied, but the long-term impacts are rarely investigated. Modeling is critical to investigate the potential response of forests to future disturbances, particularly if the nature of the disturbances is changing with climate. Unfortunately, existing models of forest dynamics are not presently able to account for hurricane disturbances. Therefore, we implement the Hurricane Disturbance in the Ecosystem Demography model (ED2) (ED2-HuDi). The hurricane disturbance includes hurricane-induced immediate mortality and subsequent recovery modules. The parameterizations are based on observations at the Bisley Experimental Watersheds (BEW) in the Luquillo Experimental Forest in Puerto Rico. We add one new plant functional type (PFT) to the model – Palm, as palms cannot be categorized into one of the current existing PFTs and are known to be an abundant component of tropical forests worldwide. The model is calibrated with observations at BEW using the generalized likelihood uncertainty estimation (GLUE) approach. The optimal simulation obtained from GLUE has a mean relative error of –21 %, –12 %, and –15 % for stem density, basal area, and aboveground biomass, respectively. The optimal simulation also agrees well with the observation in terms of PFT composition (+1 %, –8 %, –2 %, and +9 % differences in the percentages of “Early”, “Mid”, “Late”, and “Palm” PFTs, respectively) and size structure of the forest (+0.8 % differences in the percentage of large stems). Lastly, using the optimal parameter set, we study the impact of forest initial condition on the recovery of the forest from a single hurricane disturbance. The results indicate that, compared to a no-hurricane scenario, a single hurricane disturbance has little impact on forest structure (+1 % change in the percentage of large stems) and composition (<1 % change in the percentage of each of the four PFTs) but leads to 5 % higher aboveground biomass after 80 years of succession. The assumption of a less severe hurricane disturbance leads to a 4 % increase in aboveground biomass.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Heat Pump Retrofits for Central Plant Hydronic Heating Systems: A Software Toolkit for Screening and Design

Retrofitting existing central plants with high-efficiency heat pump technologies can play a crucial role in achieving long-term planning goals. Modern heat pump technologies are able to use waste heat recovery to meet a building's heating demand, but there is a lack of accessible tools designed for non-HVAC experts, such as building owners, to quickly and easily conduct what-if analysis, e.g., estimating retrofit costs and payback period for their partial or full equipment replacement. This paper introduces an open-source software toolkit designed to facilitate the initial screening and decision-making of heat pump retrofits in existing central plants using a building's yearly load profile from metered or utility bill data. The toolkit evaluates the technical and economic viability of replacing traditional central plant equipment with various options including water-to-water or air-to-water heat pumps, which can provide efficient and lower-cost heating and cooling. It allows users to compare current central plant configurations with retrofit scenarios, assessing energy consumption, life-cycle costs, and environmental impact. The toolkit offers (1) a web-based tool designed for user-friendly access by a broad audience and (2) Python-based source code for researchers and engineers conducting parametric studies and design parameter optimization. The toolkit compares a typical central plant configuration to a configuration that uses a heat pump to supply hydronic heating and cooling. The output metrics include energy consumption and output of each equipment, life-cycle cost analyses and metrics, and environmental impact of the system.

Excell, L↗