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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

Preliminary System Interface Failure Mode Analysis for Two Advanced Reactors

This study explores two distinct Balance of Plant (BOP) configurations: the Rankine cycle for a sodium-cooled fast reactor (SFR) and the Brayton cycle for a gas-cooled reactor (GCR). As representative designs, the Power Reactor Innovative Small Module (PRISM) by GE Hitachi Nuclear Energy was selected for the SFR, while the Gas Turbine Modular Helium Reactor (GT MHR) by General Atomics was chosen for the gas-cooled reactor. Both configurations were adapted to deliver high-quality heat for industrial applications. A Failure Modes and Effects Analysis (FMEA) was conducted for each system to identify critical failure modes affecting key components. This study marks the first phase of a two-step design optimization approach, integrating FMEA into the design process. Based on the analysis, design modifications and mitigation strategies were proposed to enhance system resilience. The second phase, to be detailed in a subsequent report, will focus on the role of the control system in mitigating these failures. The FMEA serves as a foundation for defining the control topology, ensuring system resilience against component failures that could compromise essential functions, such as electricity and heat production.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

COUPLED MULTIPHYSICS PRIMARY LOOP SIMULATIONS OF THE Mk1-FHR IN THE VIRTUAL TEST BED

The Virtual Test Bed (VTB) repository hosts a wide range of challenge problems to showcase modeling and simulation capabilities to support advanced reactor demonstration. A coupled multiphysics model of the Mk1 pebble-bed fluoride-salt-cooled high-temperature reactor (PB-FHR) is presented here. The analysis leverages NEAMS tools (Griffin), SAM, Pronghorn, and the MOOSE heat conduction module) for core neutronics, thermal hydraulics of the core and the primary loop, and multiscale fuel performance simulations. The analysis was entirely created by coupling standalone simulations of the reactor previously available on the VTB. All input files and documentation developed for this example are available on the VTB website: \url{mooseframework.inl.gov/virtual_test_bed/}}. This model was featured in the NRIC Tech Talk presented in December 2021.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Recharge Demand Mitigation for Latent Heat Thermal Energy Storage at Off-peak Hours

The utilization of integrated heat pump thermal energy storage (HP-TES) systems for space conditioning applications can reduce electrical power demand and achieve utility savings resulting from peak shaving and load shifting. However, issues arise when the energy required to recharge the TES exceeds the shifted energy demand, especially in extreme climates where high-temperature lifts between the outdoor air conditions and phase-change materials (PCMs) during recharging may occur. In this work, a single room-temperature (22°C) PCM-TES is integrated into a single-speed heat pump system using a secondary hydronic loop where the TES is recharged using the outdoor unit during off-peak hours. Three recharge strategies were investigated as potential pathways to reduce recharging power demand: (i) considering different heat source/sink temperatures, (ii) using a variable-speed compressor, and (iii) using a variable-speed pump. Simulations were conducted using Modelica for HP-TES recharging at different heat source/sink temperatures from -30 – 20℃ in heating mode and 0 – 30℃ in cooling mode. Results show that the most effective recharge demand reduction strategy is an HP-TES system using a single-speed compressor with a variable-speed pump for the hydronic loop run at preferable heat source/sink temperatures when the temperature lifts were reduced. Utilizing a variable-speed compressor for the HP-TES system reduced recharge time in extreme cases at the cost of additional compressor power input. The findings motivate potential control strategies that minimize recharge energy and maximize peak energy savings, hence reducing overall operating costs and annual energy consumption for HP-TES systems for space conditioning applications.

25 ENERGY STORAGE↗
DOE OSTI2021

Thermal conductivity of CaSiO 3 perovskite at lower mantle conditions

Thermal conductivity (κ) of mantle minerals is key to understanding dynamics in the deep Earth. It controls the style of mantle convection and the timescale of cooling both the mantle and the core. Cubic CaSiO 3 perovskite (CaPv) is the third most abundant mineral in the lower mantle (7 vol %). Despite its importance, no theoretical or experimental estimate of CaPv's κ is available. Theoretical investigations of its properties are challenging because of its strong anharmonicity. Experimental measurements at relevant pressures and temperatures are equally challenging. Here we present ab initio results for CaPv's κ obtained using the phonon quasiparticle approach to address its strong anharmonicity. We also offer experimental measurements of κ up to 67 GPa and 1950 K. Predictions and measurements are in good agreement and reveal a surprisingly large κ for cubic CaPv that can be explained on the basis of its high crystal structure symmetry. Despite its relatively low abundance, CaPv's κ increases the lower mantle κ by ~10 %, if accounted for. κ of mantle regions enriched in subducted crustal materials will be more strongly impacted.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

High-energy synchrotron flares powered by strongly radiative relativistic magnetic reconnection: 2D and 3D PIC simulations

ABSTRACT The time evolution of high-energy synchrotron radiation generated in a relativistic pair plasma energized by reconnection of strong magnetic fields is investigated with 2D and 3D particle-in-cell (PIC) simulations. The simulations in this 2D/3D comparison study are conducted with the radiative PIC code OSIRIS, which self-consistently accounts for the synchrotron radiation reaction on the emitting particles, and enables us to explore the effects of synchrotron cooling. Magnetic reconnection causes compression of the plasma and magnetic field deep inside magnetic islands (plasmoids), leading to an enhancement of the flaring emission, which may help explain some astrophysical gamma-ray flare observations. Although radiative cooling weakens the emission from plasmoid cores, it facilitates additional compression there, further amplifying the magnetic field B and plasma density n, and thus partially mitigating this effect. Novel simulation diagnostics utilizing 2D histograms in the n-B space are developed and used to visualize and quantify the effects of compression. The n-B histograms are observed to be bounded by relatively sharp power-law boundaries marking clear limits on compression. Theoretical explanations for some of these compression limits are developed, rooted in radiative resistivity or 3D kinking instabilities. Systematic parameter-space studies with respect to guide magnetic field, system size, and upstream magnetization are conducted and suggest that stronger compression, brighter high-energy radiation, and perhaps significant quantum electrodynamic effects such as pair production, may occur in environments with larger reconnection-region sizes and higher magnetization, particularly when magnetic field strengths approach the critical (Schwinger) field, as found in magnetar magnetospheres.

Schoeffler, K. M. (ORCID:0000000276447381)↗
DOE OSTI2021

Evaluation of cooling setpoint setback savings in commercial buildings using electricity and exterior temperature time series data

Commercial buildings account for a significant amount of total energy produced in the US, and the Heating Ventilation and Cooling (HVAC) systems are one of the most significant components of their overall consumption. In this study, we proposed a new data-driven approach to evaluate HVAC cooling systems in commercial buildings and identify savings opportunities. The focus is an investigation of the impact of thermostat setpoint setback but using only whole building, electricity data taken at 15-min intervals for the analysis. We conducted a comparative study of setpoint setback characteristics on 432 commercial buildings with 5 building usage types across the United States. To accomplish this, both piecewise and Random Forest regression algorithms were employed using electricity and exterior temperature datasets to identify operational characteristics and the effective setpoints in the building to determine the corresponding savings opportunities. Both occupied and unoccupied time periods were studied across cooling degree days (CDD), when air conditioning is typically operational. Here the results show that in commercial buildings, on average, cooling systems account for 9.5% of total consumption. When a one degree setback during the cooling season is applied, an average of approximately 1.1% of annual consumption is achieved; retail and office buildings demonstrate the highest potential for savings. Additionally, we identified that the number of cooling degree days and base to peak ratio (BPR) are the most important variables for predicting the magnitude of the consumption of cooling systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Liquid helium fluid dynamics studies. Final Technical Report

Future high energy physics accelerators depend on a number of advanced technologies to open the many doors of scientific discovery. Among these advanced technologies, superconducting magnets and superconducting radio frequency (SRF) cavities are the backbone of the accelerator and detector systems. But all these low temperature systems depend critically on successful and reliable operation of their supporting technologies, among which the liquid helium cooling system is of the utmost importance. To improve the quality of these systems both in terms of efficiency and reliability, a robust helium cryogenics research and development (R&D) effort is required. The proposed research to be conducted by the FSU cryogenics group aims to produce fundamental knowledge that meets this R&D need. The projects that we have completed over the past grant period at Florida State University consist of experimental research on liquid helium fluid dynamics and heat transfer problems relevant to the development of future superconducting particle physics accelerators. Liquid helium is the coolant used in all such facilities and in many of these facilities He II (the low temperature phase of liquid helium also known as superfluid helium) is preferred due to its outstanding heat transfer characteristics. The work consists of two main experimental studies that probe both fundamental as well as practical aspects of liquid helium cooling. The first is a broad and fundamental study of the heat and mass transfer processes that can occur during a sudden catastrophic loss of vacuum (SCLV) incident in a superconducting accelerator. SCLV refers to the remote but extremely critical accident scenario where atmospheric pressure air is allowed to flood into the insulating vacuum system and impinge on the liquid helium cooled surfaces in the accelerator. Safe performance and recovery from such accidents is essential to the reliable operation of superconducting accelerators. The dynamics of this process is quite complex and so our approach is to conduct a series of well-orchestrated experiments that probe the various physical phenomena that can occur during an SCLV event. The experiments are coupled with analytic and numerical analysis in an effort to develop a general understanding of the process and to assist with future accelerator design and development. The second activity is directed toward fundamental understanding of heat and mass transfer in He II, which is essential to the design of superconducting magnets and radio frequency cavities in accelerators. The work consists of flow visualization of the dynamics of He II using laser assisted techniques. Two complementary techniques are used to study the fundamentals of the turbulent state. The first technique uses neutrally buoyant solid hydrogen particles to probe the flow fields of the superfluid and normal fluid components. The other technique uses laser excited He2* molecules as tracers of the normal fluid motion within the He II. The activities also included an effort to use visualization techniques to locate transient hot spots in radio frequency superconducting cavities. Such work provides valuable information about the heat transfer process in He II and its impact on the performance of superconducting devices. The research effort at Florida State University is not directly in support of a specific high energy physics experiment or facility. Rather, the work is general and coordinated with HEP accelerator laboratories to provide valuable insight that can assist with future accelerator development.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

THERMAL/STRUCTURAL ANALYSIS OF THE AXION QUANTUM METROLOGY CAVITY AND ITS COMPONENTS

This research was centered around maximizing the capability to cool dielectric material within a containment unit, or Photonic Band Gap (PBG) cavity, designed for detecting axion dark matter and identifying the unit’s thermal properties. There are multiple types of PBG cavities, but the latest version that axion researchers wish to use has been theorized to contain possible issues related to its thermal properties. Thermal conductivity is an issue with the dielectric material because it is made from alumina which is highly insulative. This is important since the research is being done in a cryogenic environment and the thermal noise affects the quantum bit used for detecting the axion to photon conversion process. Therefore, any improvements to this unit should be justified and implemented but are not entirely limited to thermal contact related aspects of PBG cavities. A prospect of using sapphire in place of alumina also exists, but this is a more expensive, less tested, and more elusive material to justify the creation of a full dielectric structure out of sapphire. Thermal aspects of the cavity were analyzed using finite element method (FEM) and an experiment designed to test different thermal joint materials. FEM was used to check the contraction of the cavity during cooling, the contact quality between the dielectric material and cavity wall, theheat flow rate through the assembly, and helps visualize the cavity’s reaction to different design changes. A simple comparison between thermal conductivity curves justified the usage of sapphire over alumina from a thermal property point of view. Thus, the method of experimentation had an additional dielectric material, sapphire, to test with and compare to alumina. The thermal test identified which material is best to use for a thermal joint but also simultaneously found the conductance of the joint and dielectric material as well as an estimate for what the temperature is inside the larger scale cavity since a thermometer cannot be placed inside the PBG when it cools. Initially, the cavity simulation was tested for structural deformation properties and stress distribution since it is made of copper which contracts heavily in comparison to most other materials. The reduction in volume of the cavity was less than anticipated which gave more room for a possible usage of a modified thermal joint for additional contact area and higher conductivity.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Thermal conductivity of RHIC superconducting magnet insulation materials at low temperatures

The Electron-Ion Collider (EIC) is planned to be built upon the Relativistic Heavy Ion Collider (RHIC), which vacuum chamber will need to be upgraded to host the EIC hadron beams. For the beam pipe section running through the RHIC superconducting (SC) magnets, the baseline is to insert a screen that will get cooled by thermal contact to the 4.55 K beam pipe of RHIC. Knowing the material properties of the cold mass is thus crucial to understand which is the final temperature that the screen and the superconducting coils in the magnets will reach during the passage of the EIC beams. The thermal conductivities of two insulation materials in the RHIC superconducting magnets and a reference material were measured at cryogenic temperatures at the Magnet Science and Technology division of the National High Magnetic Field Laboratory (NHMFL). The measurements were performed in a Quantum Design physical property measurement system. This report explains the motivation behind this work and summarizes the measurement method and results.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

Conditional distribution estimation of building characteristics with diffusion models for urban energy modeling

Understanding current energy consumption behavior in communities is critical for informing future energy use decisions and enabling efficient energy management. Urban energy models, which are used to simulate these energy use patterns, require large datasets with detailed building characteristics for accurate outcomes. However, such detailed characteristics at the individual building level are often unknown and costly to acquire, or unavailable. Through this work, we propose using a generative modeling approach to generate realistic building attributes to fill in the data gaps and finally provide complete characteristics as inputs to energy models. Our model learns complex, building-level patterns from training on a large-scale residential building stock model containing 2.2 million buildings. We employ a tabular diffusion-based framework that is designed to handle heterogeneous (discrete and continuous) features in tabular building data, such as occupancy, floor area, heating, cooling, and other equipment details. We develop a capability for conditional diffusion, enabling the imputation of missing building characteristics conditioned on known attributes. We conduct a comprehensive validation of our conditional diffusion model, firstly by comparing the generated conditional distributions against the underlying data distribution, and secondly, by performing a case study for a Baltimore residential region, showing the practical utility of our approach. Our work is one of the first to demonstrate the potential of generative modeling to accelerate building energy modeling workflows.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Development of a high current density, high temperature superconducting cable for pulsed magnets

Abstract A low AC loss Rare Earth Barium Copper Oxide (REBCO) cable, based on the VIPER cable technology has been developed by Commonwealth Fusion Systems for use in high field, REBCO based tokamaks. The new cable is composed of partitioned and transposed copper ‘petals’ shaped to fit together in a circular pattern with each petal containing a REBCO tape stack and insulated from each other to reduce AC losses. A stainless steel jacket adds mechanical robustness—also serving as a vessel for solder impregnation—while a tube runs through the middle for cooling purposes. Additionally, fiber optic sensors are placed under the tape stacks for quench detection. To qualify this design, a series of experiments were conducted as part of the SPARC tokamak Central Solenoid Model Coil program—to retire the risks associated with full scale, fast ramping, high flux HTS Central Solenoid (CS) and Poloidal Field (PF) coils for tokamak fusion power plants and net energy demonstrators. These risk study and risk reduction experiments include (1) AC loss measurement and model validation in the range of ~5 T/s, (2) an IxB electromagnetic loading of over 850 kN/m at the cable level and up to 300 kN/m at the stack level, (3) a transverse compression resilience of over 350 MPa, (4) manufacturability at tokamak relevant speeds and scales, (5) cable to cable joint performance, (6) fiber optic based quench detection speed, accuracy, and feasibility, and (7) overall winding pack integration and magnet assembly. The result is a cable technology, now referred to as PIT VIPER, with AC losses that measure fifteen times lower (at ~5 T/s) than its predecessor technology; a 2% or lower degradation of critical current (Ic) at high IxB electromagnetic loads; no detectable Ic degradation up to 570 MPa of transverse compression on the cable unit cell; end to end magnet manufacturing, consistently producing Ic values within 7% of the model prediction; cable to cable joint resistances at 20 K on the order of ~15 nΩ; and fast, functional quench detection capabilities that do not involve voltage taps. This cable technology will be tested comprehensively in a Central Solenoid Model Coil to prove its readiness for compact, high field tokamak operation.

Sanabria, Charlie (ORCID:0000000150175309)↗
DOE OSTI2025

Intercalation induced quasi-freestanding layer in TiSe 2

Angle-resolved photoemission spectroscopy is employed to study the electronic structure of bulk TiSe 2 before and after doping with potassium impurities. A splitting in the conduction band into two branches is observed after room-temperature deposition. The splitting energy increases to approximately 130 meV when the sample is cooled to 40 K. One branch exhibits a nondispersive two-dimensional feature, while the other shows the characteristics of three-dimensional bulk band dispersion. Core-level spectroscopy suggests that the K impurities predominantly occupy the intercalated sites within the van der Waals gap. Furthermore, the results indicate the formation of a quasi-freestanding TiSe 2 layer. Additionally, doping completely suppresses the periodic lattice distortion in the surface region. These findings are further supported by density functional theory calculations, which compare the band structure of monolayer and bulk TiSe 2 with experimental data. Thus, the dimensional and intrinsic electronic properties of 1⁢𝑇−TiSe 2 can be controlled through the intercalation procedure used in this work.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Progress on Demonstration of a MOOSE-Based Coupled Capability for Hot Channel Factors in Fast Reactors

Hot channel factors (HCFs) are computed values that account for the impact on predicted peak fuel, cladding, and coolant temperatures due to uncertainties in the as-built reactor’s material properties and geometry as well as uncertainties due to modeling approximations. Reduction in computed HCF values via reduction or elimination of modeling approximations may translate to significant economic savings if the reactor power can be raised due to the extra temperature margin gained. While limited historical datasets exist for sodium-cooled fast reactors (SFRs), there are no available HCF data for lead-cooled fast reactors (LFRs) outside of work generated previously within NEAMS. The computation of HCFs involves insights from reactor physics, thermal fluids and heat conduction calculations to determine how the peak temperatures respond to various uncertainties in the design. Due to the significant advantages for multi-physics coupling offered by the MOOSE framework, Griffin (MOOSE-based reactor physics code), MOOSE Heat Conduction Module, and Cardinal (MOOSE-wrapped multi-physics application which includes the NekRS thermal fluids code) are being coupled together using the MOOSE MultiApp System to develop a highfidelity multi-physics modeling capability for HCF simulations. This high-fidelity coupling workflow may also be beneficial for other fast reactor applications in the future. In previous work, Griffin and NekRS were individually assessed to ensure the necessary capabilities were in place. This work describes initial efforts to couple the codes (including folding in the MOOSE Heat Conduction Module) and determining the workflow for the perturbed calculations which will leverage the Stochastic Tools Module (STM). To our knowledge, this is the first coupling of Griffin and NekRS as well as the first exploratory use of Stochastic Tools Module for Cardinal. In this report, the neutronics code Griffin, the heat conduction solver in MOOSE, and the MOOSE-wrapped application containing NekRS (Cardinal) are linked together to demonstrate the coupled capability. Griffin and Cardinal are linked dynamically by specifying shared libraries. Different coupling hierarchies are tested for selecting the most appropriate coupling strategy. A coupling scheme is selected based on the efficiency of calculation and ease of data communication. Multiple tests are performed to choose suitable mesh structure, model configurations, scheme setup and boundary conditions to avoid loss of energy due to data interpolation between different modules or weak imposition of fluxes in finite element codes. Computational experiments are performed to study the tolerance control of each type of iteration to avoid false convergence. The coupled capability is demonstrated in both single pin and 7-pin models based on LFR materials and geometry. The study finds that the use of too large a time step size in the heat conduction module can lead to temperature oscillation even though the heat conduction equation does not have a time-derivative kernel, but only the time-dependent boundary condition. A 7-pin model without duct region achieved good convergence in the coupled calculation while a 7 pin model with duct region experienced data communication issues which need to be resolved.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Transformative Efficiency and Automation in Modular Homes (TEAMH)

This report documents the Transformative Efficiency and Automation in Modular Homes (TEAMH) project, which evaluates the integration of advanced building envelope technologies and automation-assisted modular construction to improve residential energy performance and construction efficiency. The study investigates high-performance insulation systems, including vacuum insulation panels (VIPs), combined with light gauge steel (LGS) modular construction and factory automation. Laboratory testing, whole-building energy modeling across multiple climate zones, and factory demonstrations were conducted to assess thermal performance, energy savings, and production efficiency. Results indicate that upgraded envelope assemblies can achieve up to ~50% heating and ~34% cooling energy savings relative to IECC 2018 code-compliant homes, while automation-assisted construction can reduce wall assembly time by 24%–46% compared to conventional wood framing. The findings demonstrate the potential for scalable, high-performance modular homes that deliver significant energy savings with competitive projected costs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Assessing High Burnup U-19Pu-10Zr Fuel Performance against Historical and Modeled Behavior

Advancing the deployment of sodium-cooled fast reactors (SFRs) requires thorough testing of metallic fuel pins under accident conditions to establish safe operational limits of high burnup fuel. To conduct transient testing, a comprehensive understanding of steady-state fuel behavior obtained through both experimental characterization and accurate predictive capabilities is needed. This study comparatively assesses the steady-state irradiation performance of two high burnup U-19Pu-10Zr fuel pins, DP-36 and DP-40, irradiated under prototypic fast reactor conditions in preparation for planned safety testing at the Transient Reactor Test Facility. Since DP-40 was designated for use in the test and DP-36 serves as its sibling pin, non-destructive, engineering-scale post-irradiation examinations (PIE) were conducted on both pins while destructive examinations were performed exclusively on DP-36. The results were then assessed against historical performance data from similar fuel pins irradiated in the Experimental Breeder Reactor-II. Additionally, the steady-state irradiation of each pin was modeled using the BISON fuel performance code to assess the accuracy of current modeling capabilities in predicting the baseline irradiation behavior. Non-destructive examinations included neutron radiography to measure fuel column elongation, gamma scanning to verify pin integrity and fission product migration, and profilometry to assess dimensional changes. Benchmarking against existing PIE data revealed consistent patterns in axial fuel column growth and cladding diametral strain, though both pins exhibited longer low-density “fluff” structures, which can have implications for core reactivity and source term calculations. Destructive examinations on DP-36 included fission gas release analysis and sectioning for optical microscopy, which showed more complex constituent redistribution patterns than the traditionally accepted 3-ring model. The axial evolution of fractional areas and porosities of each of the redistributed zones were quantified and presented. Modeling comparisons showed agreement in fractional fission gas release but consistently overestimated axial and radial swelling and disagreed with measured axial porosity patterns. These conservative overpredictions suggested that the pins would appear closer to failure or operational limits at the start of transient tests, potentially leading to higher strain accumulation during the transient. While conservative estimates provide safety margins, they can negatively impact fuel economics. A review of the swelling models identified areas for improvement in the gaseous swelling, solid swelling, and fuel hot-pressing models when applied to ternary fuel. The results of this study highlight the critical importance of conducting pre-test characterization on both test and sibling pins to accurately capture steady-state fuel behavior, providing a precise baseline for post-test evaluations and essential inputs for transient modeling of the planned experiments. The analysis also revealed significant data gaps that require further investigation to enhance the understanding and prediction of fuel swelling and pore dynamics. Collecting comprehensive data across different irradiation conditions, burnup levels, and fuel compositions are essential for refining existing models and developing mechanistic models for both binary and ternary metallic fuels, ultimately improving the integration of modeling and experimental approaches in accident testing.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

ADDITIVELY MANUFACTURED SURFACE HEAT TRANSFER ENHANCEMENTS FOR THE TRANSFORMATIONAL CHALLENGE REACTOR

The Transformational Challenge Reactor (TCR) is a high-temperature gas-cooled reactor design that uses additively manufactured fuel elements. TCR fuel elements have walls made of silicon carbide and are filled with tristructural-isotropic fuel particles. These fuel elements can have radically different shapes and integrated features than existing designs due to the reduced cost for complex structures in binder jet additive manufacturing. As such, binder jet additive manufacturing enables wall surface features to be embedded that can deliver superior heat transfer performance than smooth wall designs. In this work, the authors conducted a computational fluid dynamics study to evaluate selected wall features integrated into TCR fuel elements. Results show that surface features can outperform smooth wall designs; however, there are unique challenges for gas-cooled reactor core designs that have not been fully explored by previous research. For example, the rough surface finish and process variability of ceramics additive manufacturing make it challenging to predict surface roughness effects before fabrication. Additionally, the small hydraulic diameters of coolant channels in reactor cores make it difficult to engineer surface features that do not significantly increase the pressure drop. Engineers must carefully size surface features for heat transfer enhancement in additive fuel elements to operate above the base material's surface roughness effects and below the coolant channel size.

Weinmeister, Justin↗
DOE OSTI2021

Performance of direct injected propane and gasoline in a high stroke-to-bore ratio SI engine: Pathways to diesel efficiency parity with ultra low soot

This work explores pathways to achieve diesel-like, high-efficiency combustion with stoichiometric 3-way catalyst compatible combustion in a single-cylinder spark ignition (SI) research engine. A unique high stroke-to-bore engine design (1.5:1) with cooled exhaust gas recirculation (EGR) and high compression ratio ( r c ) was used to improve engine efficiency by up to 30% compared with a production turbocharged gasoline direct injection spark ignition engine. Engine experiments were conducted with both 91 RON E10 gasoline and liquified petroleum gas (LPG) (i.e. autogas) and were compared to legacy gasoline data on the production engine. Geometric compression ratio ( r c ) of 13.3:1 was used for both fuels with additional experiments at 16.8:1 for LPG only. Measurements of exhaust soot particle size and number concentrations were made with both fuels. Significant reduction in soot particles across the whole particle size range were achieved with LPG due to the elimination of in-cylinder liquid films. The effects of EGR, late intake valve closing (IVC) and fuel characteristics were investigated through their effects on efficiency, combustion stability and soot production. Results of 47% gross thermal efficiency, and 45% net thermal efficiency at stoichiometric engine operation, at up to 17 bar IMEP and 2000 r/min with 16.8:1 r c were achieved with LPG. Estimated brake efficiency values were compared to a contemporary medium duty diesel engine illustrating the benefits of the chosen path for achieving diesel efficiency parity.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

Temperature-Following Thermal Barrier Coatings for High Efficiency Engines (Final Report)

HRL Laboratories and General Motors (GM), pursued this effort to increase the efficiency of internal combustion engines (ICEs) by developing and implementing temperature-following thermal barrier coatings (TBCs) to decrease heat loss from the combustion chamber. HRL developed microsphere TBCs based on hollow high-temperature alloy spheres with average diameter of 50 μm and wall thickness ~1 μm (microspheres) that achieve unprecedented low thermal conductivity and heat capacity (10X lower than the state of the art) while offering exceptional environmental and mechanical resistance.> In current ICEs, approximately 29% of the fuel’s energy is lost to the cooling system and about 22% goes into moving the car. By limiting heat losses from the combustion chamber with insulating coatings, fuel energy can be redirected into additional piston work and into the exhaust stream. The additional energy that goes into the exhaust stream can be turned into useful work through the use of an exhaust energy recovery device, such as turbocompounding and/or through driving a turbocharger to increase the power density of the engine allowing downsizing. Insulating coatings for piston crowns have been pursued in the past, but previous materials—typically ceramics—exhibited low thermal conductivity but retained high heat capacity. Such materials reduce heat losses but stabilize at a high surface temperature. The high surface temperature heats the incoming gases, which lowers volumetric efficiency and increases propensity for knock, resulting in degraded engine performance. This program developed an innovative new material that combines low thermal conductivity with low heat capacity. These unique properties allow it to follow rapid changes in gas temperature during each combustion cycle. A metallic microsphere TBC has been demonstrated that exhibits increased surface temperature during the combustion period, resulting in reduced heat transfer losses, while still returning to a low surface temperature during the gas exchange period. A 10X lower thermal conductivity and heat capacity than state-of-the-art thermal barrier coatings has been demonstrated. These unprecedented thermal properties are achieved through the coating architecture, which consists of closed pores on the microscale and exhibits a total porosity of 90% to 95%. By selecting a high-temperature nickel alloy as the coating material, the ductility and strength of metals can be harnessed to achieve much better durability and damage tolerance than brittle ceramic coatings can achieve.

33 ADVANCED PROPULSION SYSTEMS↗