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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 55 records · Page 3

Influences of lidar scanning parameters on wind turbine wake retrievals in complex terrain

Abstract. Scanning lidars enable the collection of spatially distributed measurements of turbine wakes and the estimation of wake properties such as magnitude, extent, and trajectory. Lidar-based characterizations, however, may be subject to distortions due to the observational system. Distortions can arise from the resolution of the measurement points across the wake, the projection of the winds onto the beam, averaging along the beam probe volume, and intervening evolution of the flow over the scan duration. Using a large-eddy simulation and simulated measurements with a virtual lidar model, we assess how scanning lidar systems may influence the properties of the retrieved wake using a case study from the Perdigão campaign. We consider three lidars performing range-height indicator sweeps in complex terrain, based on the deployments of lidars from the Danish Technical University (DTU) and German Aerospace Center (DLR) at the Perdigão site. The unwaked flow, measured by the DTU lidar, is well-captured by the lidar, even without combining data into a multi-lidar retrieval. The two DLR lidars measure a waked transect from different downwind vantage points. In the region of the wake, the observation system reacts to the smaller spatial and temporal variations of the winds, allowing more significant observation distortions to arise. While the measurements largely capture the wake structure and trajectory over its 4–5 D extent, limited spatial resolution of measurement points and volume averaging lead to a quicker loss of the two lobes in the near wake, smearing of the vertical bounds of the wake (< 30 m), wake center displacements up to 10 m, and dampening of the maximum velocity deficit by up to a third. The virtual lidar tool, coupled with simulations, provides a means for assessing measurement capabilities in advance of measurement campaigns.

17 WIND ENERGY↗

Reliable statistics-based detection and investigation of anomalies in a SMART valve system

Reliable anomaly detection and diagnosis are critical for the safe operation of complex engineered systems. This study presents a unified framework that integrates statistical, model-based, and data-driven techniques for anomaly detection and investigation, demonstrated on SMART valve systems in hybrid energy applications. Four detection methods—mean deviation, seasonal extreme studentized deviate, ARIMA forecasting, and matrix profiling—were implemented and compared. Matrix profiling was particularly effective in revealing subtle deviations and hidden relationships among variables. Anomaly investigation was performed by analyzing variable-level and grouped signal profiles, with system topology incorporated to distinguish primary faults from propagated effects. Grouping signals by type enhanced interpretability, enabling accurate localization of anomalies across multi-dimensional datasets. Experimental results confirmed the framework's capability to consistently detect and isolate anomalies while providing actionable insights into system interdependencies. The proposed methodology offers a robust, interpretable, and scalable solution for condition monitoring, with potential applications in safety-critical domains such as nuclear energy, aerospace, and process industries.

ARIMA models↗

In-flight performance of the XRISM/Resolve detector system

The Resolve instrument was launched on board the XRISM observatory in early September 2023. The Resolve spectrometer is based on a high-sensitivity X-ray calorimeter detector system (DS) that has been successfully deployed in many ground and sub-orbital spectrometers. However, the Resolve instrument is the first long-term implementation in space. The instrument will provide essential diagnostics for nearly every class of X-ray emitting objects, from galactic supernova remnants to the outskirts of galaxy clusters, without degradation for spatially extended objects. The Resolve DS consists of a 36-pixel microcalorimeter array operated at a heat sink temperature of 50 mK. In pre-flight testing, the DS demonstrated a resolving power of better than 1300 at 6 keV with a simultaneous bandpass from below 0.3 keV to above 12 keV and a timing precision better than 100μs. An anti-coincidence detector placed directly behind the microcalorimeter array effectively suppresses background. The detector energy-resolution budget included terms for interference from the Resolve cooling system and the spacecraft. Additional terms for energy-scale stability, on-orbit effects, and use of mid-grade events were also included, predicting an end-of-life, on-orbit performance for high- and mid-resolution grade events that meet the requirement of 7 eV FWHM at 6 keV. Here, we discuss the actual on-orbit performance of the Resolve DS and compare this with the performance in pre-flight testing, on-orbit predictions, and the almost identical Hitomi/SXS instrument. We will also discuss the on-orbit gain stability, an assessment of on-orbit interference, and measurements of the on-orbit background.

Astronomy and AstroPhysics↗

Return on Investment and Sustainability of HVDC Links: Role of Diagnostics, Condition Monitoring, and Material Innovations

HVDC cable systems are becoming an upscaled technical option, compared to AC, because of various factors, including easier interconnections, lower losses, and longer transmission distances. In addition, renewables providing direct DC energy, electrified transportation, and aerospace where DC can be favored because of higher carried specific power all point in the direction of broad future usage of HV and MV DC links. However, contrary to AC, there is little return from on-field installation as regards long-term cable reliability and aging processes. This gap must be covered by intensive research, and contributing to this research is the purpose of this paper. The focus is on key points for HVDC (and MVDC) cable reliability and sustainability, from design modeling able to account for voltage transients and extrinsic aging (such as that caused by partial discharges) to the impact of aging on insulation conductivity (which rules the electric field distribution, thus aging rate). Also, recyclable and nanostructured materials, as well as health conditions, are considered. It is shown how cable design can account for accelerated aging due to voltage transients, as well as for aging-time dependence of conductivity, and how design can be free of extrinsic aging caused by PDs. Algorithms for health condition evaluations, which have additional value in a relatively new technology such as HVDC polymeric cables, are applied to insulation system aging under partial discharges, showing how they can provide an indication of insulation degradation globally or locally (weak spots) and of possible maintenance times. All of this can effectively contribute to reducing the risk of major cable breakdown and damage under operation, which would significantly affect the return on investment (ROI).

Montanari, Gian Carlo (ORCID:0000000320258693)↗

Ultra-High Operation Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing: Test Facility & Performance Evaluations

Solar Heat for Industrial Processes (SHIP) cavity receivers are capable of generating electricity or industrial process heat by absorbing thermal energy from solar radiation, focused on a small area. The concentration of solar radiation on the small area of the receiver enables the achievement of high temperatures (ranging from 400°C to 1,100°C) of a working fluid, thus making the SHIP technology thermodynamically comparable with conventional power plants. A volumetric receiver consists of a porous structure-generally made of silicon carbide or metal, which absorbs solar radiation and converts it into heat energy. Heat energy from the porous materials is then transferred to the fluid following through them. A volumetric receiver acts as a convective heat exchanger, transferring heat to the fluid through convection. Open-loop volumetric receivers work with air at atmospheric pressure and are suitable for single-cycle or multi-cycle energy plants. A Model Based Systems Engineering (MBSE) approach was used to develop a test bed at Sandia national Laboratories (SNL) capable of demonstrating an open-loop volumetric air receiver developed by General Electric Aerospace (GE Aerospace). This paper presents the development of the various MBSE methods, test bed, and testing operations for the GE air receiver, which was experimentally demonstrated to achieve 1,350°C for over 3 hours of operation and an approximate 70% receiver efficiency. By being able to achieve such high temperatures >1,000°C, this work provides the potential to support many SHIP industrial use cases.

14 SOLAR ENERGY↗

Flat-band driven Kondo breakdown and reentrant effects in heavy-fermion moiré superlattices

Moiré superlattices (MSLs) in van der Waals heterostructures have demonstrated their incredible power in driving emergent electronic phenomena, some of which are reminiscent of those usually only observed in bulk strongly correlated quantum materials. With the recent discovery of van der Waals 𝑓-electron materials, the design of novel MSLs of intrinsic strong correlation is now within the reach. Here we study the novel electron phases of two-dimensional heavy-fermion MSL with increasingly diluted 𝑓-electron local moments. By applying dynamical mean-field theory with numerical renormalization group as an impurity solver, we demonstrate the appearance of a different energy scale and a reentrant Kondo breakdown in connection with the emergence of a flat band in the system. We further compare our numerical findings with predictions derived from the Lieb-Mattis theorem and show the necessity of this energy scale to consistently reconcile the predictions with the conventional single-impurity limit for exceedingly large unit cells.

36 MATERIALS SCIENCE↗

Influence of printing parameters on the mechanical behavior of 3D-printed SS316L parts manufactured using laser hot wire directed energy deposition

Hybrid manufacturing combines the simultaneous benefits of additive manufacturing (complex geometries, part consolidation, and mass customization) with the advantages of subtractive manufacturing (superior surface finish and enhanced dimensional accuracies) by integrating a suite of complementary traditional processes into a base platform of additive manufacturing. The use of hybrid technology has grown in recent years given its capabilities on repairing metallic structures, producing parts with conformal cooling features, and manufacturing functionally graded products. These kinds of capabilities are of great interest to the medical implant, energy, automotive, maritime, and aerospace industry sectors, among many other fields. This work investigated the mechanical properties of stainless steel (SS) 316L as a function of different tool paths strategies using an integrated 5-axis CNC hybrid Mazak system with a laser hot wire deposition system (LHWDS). This study includes the evaluation of different printing parameters and their impact on the quality of the printed bead as well as the incorporation of a structure–property material relationship based on the mechanical performance of the manufactured coupons.

36 MATERIALS SCIENCE↗

Pitfalls in parameters: practical process development in chemical vapor processing of SiC

Vapor processing of high-value materials, such as silicon carbide (SiC), is of interest for many industries, including aerospace and energy production. Chemical vapor infiltration (CVI) of additively manufactured components is an especially attractive manufacturing process currently in development. Here, a novel development workflow is demonstrated with the H 2 –CH 3 SiCl 3 gas system for SiC to accelerate the process optimization of CVI SiC. A combination of calculated thermodynamics and high-throughput experimental chemical vapor deposition (CVD) coatings substantially reduced the experiments required with slow CVI processes. The computational results accurately predicted changes in the thermodynamic conditions tested, while CVD coatings – characterized by Raman spectroscopy – addressed changes in kinetic parameters. This workflow is also applicable to other vapor-processing systems, such as pyrolytic carbon, ZrC, or Si 3 N 4 .

Lamm, Benjamin W. [Oak Ridge National Laboratory (↗

Evaluation of cloud height, optical thickness, and phase retrievals from the CHROMA algorithm applied to Sentinel-3 OLCI data

We previously developed the Cloud Height Retrieval from O 2 Molecular Absorption (CHROMA) algorithm for the Ocean Color Instrument (OCI) on the new NASA Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) mission. Here, we apply CHROMA to observations from the Ocean Land Colour Instrument (OLCI) to guide expectations for PACE, as it will take some time to obtain large-scale validation data for OCI. We use cloud top height (CTH), phase, and (for liquid clouds) cloud optical thickness (COT) data from the ground-based Atmospheric Radiation Measurement (ARM) network to evaluate the OLCI retrievals. We found that OLCI and Moderate Resolution Imaging Spectroradiometer (MODIS) CTH compare similarly well to the ARM reference. OLCI has a tendency to underestimate CTH as CTH increases, and algorithm assumptions about cloud geometric thickness may contribute to this. ARM COT from multifilter shadowband radiometers (MFRSR) and Sun photometers are well-correlated with one another, albeit with a roughly 30 % offset on average; OLCI and MODIS COT agree more closely with the MFRSR data. OLCI retrieval uncertainty estimates show skill at telling low-uncertainty cases from high-uncertainty ones, although CTH uncertainties are underestimated. Additionally, we compare the OLCI data to satellite retrievals based on thermal infrared measurements from MODIS and Sea and Land Surface Temperature Radiometer (SLSTR) data. Differences are broadly consistent with physical expectations based on the A-band vs. thermal techniques, although one key challenge in such aggregated comparisons is different cloud masking sensitivities and algorithm failure rates meaning additional sampling differences are introduced. We conclude by discussing the transition to and possible enhancements for PACE OCI.

Sayer, Andrew M. [Univ. of Maryland Baltimore Coun↗

Assessment of RELAP5-3D Code with Molten Salt Heat Transfer Experiments

The accurate thermal-hydraulic assessment of thermal storage systems is crucial for addressing the integrity and performance of the storage system design. This is particularly important for thermal storage systems using molten salts as a heat transport and storage medium, as the chemical corrosion and erosion by the high-temperature molten salts can cause serious damage to the structural components of the storage system. To understand these effects for TerraPower’s Natrium® Demonstration Reactor design, the system thermal-hydraulic analysis code, RELAP5-3D, is utilized to analyze the thermal storage system. This study evaluates two heat transfer correlations implemented in the RELAP5-3D code—the Dittus-Boelter and Gnielinski correlations—using selected benchmark cases from two molten salt heat transfer experiments conducted at Xi’an Jiao Tong University and the German Aerospace Center. The Nusselt numbers calculated using the Gnielinski correlation agree with the experimental data within ±5% of the relative deviations at 300°C and 400°C. With the increasing Reynolds numbers, the Dittus-Boelter correlation underestimates the Nusselt numbers by up to 22% compared to the Gnielinski correlation. Comparison of the RELAP5-3D calculation results with experimental data at a high temperature of 550°C revealed that the thermo-chemical characteristics of solar salt at high temperatures surpassing the decomposition temperatures of nitrate salts reduce the accuracy of heat transfer model of the RELAP5-3D code. Specifically, it has been observed that the temperatures of the wall surface and liquid near the wall can surpass the decomposition temperatures, even though the bulk temperature of molten salts remains significantly lower than these decomposition temperatures. In summary, this study recommends the use of the Gnielinski correlation for the heat transfer analysis of molten salt, rather than the Dittus-Boelter correlation.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

Efficient Silicon Carbide (SiC) Fiber Manufacture: Continuous Processing of Novel Precursors via Modified Material Handling

General Atomics Electromagnetic Systems (GA-EMS) together with The Nonwovens Institute (NWI) and Harper International have executed on a development project to improve the production efficiency and reduce the production cost of silicon carbide (SiC) fiber – a critical material that advances US energy security and aerospace leadership. In the first budget period (BP1), the modified tow throughput (MTT) apparatus was developed, enabling fiber spinning in the form of loose coils rather than tightly packed spools (Figure 1) for batch processing of SiC fiber. This coil-based approach was proven to be capable of uniform fiber crosslinking and ceramic conversion, as well as demonstrating key process efficiencies while meeting the program fiber property targets.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Sonic Wafering of III-V substrates for High Efficiency Cells: A path to <$0.50/W

This project developed and demonstrated Sonic Lift-off, a novel technology that enables the reuse of expensive semiconductor substrates used to manufacture high-efficiency solar cells. By using sound waves to precisely separate thin layers of material, the process significantly reduces manufacturing costs while maintaining the performance of advanced III–V solar cells. These solar cells are among the most efficient in the world and are used in space, aerospace, and emerging terrestrial applications. The results of this work show that substrate reuse can be achieved without degrading device performance, offering a pathway to more affordable, high-performance solar technologies. This advancement supports U.S. clean energy goals by enabling broader deployment of renewable energy systems and strengthening domestic manufacturing capabilities in advanced photovoltaics.

14 SOLAR ENERGY↗

Stratospheric aerosol forcing for CMIP7 – Part 1: optical properties for pre-industrial, historical, and scenario simulations

Stratospheric aerosols, most of which originate from explosive volcanic sulfur emissions into the stratosphere, are a key natural driver of climate variability. They are thus a forcing provided by the Coupled Model Intercomparison Project (CMIP) Climate Forcings Task Team to climate modelling groups participating in phase 7 of CMIP. For the historical period, we provide two datasets covering 1750–2023: (i) a volcanic upper tropospheric-stratospheric sulfur emission dataset, documented in a companion paper; and (ii) a stratospheric sulfate aerosol optical property dataset, documented in this paper. For the satellite era (from 1979 onwards), stratospheric aerosol optical properties are derived from the Global Space-based Stratospheric Aerosol Climatology (GloSSAC) dataset. For the pre-satellite era (1750–1978), optical properties are derived from our volcanic SO 2 emission dataset using a new version of the reduced-complexity volcanic aerosol model Easy Volcanic Aerosol (Height) (EVA_H v2). A background, non-volcanic stratospheric aerosol climatology is derived from the 1998–2001 period with a trend over 1850–1978 accounting for increasing anthropogenic aerosols. A monthly stratospheric aerosol climatology is derived from the 1850–2021 average for both pre-industrial and scenario (future) simulations, with a 9-year ramp over 2022–2030 for scenario simulations to ensure a smooth transition from the historical period. CMIP7 simulations should use version 2.2.1 of our pre-industrial and historical datasets, and version 2.2.2 of our scenario dataset. Our methodology to produce historical aerosol optical properties significantly differs from CMIP6 for the pre-satellite era, and the resulting forcings in turn largely differ. In particular, the CMIP6 dataset was mostly based on the sparse and uncertain pyrheliometer record, which resulted in strongly underrepresented emissions from small-to-moderate magnitude eruptions. The resulting bias is addressed in CMIP7, which is entirely emission-derived in the pre-satellite era and uses more recent ice-core-based volcanic sulfur emission inventories than CMIP6. Our approach results in an overall larger volcanic aerosol forcing for CMIP7, with the 1850–2014 mean mid-visible global mean stratospheric aerosol optical depth (SAOD) in CMIP7 (0.0138) being 29 % higher than in CMIP6 (0.0107). The pre-industrial mean of the same variable is 26 % higher in CMIP7 (0.0135, derived from the historical 1850–2021) than CMIP6 (0.0107, derived from the historical 1850–2014 mean). Using a reduced-complexity climate model, we simulate a global mean surface temperature that is 0.07 °C colder for 1850–1900 when using the CMIP7 dataset instead of CMIP6, whereas 2000–2014 is 0.03 °C warmer in CMIP7. Our dataset also exhibits lower forcing for 1960–1980, resulting in temperatures 0.06 °C warmer when averaged over 1960–1990, a period for which CMIP6 climate models exhibit a cold bias. Given the large uncertainties characterizing the dataset, in particular for the pre-satellite era, we advise against treating the CMIP7 or CMIP6 dataset as uniquely superior for any specific year and highlight the need for further evaluation. We conclude the study by discussing sources of uncertainty for the dataset, future research avenues to improve it, as well as requirements to operationalize the production of the dataset, i.e. extend it and update it on an annual basis instead of every 5–7 years following CMIP cycles.

Aubry, Thomas J. [Univ. of Exeter, Devon (United K↗

Extending wire-arc directed energy deposition using non-gravity aligned (NGA) torch methods

For standard Additive Manufacturing (AM) processes, traditional path planning typically relies on a 2.5-dimensional approach. In wire-arc directed energy deposition (DED), commonly referred to as wire-arc additive manufacturing (WAAM), this 2.5D approach inherently limits final near net shape due to the stair-step effect and restricts the maximum overhang angle achievable without part degradation. To achieve better near net shape and part quality, a 3D planning approach that modulates the tool tip position and angle without process changes is demonstrated in components containing up to 105° of unsupported overhang. The experimental methods are validated with half and fully enclosed cylinder sections containing 90° of overhang. The non-gravity aligned methods are then applied to a commercial WAAM system for a composite tool mold demonstrator part. As a result, the methods developed in this paper enable expansion of WAAM system capabilities to parts containing large overhangs without compromising the net shape or material structure of the resulting parts and without the need for a part positioner.

Additive manufacturing↗

Unlocking the Future of Aircraft Manufacturing: The Environmental Benefits of Laser Patterning for Surface Enhancement of Aircraft-Certified Alloys

Surface protection and functional modification of aircraft-certified aluminum alloys are essential for corrosion resistance, durability, and long-term airworthiness. At the same time, increasingly restrictive environmental regulations motivate the development of alternatives to legacy wet-chemical surface treatments. This study presents an integrated assessment of ultrafast femtosecond laser surface texturing as a surface functionalization approach for Aluminum 6061 alloys within an aerospace manufacturing and sustainability context. Ultrashort-pulse laser processing enables controlled micro- and nano-scale surface topographical modification with limited thermal impact, allowing adjustment of wettability and surface functionality while preserving bulk material integrity. As a dry and contactless process, femtosecond laser treatment eliminates the use of hazardous chemicals, reduces consumable inputs, and generates minimal secondary waste. A streamlined cradle-to-gate life cycle assessment conducted in accordance with ISO 14040/14044 indicates a lower global-warming potential per functional unit compared with conventional surface treatments, including anodization, plasma-assisted coatings, and organic coating systems. Complementary qualitative analyses addressing environmental health and safety, supply-chain risk, and ESG alignment indicate potential advantages related to occupational safety, regulatory compliance, waste management, and end-of-life recyclability. The investigation is performed on planar Aluminum 6061 reference surfaces with a treated area of 25 mm 2 , providing a controlled laboratory-scale basis for analyzing process behavior, functional surface modification, and associated environmental metrics. Within this defined scope, the results support further evaluation of femtosecond laser surface texturing as a surface engineering option for future aerospace manufacturing.

corrosion resistance↗

From Chaos to Clarity: Autonomous Materials Discovery for Extreme Environments [Slides]

The pursuit of advanced functional materials for energy applications demands an understanding of their behavior under the most challenging conditions. Extreme environments, characterized by intense radiation, high temperatures, and corrosive chemistries, push materials to their limits, often revealing unexpected behaviors and degradation pathways. Traditional materials research approaches, relying on trial-and-error experimentation, are often slow and resource-intensive, ill-suited to the complexities of extreme environments. This talk will explore the transformative potential of autonomous materials science in revolutionizing our understanding of materials synthesis and degradation in extreme environments. By integrating advanced microscopy techniques, artificial intelligence, and robotic experimentation, we can accelerate the discovery and design of resilient materials for a sustainable future. The presentation will highlight recent breakthroughs in autonomous microscopy, computer vision, and machine learning, showcasing their ability to unravel complex material transformations at the atomic scale. The talk will also delve into the challenges and opportunities associated with deploying autonomous systems to probe extreme environments, emphasizing the importance of robust algorithms, real-time data analysis, and adaptive experimentation. The ultimate goal is to empower scientists with unprecedented capabilities to explore, understand, and engineer materials that can withstand the harshest conditions, paving the way for innovations in energy, aerospace, and beyond.

14 SOLAR ENERGY↗

From Chaos to Clarity: Autonomous Materials Discovery for Extreme Environments

The pursuit of advanced functional materials for energy applications demands an understanding of their behavior under the most challenging conditions. Extreme environments, characterized by intense radiation, high temperatures, and corrosive chemistries, push materials to their limits, often revealing unexpected behaviors and degradation pathways. Traditional materials research approaches, relying on trial-and-error experimentation, are often slow and resource-intensive, ill-suited to the complexities of extreme environments. This talk will explore the transformative potential of autonomous materials science in revolutionizing our understanding of materials synthesis and degradation in extreme environments. By integrating advanced microscopy techniques, artificial intelligence, and robotic experimentation, we can accelerate the discovery and design of resilient materials for a sustainable future. The presentation will highlight recent breakthroughs in autonomous microscopy, computer vision, and machine learning, showcasing their ability to unravel complex material transformations at the atomic scale. The talk will also delve into the challenges and opportunities associated with deploying autonomous systems to probe extreme environments, emphasizing the importance of robust algorithms, real-time data analysis, and adaptive experimentation. Our ultimate goal is to empower scientists with unprecedented capabilities to explore, understand, and engineer materials that can withstand the harshest conditions, paving the way for innovations in energy, aerospace, and beyond.

artificial intelligence↗

Microwave-Assisted Production of Polycarbonate Diols using Carbon Dioxide

Carbon dioxide (CO2) is a cheap and readily available resource that can be converted to value-added chemicals including fuels, polymers, and other products. One lucrative option is polycarbonate diols, which are the precursor to polyurethanes that find wide applications in automotive and aerospace industries. The traditional process for the synthesis of polycarbonate diols involves using hazardous phosgene and alcohols in a strongly basic medium that generates significant amounts of salt. Alternately, CO2 can be reacted with alkanediols over CeO2 catalysts to produce polycarbonate diols. For the current work, a microwave-assisted atmospheric flow system was investigated for converting CO2 into polycarbonate diols and was compared against a thermal system. Various parameters such as type and ratio of solvents, and the addition of dehydrating agents for the microwave system was tested. The different CeO2 catalysts used were characterized using Brunauer–Emmett–Teller (BET) surface area analysis, Raman spectroscopy, X-ray diffraction, and temperature programmed desorption (NH3-TPD and CO2-TPD).

CO2 utilization↗