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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

The NREL Sensor Laboratory: Hydrogen Leak Detection for Large Scale Deployments: Preprint

The NREL Hydrogen Sensor Laboratory was commissioned in 2010 as a resource for sensor developers, end-users, and regulatory agencies within the national and international hydrogen community. The Laboratory continues to provide as its core capability the unbiased verification of hydrogen sensor performance to assure sensor availability and their proper use. However, the mission and strategy of the NREL Sensor Laboratory has evolved to meet the needs of the growing hydrogen market. The Sensor Laboratory program has expanded to support research in conventional and alternative detection methods as hydrogen use expands to large-scale markets as envisioned by the DOE National Clean Hydrogen Strategy and Roadmap. Current research encompasses advanced methods of hydrogen leak detection including stand-off and wide area monitoring approaches for large scale and distributed applications. In addition to safety applications, low-level detection strategies to support the potential environmental impacts of hydrogen and hydrogen product losses along the value chain are being explored. Many of these applications utilize detection strategies that supplement and may supplant the use of traditional point sensors. The latest results of the hydrogen detection strategy research at NREL will be presented.

detection↗
DOE OSTI2025

Benchmark study of the DTU OWC chamber with both two-way and one-way absorption

This paper reports on a benchmark study based on small-scale (1:50) measurements of a single, oscillating water column chamber mounted sideways in a long flume. The geometry of the OWC chamber is extracted from a barge-like, attenuator-type floating concept “KNSwing” with 40 chambers targeted for deployment in the Danish part of the North Sea. In addition to traditional two-way energy extraction we also consider one-way energy extraction with passive venting and compare chamber response, pressures and total absorbed energy between the two methods. A blind study was established for the numerical modeling, with participants applying several implementations of weakly nonlinear potential flow theory and commercial Navier–Stokes solvers (CFD). Both compressible and incompressible models were used for the air phase. Potential flow calculations predict more energy absorption near the chamber resonance for one-way absorption than for two-way absorption, but the opposite is found from the experimental measurements. This outcome is mainly attributed to energy losses in the experimental passive valve system, but this conclusion must be confirmed by better experimental measurements. Modeling the one-way valve in CFD proved to be very challenging and only one team was able to provide results which were generally closer to the experiments. The study illustrates the challenges associated with both numerical and experimental analysis of OWC chambers. Air compressibility effects were not found to be important at this scale, even with the large volume of additional air used for the one-way case.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

Role of Computational Parameters on Predicting Self-Consistent Residual Stress and Distortion during Wire Arc Additive Manufacturing

Production of three-dimensional metallic parts through integration of an articulated robot and gas metal arc welding, also known as wire arc additive manufacturing (WAAM), can produce large-scale components with moderate geometrical complexity. This technology is particularly appealing due to its high deposition rates, scalability, and cost-effective feedstock compared to other AM processes. Despite its advantages, WAAM adoption is hindered by challenges in ensuring geometric conformity without extensive distortion, defect-free structures, and consistent mechanical properties. Finite element analysis (FEA) is often used to address the challenge of geometrical conformity. As the size of parts increases, the best practices for mesh size and temporal resolution known in the literature become computationally unviable. This research examined the effects of mesh and time-step resolutions during transient FEA of a large-scale (248 layers) metallic part. The impact of computational parameters on the thermal history, displacement, and residual stress distributions were evaluated. The results showed that predicted distortion was consistent across resolutions, while time-step length significantly affected predicted thermal history, and mesh size influenced residual stress distributions. To investigate this relationship further, directionally biased meshes were considered and analyzed. The results indicated that increasing mesh resolution perpendicular to the welding path yielded stress predictions that aligned closely with higher-resolution models while offering substantial computational savings. In conclusion, the significances of this research are related to verification and validation of WAAM models for widespread industrial adoption and pragmatic guidelines for optimizing computation parameters for balancing computational efficiency and predictive accuracy of residual stress and distortion.

Solsbee, Brandon [Univ. of Tennessee, Knoxville, T↗
DOE OSTI2025

DeepAndes: A Self-Supervised Vision Foundation Model for Multispectral Remote Sensing Imagery of the Andes

By mapping sites at large scales usingremotely sensed data, archaeologists can generate unique insights into long-term demographic trends, interregional social networks, and human adaptations in the past. Remote sensing surveys complement field-based approaches, and their reach can be especially great when combined with deep learning and computer vision techniques. However, conventional supervised deep learning methods face challenges in annotating fine-grained archaeological features at scale. In addition, while recent vision foundation models have shown remarkable success in learning large-scale remote sensing data with minimal annotations, most off-the-shelf solutions are designed for RGB images rather than multispectral satellite imagery, such as the eight-band data used in our study. In this article, we introduce DeepAndes, a transformer-based vision foundation model trained on three million multispectral satellite images, specifically tailored for Andean archaeology. DeepAndes incorporates a customized DINOv2 self-supervised learning algorithm optimized for eight-band multispectral imagery, marking the first foundation model designed explicitly for the Andes region. We evaluate its image understanding performance through imbalanced image classification, image instance retrieval, and pixel-level semantic segmentation tasks. Our experiments show that DeepAndes achieves superior F1 scores, mean average precision, and Dice scores in few-shot learning scenarios, significantly outperforming models trained from scratch or pretrained on smaller datasets. This underscores the effectiveness of large-scale self-supervised pretraining in archaeological remote sensing.

Guo, Junlin [Vanderbilt Univ., Nashville, TN (Unit↗
DOE OSTI2024

Responses of summer mesoscale convective systems to irrigation over the North China Plain based on convection-permitting model simulations

Extensive irrigation activities in the North China Plain (NCP) significantly influence regional weather and climate. However, previous studies focusing on the NCP were primarily based on coarse-resolution models, which are unable to explicitly resolve convection systems, causing large uncertainty in precipitation simulations. In this study, a convection-permitting model coupled with a dynamic irrigation scheme is utilized to investigate the impacts of irrigation on summertime mesoscale convective systems (MCSs) over the NCP. Sensitivity experiments with irrigation off and on are conducted for 5 summers and an MCS identification and tracking algorithm is applied to both satellite observations and model simulations. We find that incorporating irrigation in the model increases MCS precipitation, which agrees more with observations. The probability distributions of MCS lifetime, area, propagation speed, and intensity are all better simulated with irrigation. Irrigation increases the occurrence frequency of MCSs throughout the entire day. The nighttime increase is partly because of more frequent local initiation of MCS developed from isolated deep convection, while the daytime increase is mainly attributed to the changes in MCSs initiating elsewhere and then propagating to the NCP. On average, irrigation induces additional moisture that is more thermodynamically favorable for precipitation, but this effect is partially offset by the weakened ascending air motion primarily caused by irrigation surface cooling. Compared to weak MCS precipitation events, strong MCS precipitation events experience greater enhancement in precipitation intensity when including irrigation because the offset effect from the change in large-scale ascending air motion is insignificant. In addition, irrigation makes the variation of MCS precipitation intensity more correlated with the variation in ascending motion but less correlated with that in atmospheric moisture. Our results suggest the pronounced impacts of irrigation on MCSs over the NCP which should be included in numerical models to improve regional precipitation simulation and prediction.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Next-Generation Electric Motors and Electromagnetic Devices (CRADA Final Report)

As part of the Cyclotron Road program, the Foli Research team investigated electric motors and other electromagnetic devices additively manufactured by depositing fine conducting wire onto a substrate. By leveraging modern motion control and efficient upstream manufacturing processes, the team explored using geometric control and turnkey production comparable to printed circuit board manufacturing, aiming at ten-fold improvements in signal density, while eliminating the material use, cost, and complexity overheads of subtractive processes at large scales. Owing to the achievable density and additive scaling, disparate components became monolithic, and disparate processes were combined with the aim of reducing development costs, uncertainties, and timelines. When applied to electric motors, this technology may enable agile manufacturing of next-generation designs, with dramatic increases in achievable power density and material utilization. Electric motors represent the single largest user of electricity in the U.S. and a critical component of decarbonized infrastructure. Despite this significance, the manufacturing of motors and other electromagnetic devices remains capital-intensive, labor-intensive, and performance-limiting. Advanced manufacturing processes were required to produce high-performance, low-cost, application-specific electric motors and electromagnetic devices to support an electrified future.

42 ENGINEERING↗
DOE OSTI2024

Local primordial non-Gaussianity from the large-scale clustering of photometric DESI luminous red galaxies

ABSTRACT We use angular clustering of luminous red galaxies from the Dark Energy Spectroscopic Instrument (DESI) imaging surveys to constrain the local primordial non-Gaussianity parameter fNL. Our sample comprises over 12 million targets, covering 14 000 deg2 of the sky, with redshifts in the range 0.2 < z < 1.35. We identify Galactic extinction, survey depth, and astronomical seeing as the primary sources of systematic error, and employ linear regression and artificial neural networks to alleviate non-cosmological excess clustering on large scales. Our methods are tested against simulations with and without fNL and systematics, showing superior performance of the neural network treatment. The neural network with a set of nine imaging property maps passes our systematic null test criteria, and is chosen as the fiducial treatment. Assuming the universality relation, we find $f_{\rm NL} = 34^{+24(+50)}_{-44(-73)}$ at 68 per cent (95 per cent) confidence. We apply a series of robustness tests (e.g. cuts on imaging, declination, or scales used) that show consistency in the obtained constraints. We study how the regression method biases the measured angular power spectrum and degrades the fNL constraining power. The use of the nine maps more than doubles the uncertainty compared to using only the three primary maps in the regression. Our results thus motivate the development of more efficient methods that avoid overcorrection, protect large-scale clustering information, and preserve constraining power. Additionally, our results encourage further studies of fNL with DESI spectroscopic samples, where the inclusion of 3D clustering modes should help separate imaging systematics and lessen the degradation in the fNL uncertainty.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

A Boundary Element Model for Assessing Large‐Scale Pressurization in Faulted Geological Storage Systems

Assessing large-scale pressurization at the regional scale—a possible outcome of large subsurface storage applications such as wastewater injection and geological carbon sequestration—presents significant computational challenges. These challenges are particularly pronounced when accounting for complex geologic structures with multiple reservoir and caprock layers, fault zones, and wells. This study introduces a computationally efficient model that integrates single-phase semi-analytical solutions with a boundary element (BE) approach. The model simulates pressure propagation in multilayered 3D systems, including vertical faults, caprock, basement, and confining units. We apply this new model to a representative scenario involving CO 2 injection near a partially sealing fault with verification against an independent two-phase flow model. Results demonstrate that our model accurately captures far-field pressure responses and that, outside the CO 2 plume zone, pressure predictions from single-phase and two-phase models are nearly identical. This supports the use of single-phase models like ours for efficient estimation of far-field pressure changes. Additionally, we demonstrate its effectiveness at a large scale, incorporating multiple wells and faults. With its ability to represent multiple wells, fault zones, and geological heterogeneity, our model is well suited for assessments of basin-scale pressurization. Its computational efficiency also makes it a promising tool for integration with optimization frameworks aimed at designing and managing injection strategies in faulted storage systems.

Cihan, A. [Lawrence Berkeley National Laboratory (↗
DOE OSTI2024

Driving macro-scale transformations in three-dimensional-printed biopolymers through controlled induction of molecular anisotropy at the nanoscale

Motivated by the need to harness the properties of renewable and biodegradable polymers for the design and manufacturing of multi-scale structures with complex geometries, we have employed our additive manufacturing platform that leverages molecular self-assembly for the production of metre-scale structures characterized by complex geometries and heterogeneous material composition. As a precursor material, we used chitosan, a chemically modified form of chitin, an abundant and sustainable structural polysaccharide. We demonstrate the ability to control concentration-dependent crystallization as well as the induction of the preferred orientation of the polymer chains through the combination of extrusion-based robotic fabrication and directional toolpathing. Anisotropy is demonstrated and assessed through high-resolution micro-X-ray diffraction in conjunction with finite element simulations. Using this approach, we can leverage controlled and user-defined small-scale propagation of residual stresses to induce large-scale folding of the resulting structures.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Design and scale-up of 3D printed bat houses with biomass-derived polymer composites

Biomass (e.g., pine sawdust, especially high–ash content pine sawdust) is commonly disposed of as waste. Combining biomass with polymers to make composite feedstocks for 3D printing has been explored as a method to reduce or repurpose the biomass waste. Although not all biocomposite properties are known, the wood-based polylactic acid (PLA) composite has promising qualities for applications in ecological settings. In this work, pine wood–PLA composite feedstock was used to 3D print supplemental roost structures for endangered tree-roosting bats, which often face a paucity of suitable naturally occurring roosts. This material combination was selected because it is estimated to degrade faster than the synthetic material systems that are used widely in supplemental bat roosting structures to aid in the conservation of tree roosting bats. The layered, rough surface created by the 3D printing process serves as a surface that bats can grip while roosting. Computer-aided design (CAD) models were generated based on natural roost structures, and a full-size bat house was successfully additively manufactured using a pellet-fed large-scale 3D printing system. The 3D printed hexagon exhibited a tensile strength of 22–23 MPa and a Young’s modulus of 3202–3218 MPa in the x-direction. It has been demonstrated that the 3D printed bat house can be installed on a tree in a stable fashion. This successful demonstration of a bat roost manufactured using a bioderived composite should promote its use in other fish and wildlife structures and broader industrial applications such as construction and automobiles.

3D printing↗
DOE OSTI2025

Assessing the deployment of solar-driven hydrogen from biomass at scale in the U.S.

Solar hydrogen from biomass gasification is a promising technology to sustainably produce hydrogen, responsibly dispose biomass waste, and reduce reliance on fossil fuels. However, its large-scale deployment faces challenges due to the geospatial misalignment between biomass resources and solar intensity, which introduces additional supply chain logistics costs. We analyze the logistics cost burden imposed by this misalignment and its impact on successful large-scale deployment of solar-driven hydrogen from biomass in the United States. We also consider associated carbon emissions and explore how the mix of deployed technologies evolves under externally imposed carbon penalties. Our findings show that while economies of scale are known to apply at the processing facility level, the reverse effect occurs at the broader systems-level, driven by logistics. Also, at current technology costs, high carbon penalties would be required to favor deployment of solar based technologies over conventional and hybrid alternatives. We further illustrate strategies and system-level changes to reduce logistics costs and enable sustainable, low-cost hydrogen for decarbonizing different industrial sectors.

Iloeje, Chukwunwike O. [Argonne National Laborator↗
DOE OSTI2024

A Machine Learning Bias Correction on Large–Scale Environment of High–Impact Weather Systems in E3SM Atmosphere Model

Large–scale dynamical and thermodynamical processes are common environmental drivers of high–impact weather systems causing extreme weather events. However, such large–scale environmental conditions often display systematic biases in climate simulations, posing challenges to evaluating high–impact weather systems and extreme weather events. In this paper, a machine learning (ML) approach was employed to bias correct the large–scale wind, temperature, and humidity simulated by the atmospheric component of the Energy Exascale Earth System Model (E3SM) at ~1° resolution. The usefulness of the ML approach for extreme weather analysis was demonstrated with a focus on three high–impact weather systems, including tropical cyclones (TCs), extratropical cyclones (ETCs), and atmospheric rivers (ARs). We show that the ML model can effectively reduce climate bias in large–scale wind, temperature, and humidity while preserving their responses to imposed climate change perturbations. The bias correction is found to directly improve water vapor transport associated with ARs, and representations of thermodynamical flows associated with ETCs. When the bias–corrected large–scale winds are used to drive a synthetic TC track forecast model over the Atlantic basin, the resulting TC track density agrees better with that of the TC track model driven by observed winds. In addition, the ML model insignificantly interferes with the mean climate change signals of large–scale storm environments as well as the occurrence and intensity of three weather systems. This study suggests that the proposed ML approach can be used to improve the downscaling of extreme weather events by providing more realistic large–scale storm environments simulated by low–resolution climate models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Historical and Future Learning for the New Era of Multi-Terawatt Photovoltaics

Solar photovoltaics (PV) is entering a new era of multi-terawatt deployment, with 2 TW already in service and more than 75 TW predicted in many scenarios by 2050. This next era has been enabled by over five decades of cumulative advances in PV module cost reduction, performance and reliability. The current scale of deployment also introduces new needs, opportunities and challenges. In this Perspective we frame a path forwards based on learning, broadly defined as a combination of expansion of knowledge and advances through research and development, experience and collaboration. We discuss historical topics where learning has driven PV deployment until now, and emerging areas that are required to sustain high levels of future deployment. We expect progress to continue in terms of module price, performance and reliability, driven by advances in PV cell and module design, the emergence of tandem devices and increased focus on extending module lifetimes. Large-scale deployment also means large-scale sustainability and responsibility. We therefore posit that additional metrics, such as the impact on global CO2 emissions, resource consumption and design for reuse and recycling, will become increasingly important to the PV industry and provide opportunities for further learning.

14 SOLAR ENERGY↗
DOE OSTI2025

Unique Structural Features Relate to Evolutionary Adaptation of Cytochrome P450 in the Abyssal Zone

Cytochromes P450 (CYPs) form one of the largest enzyme superfamilies, with similar structural folds yet biological functions varying from synthesis of physiologically essential compounds to metabolism of myriad xenobiotics. Sterol 14α-demethylases (CYP51s) represent a very special P450 family, regarded as a possible evolutionary progenitor for all currently existing P450s. In metazoans CYP51 is critical for the biosynthesis of sterols including cholesterol. Here we determined the crystal structures of ligand-free CYP51s from the abyssal fish Coryphaenoides armatus and human-. Comparative sequence–structure–function analysis revealed specific structural elements that imply elevated conformational flexibility, uncovering a molecular basis for faster catalytic rates, lower substrate selectivity, and intrinsic resistance to inhibition. In addition, the C. armatus structure displayed a large-scale repositioning of structural segments that, in vivo, are immersed in the endoplasmic reticulum membrane and border the substrate entrance (the FG arm, >20 Å, and the β4 hairpin, >15 Å). The structural distinction of C. armatus CYP51, which is the first structurally characterized deep sea P450, suggests stronger involvement of the membrane environment in regulation of the enzyme function. We interpret this as a co-adaptation of the membrane protein structure with membrane lipid composition during evolutionary incursion to life in the deep sea.

Biochemistry & Molecular Biology↗
DOE OSTI2024

Testing Protocol Development for the Fracture Toughness of Parts Built with Big Area Additive Manufacturing

The mechanical testing of additively manufactured parts has largely relied on the existing standards developed for traditional manufacturing. While this approach leverages the investment made in current standards development, it inaccurately assumes that the mechanical response of additive manufacturing (AM) parts is identical to that of parts manufactured through traditional processes. When considering thermoplastic, material extrusion AM, the differences in response can be attributed to an AM part’s inherent inhomogeneity caused by porosity, interlayer zones, and surface texture. Additionally, the interlayer bonding of parts printed with large-scale AM is difficult to adequately assess, as much testing is performed such that stress is distributed across many layer interfaces; therefore, the lack of AM-specific standards to assess interlayer bonding is a significant research gap. To quantify interlayer bonding via fracture toughness, double cantilever beam (DCB) testing has been used for some AM materials, and DCB has been generally used for a variety of materials including metal, wood, and laminates. Mode I DCB testing was performed on thermoplastic matrix composites printed with Big Area Additive Manufacturing (BAAM). Of particular interest was the notch shape and deflection speed during testing. The results examine the differences when using two notch types and three deflection speeds. The testing method introduced by the following paper differentiates itself from the ones described in the standards used by modernizing the methodology. This was conducted with the introduction of Digital Image Correlation (DIC) to gather displacement and load data simultaneously without human intervention.

Polymer Science↗
DOE OSTI2024

Post-processing of phase change material in a zero-change commercial silicon photonic process

Integration of phase change material (PCM) with photonic integrated circuits can transform large-scale photonic systems by providing non-volatile control over phase and amplitude. The next generation of commercial silicon photonic processes can benefit from the addition of PCM to enable ultra-low power, highly reconfigurable, and compact photonic integrated circuits for large-scale applications. Despite all the advantages of PCM-based photonics, today’s commercial foundries do not provide them in their silicon photonic processes yet. We demonstrate the first-ever electrically programmable PCM device that is monolithically post-processed in a commercial foundry silicon photonics process using a few fabrication steps and coarse-resolution photolithography. These devices achieved 1.4 dB/μm of amplitude switching contrast using a thin layer of 12.5 nm GeSbTe in this work. We have also characterized the reconfiguration speed as well as repeatability of these devices over 20,000 switching cycles. Our solution enables non-volatile photonic VLSI systems that can be fabricated at low cost and high reliability in a commercial foundry process, paving the way for the development of non-volatile programmable photonic integrated circuits for a variety of emerging applications.

Optics↗
DOE OSTI2024

Disruptive Technology for Carbon Negative Commodity Chemicals

This project was designed to develop an economically attractive process for the carbon negative production of the commodity biochemical succinic acid. To compete against petroleum derived biochemicals, the process must deliver high raw material conversion efficiency and high volumetric productivity to reduce both recurring and capital-related costs, respectively. The proposed process introduces additional electrons sourced from hydrogen into the biosynthetic pathway so that the carbon from two CO2 molecules can be combined with each glucose to significantly increase succinic acid yields. The process also uses ultrafiltration to continuously remove the product from the bioreactor to avoid product inhibition and extend the productive life of the cell extract. Genetic deletions and specific enzyme removal during extract preparation more efficiently direct both atomic and electronic resources toward product formation. A preliminary technoeconomic analysis indicates that these process innovations made possible by cell-free production will enable large scale production with attractive ROI and profitability. This two-year project provided some 29 distinct insights, analytical advances, and process improvements that resulted in a demonstration of process feasibility. However, an estimated two to three years of additional development will be required to achieve convincing pilot scale demonstrations that will motivate large scale investments.

60 APPLIED LIFE SCIENCES↗