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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 Fuel Motion Monitoring System at TREAT - Current Status and Future Plans

An important component of the United States Nuclear Fuel Safety Transient Testing Program, the Fuel Motion Monitoring System (FMMS) at Idaho National Laboratory's Transient Reactor Test Facility (TREAT) is fast-neutron hodoscope capable of imaging the location, movement, and relocation of nuclear fuel experiments under simulated transient accident conditions. The FMMS was refurbished in parallel with the TREAT restart program starting in 2014, restoring 96-channels of fast-neutron detection. Since returning to operation in 2017 the FMMS has supported many fuel safety experiments supporting accident tolerant fuel development, light-water reactor safety, space thermal nuclear propulsion fuel development, and advanced reactor research and development. In Phase 2 of the FMMS restoration. work is now under way to expand the FMMS' field-of-view by adding an additional 96 channels of fast neutron detectors to the system's hodoscope, along with an expanded data acquisition system and associated transient timing electronics. An overview of the FMSS system and its fast-neutron detectors will be presented along with examples of current FMMS imaging performance and associated information.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2026

Garnet/PVDF-HFP Hybrid Membranes for Li-Metal Batteries: Cooperative Research and Development Final Report, CRADA Number CRD-19-00807

Hazen Research, Inc., in collaboration with University of Colorado, Boulder (CU-B) and National Renewable Energy Laboratory (NREL), will develop and demonstrate a ceramic-polymer hybrid membrane based on garnet (Li7La3Zr2O12) and PVDF (Poly Vinylidene Fluoride)-HFP (Hexafluoropropylene) adaptable to Li-metal anodes. Under this CRADA, NREL will test the developed membranes providing feedback and advice to demonstrate hybrid membranes with Li-ion conductivity >10-4 S/cm at room temperature that are stable with Li-metal, followed by demonstration of full cells with Li-metal anode.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2008

Vehicle Technologies Program: Energy Storage R&D (2008 Annual Progress Report)

One of the primary objectives of the Energy Storage effort is the development of durable and affordable advanced batteries (and ultracapacitors) for use in a full range of vehicle applications, from start/stop to full-power HEVs, EVs, and PHEVs. The battery technology development activity spans three areas: system development of full battery systems; benchmark testing of emerging technologies in order to remain abreast of the latest industry developments; and Small Business Innovative Research (SBIR) to fund early-stage R&D for small businesses/entrepreneurs.

25 ENERGY STORAGE↗
DOE OSTI2026

Two-Phase Cooling for High Packaging Density Planar Inverter: Cooperative Research and Development Final Report, CRADA Number CRD-15-00592

The project objective was to utilize two-phase heat transfer to enable compact and power-dense inverters. The high heat transfer capacity and near isothermal characteristics of two-phase cooling can enable higher power densities, reducing the size and cost of the power electronics system. This project focused on developing efficient, passive (no pump or compressor) two-phase cooling strategies that consist of an air-cooled condenser and evaporator. This report describes the modeling work conducted to design the evaporator and air-cooled condenser for a prototype inverter development work underway in the John Deere. Prototypes of the final evaporator and condenser designs were then fabricated via 3D printing for testing. Experiments on the evaporator confirmed that this component can meet the heat load and junction temperatures requirements for Si IGBT (insulated-gate bipolar transistor) inverter. Experiments with the air-cooled condenser were not possible due to leaks through the condenser walls.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Hybrid Energy Management with Real-Time Control of a High-Power EV Charging Site

Decarbonization of transportation systems is driving higher capacity energy storage and faster charging power requirements in electric vehicles (EVs). Given the potential advantages - such as increased efficiency, reduced inverter capacity, and less total cable mass - there is a demand in the industry for more DC distribution for high-power charging (HPC) hubs. However, the cost-effective, adaptive, and robust operation of the DC-coupled HPC hub necessitates a robust site energy management system (SEMS). Validating SEMS operation using a digital twin of an HPC hub in a real-time simulator (RTS) platform is crucial before field deployment. In this study, we propose a hybrid energy management site controller designed to achieve high-level, long-term operational objectives while managing low-level power sharing control between hub assets. We develop a centralized model predictive controller (MPC) to optimize hub operating points and use these points to update the droop parameters of the site energy storage system (ESS). This approach ensures the hub follows an optimal operating point while maintaining the flexibility to respond to load surges. We tested and verified our proposed approach both offline and on a Controller Hardware-in-the-loop (C-HIL) simulation platform integrated with a SEMS framework, demonstrating real-time site operation and validating a cost-effective and robust site controller.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Ultra-high temperature testing and performance of L-PBF C103

Additive Manufacturing (AM) of refractory alloys is gaining traction as a materials processing route for components subject to extreme temperature environments. Due to the low oxidation resistance of refractory alloys, novel methods for evaluating their elevated temperature performance must be developed. In this work, a Gleeble® 3800 thermomechanical load frame was modified to evaluate the mechanical properties of laser powder bed fusion (L-PBF) consolidated niobium alloy C103 ranging from room temperature (RT) to 1400 °C. The fixturing and sample geometry were designed to accommodate Joule heating and prevent damage to the test chamber. Oxidation of the samples was minimized via testing in vacuum level of 1E-5 Torr. Ultimate tensile strength (UTS), yield strength (YS), elongation, and strain-hardening behavior were determined as a function of temperature. L-PBF C103 presented an average UTS of ∼650 MPa and over 25 % elongation at RT. Above RT, the UTS and YS dropped then leveled off from 500 °C to 1000 °C with values ranging from ∼400 MPa to ∼460 MPa, which is consistent with dynamic strain aging observed in this class of alloys. The strength rapidly declined after 1200 °C to ∼150 MPa at 1400 °C. Fractography indicated ductile fractures for the C103 at all test temperatures, and Electron Backscatter Diffraction (EBSD) analysis revealed a textured microstructure and the presence of dynamic recrystallization within the necked region of the sample tested at 1400 °C.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Low Cost High-Performance HRE-Free 3-in-1 Electric Drive Unit

The project team completed work to expand upon American Axle & Manufacturing’s (AAM) baseline technology and develop a high-speed, AC induction electric drive unit (EDU) with total direct-oil-cooling and integrated power electronics. The project accelerated advancements in EDU technology by allowing AAM to build upon the progress made in developing the underlying baseline technologies. The following seven improvements to AAM’s baseline technology were implemented in this research and development program: 1) Increased speed (30k RPM) AC induction motor, 2) Silver-sintering of discrete silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFET) to heat sinks, 3) Electrically insulated rotor bars, 4) Optimized lamination steel, 5) EDU-integrated 650VDC inverter package, 6) Over-molded stator with molded liners, and 7) 650VDC power-dense stator design. The successful development of the technology resulted in a meaningful cost reduction for EDU systems in the market. Coupled with falling battery system costs, lower EDU costs will likely accelerate the market acceptance and related production scaling of battery electric vehicles. The objective of this project was to research, develop, and test a Heavy Rare Earth (HRE)-free 3-In-1 electric drive unit (EDU) that has class leading power density and cost. The key technologies to be developed were anticipated to meet or exceed the Department of Energy (DOE) targets of a cost ≤ $\$$7/kilowatt (kW), power density ≥ 12 kW/liter, and operating voltage ≥ 600 VDC.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Evaluations of Connectors, Inlets, and Adapters on Side-Load and Withstand Force

This report examines the mechanical forces that direct current fast charging (DCFC) electric vehicle supply equipment (EVSE) connectors and electric vehicle (EV) inlet ports experience during normal usage. As we witness the fast and growing variety of EVs, charge port locations, and bigger and more powerful EVSE configurations including the SAE J3400 North American Charging Standard (NACS), which has increased the use of adapters with J3400 and J1772 compatibility. These new conditions contribute to increased mechanical forces due to their size, weight and lever arm effect, which creates the need to study and compare these forces to the limits on UL2251 and IEC 62196-1 standards. This report focuses solely on high power DC charging EVSE connectors, EV inlets and adapters for the specific compatibility cases on J3400 with J1772. We first describe the details of the 100N and the 750N side-load evaluations as described in the standards, then present the data obtained by replicating these tests to finally go into more detail on the findings and our recommendations.

100N↗
DOE OSTI2024

Greybox Thermal Parameter Identification of Electric Machine Stators

The parameters of electric machine thermal equivalent circuit networks are difficult to predict due to material and manufacturing uncertainties. In this paper, a Greybox system identification approach is used to identify parameters of electric machine stator lumped parameter thermal networks (LPTNs). LPTNs provide a low order, computationally efficient, dynamic model of temperatures at specific locations. Second and third order LPTN model structures are defined as state space equations with stator thermal parameters to be identified. To test the Greybox electric machine stator thermal system identification, five stator motorette prototypes were constructed with controlled variations in slot fill and slot liner thickness. The variation in the motorette thermal parameters and thermal time constants are detected using the Greybox identification. Special attention is given to the impact of sampling rate and Greybox data record length on parameter estimation accuracy.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Assessing Simulations of Forest Hurricane Disturbance and Recovery in Puerto Rico by ELM-FATES Using Field Measurements

In the past three decades, Puerto Rico (PR) experienced five hurricanes that met or exceeded category three, and they caused severe forest structural damage and elevated tree mortality. To improve our mechanistic understanding of hurricane impacts on tropical forests and assess hurricane-affected forest dynamics in Earth system models, we use in situ forest measurements at the Bisley Experimental Watersheds in Northeast PR to evaluate the Functionally Assembled Terrestrial Ecosystem Simulator coupled with the Energy Exascale Earth System Model Land Model (ELM-FATES). The observations show that before Hurricane Hugo, 77.3% of the aboveground biomass (AGB) is from the shade-tolerant plant function type (PFT). The Hugo-induced mortality rates are over ~50%, and they induce a ~39% AGB reduction, which recovers to a level like the pre-Hugo condition in 2014, following a second, lower intensity hurricane, Georges. We perform numerical experiments that simulate damage from Hugo and Georges on the forests, including defoliation, sapwood and structural biomass damage, and hurricane-induced mortality. ELM-FATES can reasonably represent coexistence between the two PFTs–light-demanding and shade-tolerant–for both the pre-Hugo and post-Hugo conditions. The model represents a reasonable size distribution of mid-and large-sized trees although it underestimates AGB, likely due to the overestimated nonhurricane mortality. ELM-FATES temporarily stimulated leaf biomass and diameter increment after Georges, an effect that should be tested with observations of future hurricane defoliation events. This research indicates that addressing model-data mismatches in tree mortality and understory dynamics are essential to simulation of more extreme hurricane effects under climate change.

58 GEOSCIENCES↗
DOE OSTI2025

Synopsis of NREL's Automated Mobility District (AMD) Research Program and Associated Publications

An automated mobility district (AMD) envisions a system of integrated mobility options that serves major activity centers such as campuses, central business districts, and large medical facilities. The National Renewable Energy Laboratory (NREL) has been investigating the implementation prospects for fully automated passenger transport systems that are deployed to operate within dense urban settings. This document provides a synopsis of findings revealed over the last three phases of work, which have yielded insights into the creation and management of AMDs anticipated to use automated vehicle (AV) technology over the next decade. Phase I and Phase II tracked the deployment and lessons learned from 10 early-stage demonstrations of automated shuttle deployments, and their associated insights into the challenges for automated driving systems to achieve safe operations within district-scale deployments. Phase III began in-depth investigations of critical subsystem components, as automation, electrification, and on-demand service continue to converge within initial AMD operations. These directed studies focus on elements of electrification, curbfront/station management, the role of infrastructure sensing, and overall integration of AMD safety management in central, simultaneous coordination of multiple AMD fleets. Future research in AMDs includes systems engineering methodology (more frequently referred to as "digital twins") for planning, design, testing, and ongoing operation of AMDs; location (or co-location) of management functions; and human supervision and passenger communications for safety and security in unattended vehicles. The synopsis references the foundational research products (papers and presentations) that have been published through conference proceedings, journal articles, and NREL reports.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Wind 2H2 Project (CRADA Final Report)

The Xcel-NREL Wind Electrolysis R&D Project is designed to gain knowledge and insight about producing hydrogen from electricity for use as a vehicle fuel and as a “stored wind”. The project will analyze producing hydrogen directly from wind as well as from the electric grid. In addition, it will look at storing hydrogen and then using it to put electricity back onto the grid. Modifications were made to the original scope to also include electric vehicles integration with the electric grid. This report addresses Task 8 portion of the CRADA, focused on testing and measuring the attributes of plug-in electric vehicles.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

MAT 332: Recyclable-By-Design Carbon Fiber Composites for Battery Enclosures

This work aims to fabricate a small-scale battery module with the baseline RBD-CFRC and conduct mechanical crush test to develop an initial thermal runaway model. Test the adhesive properties of the RBD-CFRCs using their resin constituent, ultrasonic welding, and other resins employed today. Recommend a future direction for resin development to enable the welding of RBDCFRCs to dissimilar materials. Time and Cost Permitting. Iterate on resin development for flame resistance and adhesive properties, demonstrating how thermal runaway can be reduced or joining properties can be improved.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

EVs@Scale NextGen Profiles: EVSE Characterization 2024

As part of the U.S. Department of Energy's EVs@Scale consortium, the Next-Generation Profiles (NextGen Profiles) project presents analysis and results from the characterization of high-power conductive and wireless charging infrastructure. High power charging equipment is capable of recharging electric vehicle traction batteries at power levels of 200KW and above. EVSE characterization was conducted over a wide range of DC output current and DC voltage charging for nominal and off-nominal test conditions. Test plans and procedures were developed and refined to define the test configurations and requirements, measurement parameters, and test procedures used throughout NextGen Profiles testing.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Heavy-Duty Nonroad Material Handler Electrification Part 1: Real-World Drive Cycle Development

Knowing a detailed operating cycle is critical for developing and testing equipment. Operating cycles can be separated by two clear distinctions: (1) regulatory or non-regulatory and (2) application at the engine-only or full machine level. The Environmental Protection Agency’s (EPA) Nonroad Transient Cycle (NRTC) may be a good representation of engine use in many types of equipment, but there is a gap in standardized and validated drive cycles specifically for nonroad material handlers. Lacking a standardized drive cycle makes it difficult to accurately benchmark machine performance and validate new powertrain technologies. The objective of this investigation is to illustrate the development of a custom drive cycle augmented with real-world customer use data that serves multiple purposes: (1) understand the range of operation and utilization that formulated inputs for electrified architecture analysis and (2) develop a repetitive and consistent maneuver to establish baseline energy consumption enabling equivalent comparison to future electrified prototype builds. This article presents a solution specifically for a 23-ton nonroad material handler in which material handling, machine transport, and extended idle were homologated to form representative short cycles defined by machine velocity and hydraulic cylinder position. The most intensive material handling short cycles had a load factor of 40% and an average fuel rate of 16 L/h. Combined with a visual aid, the short cycles exhibited low variability, having less than 5% root mean square (RMS) error in lift and reach position with respect to the average. The machine’s performance on these short cycles at the Advanced Power Systems Research Center (APSRC) was compared to results from two real-world customer locations operating the instrumented test machine in a cyclical manner, and for similar ground conditions were found to be comparable in fuel consumption.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Fast, Controllable, and Modular Solid-State Circuit Breaker Design for Battery Management Systems

Electric power grid is experiencing a growing number of distributed and inertia-free generation resources. To facilitate the growing generation and load demands, and ensure stable operation, energy storage systems, especially behind-themeter-storage (BTMS), have emerged as a potential candidate. BTMS plays a vital role in the grid storage sector and supports high power charging for EVs. However, the potential of thermal runaway and associated safety concerns in the batteries can hamper their widespread adoption. In this work, we provide a solution for a fast and controllable discharge of a cell that was identified as a stressful/faulty, in the battery pack, and fast circuit breaking leveraging the Solid-State Circuit Breaker (SSCB) technology which provides active control over the cell connection as opposed to conventional passive solutions. Testing on the simulation platform successfully validated the concept, demonstrating its efficacy. Controlled discharge testing with 20Ah LiFePO4 Lithium Iron Phosphate (LFP) cells from 1C-10C current rate on the hardware prototype corroborated simulation results, demonstrating design feasibility and providing essential data for its performance and thermal characteristics, while also revealing limitations that inform areas for further optimization.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

An Exploratory Data Mining Investigation for Constructing a Publicly Sourced Dataset of Foreign Hypersonic Tests

This document details a data mining exercise that resulted in an exploratory dataset of publicly reported foreign (non-US) hypersonic vehicle test events. Using a combination of targeted English language searches and country-specific queries, the study aggregates information from digital news media, official press releases, and social media posts. The resulting list of events captures the publicly available accounts of foreign hypersonic tests, although it does not represent an exhaustive record. Limitations such as inconsistent reporting, translation challenges, and the inherently provisional nature of open-source data are acknowledged. This dataset serves as an initial reference point for further inquiries into high-speed atmospheric phenomena and may facilitate future efforts to correlate these events with geophysical measurements.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Implementation of WBG devices in circuits - Electric Drive Technologies Project (Final Technical Report)

The objective of the project is to ensure that SiC devices are reliable and rugged as required in automotive applications for operational life of 300,000 hrs and create new device designs to address various weaknesses in currently available commercial devices. OSU has worked closely with SUNY Polytechnic. OSU has carried out the reliability and ruggedness evaluations of commercial devices as well as those fabricated by SUNY Polytechnic, discussed the results with SUNY Poly, and collaborated with the PI at SUNY Poly to improve the designs with respect to reliability/ruggedness. OSU work focused on reliability/ruggedness evaluation of SiC devices by individually testing them and then evaluate them in a 10 kW, 3 phase inverter system built with a specific purpose of stressing devices using realistic drive cycles such as a 10-minute hill climb. It should be noted that the primary purpose of the 10 kW inverter is to provide a platform for stressing the SiC devices under accelerated but realistic drive conditions.

33 ADVANCED PROPULSION SYSTEMS↗