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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 OSTI2026

Micro-architected material design for mechanical response

Rapid advances in additive manufacturing (AM) have enabled the creation of micro-architected materials—also known as mechanical metamaterials—with unprecedented control over fine-scale geometries and arrangements of multiple material constituents. These “materials” can achieve unique and extraordinary effective mechanical properties through their complex architectures rather than composition alone. A key challenge is to design for these bespoke effective mechanical responses within the constraints of available AM techniques (i.e., given a set of desired effective properties), identify a (often nonunique) micro-architecture and selection of material constituents that achieves them. Two main strategies have emerged. Gradient-based methods use sensitivity analysis to iteratively refine candidate designs, while data-driven methods learn micro-architecture-constituent relationships from existing examples to propose new designs. This article reviews these design approaches for micro-architected materials with tailored mechanical responses that can be fabricated by AM as well as their applications.

Spadaccini, Christopher M [Lawrence Livermore Nati↗
DOE OSTI2020

Development of a Fast Spectrum Test Loop at the Advanced Test Reactor

The United States currently has no infrastructure to provide a fast neutron flux for research purposes. With the increased interest in Sodium Fast Reactor (SFR) technology, this type of infrastructure is necessary for further development of key components such as Versatile Test Reactor. The purpose of this research is to characterize the thermal hydraulics of a test loop capable of providing SFR like operating conditions. This includes showcasing feasibility in mechanical design, reaching a high fast to thermal neutron flux ratio ideally near 15, an inlet temperature of 600 K, a temperature increase of 50 K from inlet to outlet, and test chamber radial temperature profiles similar to SFR fuel rods. Existing infrastructure must be used to provide the neutron flux for the test loop, and it was decided that the Advanced Test Reactor (ATR) was the optimal choice due to its availability and previous work conducted similar to this project. To achieve the goals of this project, several mechanical designs were put forward with the most feasible design being chosen. The neutronics and thermal hydraulics analysis were conducted in tandem, with an iterative process used to maximize efficiency of both systems. Analysis of the neutronics system was done using Attila and MCNP while the thermal hydraulic analysis was done using RELAP5. This document outlines the thermal hydraulic analysis, though it includes the results from the mechanical design and neutronics analysis. The loop design includes a primary system with molten sodium, a set of “booster fuel plates” to increase the fast flux within the test section, a water system to cool the booster fuel plates, a helium system to separate the sodium and water systems, and a thermal neutron shield to decrease the thermal flux. Each of these systems is modeled in the neutronics and thermal hydraulic analyses. The RELAP5 model showcased the feasibility of the design proposed by this report. For all designs tested, the desired 50 K temperature increase from inlet to outlet was reached. The fuel rod radial temperature profile was lower than was expected, likely due to a lower rod thermal power than expected. A parametric study was also conducted to characterize the system with three fuel pins. This study showed the effect of thermal power, fluid pressure, fluid velocity, and inlet temperature on the system. ©Copyright by Anton Higgins December 11, 2019 All Rights Reserved

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

Evaluation of a New Chemical Mechanism for 2-Amino-2-methyl-1-propanol in a Reactive Environment from CSIRO Smog Chamber Experiments

Amines are considered as an emerging class of atmospheric pollutants that are of great importance to atmospheric chemistry and new particle formation. As a typical amine, 2-amino-2-methyl-1-propanol (AMP) is one of the proposed solvents for capturing CO 2 from flue gas streams in amine-based post-combustion CO 2 capture plants, and it is expected to result in AMP emission and secondary products formation in the atmosphere. However, the current knowledge of its atmospheric chemistry and kinetics is poorly understood, particularly in a reactive environment. As such, in this work we used the CSIRO smog chamber to study the photo-oxidation of AMP in the presence of VOCs–NOx surrogate mixtures over a range of initial amine concentrations. O 3 formation was significantly inhibited when AMP was added to the surrogate VOCs–NOx mixtures, implying that AMP could alter known atmospheric chemical reaction pathways and the prevailing reactivity. Simultaneously, a large amount of AMP-derived secondary aerosol was formed, with a considerably high aerosol mass yield (i.e. ratio of aerosol formed to reacted AMP) of 1.06±0.20. Based on updated knowledge of its kinetics, oxidation pathways and product yields, we have developed a new mechanism (designated as CSIAMP-19) and integrated into the Carbon Bond 6 (CB6) chemical mechanism, and evaluated it against available smog chamber data. Compared with the existing AMP mechanism (designated as CarterAMP-08), the modified CB6 with CSIAMP-19 mechanism improves prediction against AMP–VOCs–NOx experiments across a range of initial AMP concentrations, within ±10% model error for gross ozone production. Our results contribute to scientific understanding of AMP photochemistry and to the development of the chemical mechanism of other amines. The updated AMP chemical reactions scheme can be further embedded into the chemical transport model for regional modelling scenarios where AMP-related emissions are of concern.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Overview of TAE technologies’ HHFW project on LAPD

Simulation survey performed at TAE Technologies, has demonstrated that high harmonic fast wave (HHFW) heating is a promising scenario to heat core electrons of FRC plasma. To prepare the proposed experimental study of HHFW antenna-plasma coupling and wave propagation on LAPD machine at UCLA, a high-power-capable 4-strap antenna has been calculated and designed through collaboration among TAE, ORNL, ASIPP, and UCLA. This antenna was mechanically designed and fabricated by ASIPP and it has been installed recently on LAPD. Meanwhile, by using the Petra-M code, a newly developed generic electromagnetic simulation tool for modeling RF wave propagation, the RF-SciDAC team starts 3D full wave simulations. Detailed information on antenna electromagnetic simulations and mechanical design, as well as preliminary experimental results of wave propagation study with the newly installed phased- array antenna, will be presented in this paper.REFE

Yang, Xiaokang↗
DOE OSTI2025

Simplifying the creation of thermal decomposition mechanisms for designing mixed fibre composites

Among the most challenging aspects of simulating thermal decomposition of fibre reinforced polymers is the determination of appropriate reaction parameters. Thermogravimetric analysis is typically used to generate decomposition data, to which the reaction parameters are then fit. When designing mixed fibre materials (e.g. combinations of glass and carbon fibres), the number of TGA experiments needed to explore the entire design space may be intractable. Here, we demonstrate the creation of two candidate proxy mixed fibre mechanisms and compare them to a mechanism created by fitting parameters from TGA on the mixed fibre composite. These mechanisms are then demonstrated in a 2D axisymmetric numerical decomposition, heat transfer, and porous flow model. We find a maximum 11% uncertainty in mass and 4% in temperature difference when using a proxy mechanism.

Scott, Sarah N. [Sandia National Lab. (SNL-CA), Li↗
DOE OSTI2024

Boiling-Water Reactor Testing Capability in the Advanced Test Reactor

I-Loop is an irradiation facility that is currently being installed at the Advanced Test Reactor. It is a two-loop test facility capable of performing Light Water Reactor (LWR) irradiations in prototypic coolant conditions. The two loops are being installed to be capable of both Boiling Water Reactor (BWR) and Pressurized Water Reactor (PWR) pressure, temperature, and chemistry environments. Each loop is nominally dedicated as a BWR or PWR for simplicity of operations. In-reactor water loop testing that an I-Loop provides is key to the deployment of new accident tolerant fuel technologies and other advanced LWR fuel concepts. Currently, pressurized water loops are the only testing facilities available to test BWR fuel concepts. Their test environments are non-prototypic at higher pressure/temperature and at single-phase fluid flow conditions. This void in the LWR test bed capabilities is one that the I-Loop is uniquely situated to provide. This report discusses the mechanical design, thermal hydraulic calculations, and neutronic calculations of a proposed standard experiment of accident tolerant BWR fuel concepts. Mechanical design examines the geometry and features of the main components. Thermal hydraulic calculations examine the modeling and results of the two-phase flow options available. Lastly, neutronic calculations examine the Monte Carlo analysis of enrichment, heat rates, and flux spectrum.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Reticular chemistry for the rational design of mechanically robust mesoporous merged-net metal-organic frameworks

Access to metal-organic frameworks (MOFs) with enhanced mechanical stability is key to their successful deployment in practical applications. However, the high porosity of the material often affects mechanical stability. In this article, to achieve highly porous MOFs with enhanced mechanical stability, we explored the merged-net approach where two relatively fragile frameworks were merged into a robust MOF structure. We demonstrate the effectiveness of this approach by computationally evaluating mechanical properties of sph-MOFs with varying lengths of linkers. Prominently, we pinpoint the significance of triangular rigidity on the robustness of large-pore MOFs and, subsequently, designed and synthesized a rare earth (RE)-based RE-sph-MOF-5 by the reticulation of hexanuclear RE clusters, tritopic linkers, and unprecedentedly large planar hexatopic linkers containing 19 phenyl rings. The mechanical properties of sph-MOFs were characterized and quantified using amplitude-frequency modulation (AM-FM) bimodal atomic force microscopy (AFM) analyses. Markedly, the mesoporous RE-sph-MOF-5 expresses high mechanical stability despite its large mesoporous cavities.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Data for NB6 HBRR Science Design ORNL/TM-2025/3807

Data for the report (ORNL/TM-2025/3807) that describes the calculations and the Monte Carlo Ray Tracing simulations performed using the McStas package to determine the coatings and geometry for the NB-6 guide. It provides the information to inform the mechanical design, validation tests and verification that it meets the science requirements.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Rational design of mechanically robust Ni-rich cathode materials via concentration gradient strategy

Mechanical integrity issues such as particle cracking are considered one of the leading causes of structural deterioration and limited long-term cycle stability for Ni-rich cathode materials of Li-ion batteries. Indeed, the detrimental effects generated from the crack formation are not yet entirely addressed. Here, applying physicochemical and electrochemical ex situ and in situ characterizations, the effect of Co and Mn on the mechanical properties of the Ni-rich material are thoroughly investigated. As a result, we successfully mitigate the particle cracking issue in Ni-rich cathodes via rational concentration gradient design without sacrificing the electrode capacity. Our result reveals that the Co-enriched surface design in Ni-rich particles benefits from its low stiffness, which can effectively suppress the formation of particle cracking. Meanwhile, the Mn-enriched core limits internal expansion and improve structural integrity. The concentration gradient design also promotes morphological stability and cycling performances in Li metal coin cell configuration.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A High-Speed High-Power-Density Non-Heavy Rare-Earth Permanent Magnet Traction Motor

There has been a global push for higher torque density and lower cost traction motors. The use of non-heavy rare-earth (non-HRE) permanent magnet materials in traction motors are being investigated for the sustainability, profitability and affordability of electric vehicles and to broaden their adoption. A 20,000-rpm permanent magnet traction motor using non-HRE magnet materials is proposed. A dual three-phase winding configuration driven by a segmented dual three-phase drive is proposed to reduce the current ripple, and as a result, the DC Link capacitor, as well as to ease the voltage constraint at high speed and eliminate any risk of uncontrolled regeneration. Furthermore, the dual winding configuration enables a fault tolerant design which is useful for reliability. The paper presents comprehensive electromagnetic, thermal and mechanical designs and analyses using an integrated approach. The results have shown that the design is robust against demagnetization and confirmed its thermal and mechanical viability.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Transactive energy systems for distributed blackstart and service recovery

Abstract Current transactive controls use marginal benefits and marginal costs to achieve an economic market efficiency during normal grid operations. However, the transactive mechanisms designed for normal economic operations cannot be applied directly for the contingencies because the grid operations during contingencies are often dictated by technical needs rather than purely economic criteria. For instance, one of the key technical requirements for the blackstart is to have at least one blackstart capable resource cleared which cannot be ensured by the transactive mechanism designed for normal economic operations because they work primarily based on the marginal benefit and marginal cost of the participants. This article presents one of the first attempts to develop a transactive mechanism to be used during grid contingencies. A distributed blackstart and service recovery is used as an example contingency to evaluate the performance of the proposed transactive mechanism. The performance of the proposed transactive mechanism is demonstrated for various use cases using a modified IEEE‐123 node test system. The simulation results demonstrated the proof of concept of applying a transactive mechanism to enable distributed blackstart and service recovery by engaging the mix of blackstart capable and non‐capable distributed energy resources.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Utilizing computer vision and artificial intelligence algorithms to predict and design the mechanical compression response of direct ink write 3D printed foam replacement structures

Additive Manufacturing (AM) of porous polymeric materials, such as foams, recently became a topic of intensive research due their unique combination of low density, impressive mechanical properties, and stress dissipation capabilities. Conventional methods for fabricating foams rely on complex and stochastic processes, making it challenging to achieve precise architectural control of structured porosity. In contrast, AM provides access to a wide range of printable materials, where precise spatial control over structured porosity can be modulated during the fabrication process enabling the production of foam replacement structures (FRS). Current approaches for designing FRS are based on intuitive understanding of their properties or an extensive number of finite element method (FEM) simulations. These approaches, however, are computationally expensive and time consuming. As such, in this work, we present a novel methodology for determining the mechanical compression response of direct ink write (DIW) 3D printed FRS using a simple cross-sectional image. By obtaining measurement data for a relatively small number of samples, an artificial neural network (ANN) was trained, and a computer vision algorithm was used to make inferences about foam compression characteristics from a single cross-sectional image. Finally, a genetic algorithm (GA) was used to solve the inverse design problem, generating the AM printing parameters that an engineer should use to achieve a desired compression response from a DIW printed FRS. The methods developed herein present an avenue for entirely autonomous design and analysis of additively manufactured structures using artificial intelligence.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Thinking Beyond the Default User: The Impact of Gender, Stereotypes, and Modality on Interpretation of User Needs

Throughout the mechanical design process, designers, the majority of whom are men, often fail to consider the needs of women, resulting in consequences ranging from inconvenience to increased risk of serious injury or death. Although these biases are well studied in other fields of research, the mechanical design field lacks formal investigation into this phenomenon. In this study, engineering students (n = 301) took a survey in which they read a Persona describing a student makerspace user and a Walkthrough describing the user’s interaction with the makerspace while completing a project. During the Walkthrough, the user encountered various obstacles or Pain Points. Participants were asked to recall and evaluate the Pain Points that the user encountered and then evaluated their perceptions of the makerspace and user. Furthermore, the independent variables under investigation were the gender of the user Persona (woman, gender-neutral, or man), the Walkthrough room case (crafting or woodworking makerspace), and the modality of the Persona and Walkthrough (text- or audio-based). Results showed that participants from the Text-based modality were better able to recall Pain Points compared to participants from the Audio-based modality. Pain Points were assessed as more severe when they impacted women users, potentially stemming from protective paternalism. In addition to finding that the gender of a user impacted the way a task environment was perceived, results confirmed the presence of androcentrism, or “default man” assumptions, in the way designers view end users of unknown gender. Promisingly, providing user Persona information in an audio modality significantly reduced this bias compared to text-based modalities, indicating that providing richer detail in user personas has the capability to reduce gender bias in designers.

cognitive-based design↗
DOE OSTI2020

CCAT-prime: Designs and status of the first light 280 GHz MKID array and mod-cam receiver

The CCAT-prime project's first light array will be deployed in Mod-Cam, a single-module testbed and first light cryostat, on the Fred Young Submillimeter Telescope (FYST) in Chile's high Atacama desert in late 2022. FYST is a six-meter aperture telescope being built on Cerro Chajnantor at an elevation of 5600 meters to observe at millimeter and submillimeter wavelengths. 1 Mod-Cam will pave the way for Prime-Cam, the primary first generation instrument, which will house up to seven instrument modules to simultaneously observe the sky and study a diverse set of science goals from monitoring protostars to probing distant galaxy clusters and characterizing the cosmic microwave background (CMB). At least one feedhorn-coupled array of microwave kinetic inductance detectors (MKIDs) centered on 280 GHz will be included in Mod-Cam at first light, with additional instrument modules to be deployed along with Prime-Cam in stages. The first 280 GHz detector array was fabricated by the Quantum Sensors Group at NIST in Boulder, CO and includes 3,456 polarization- sensitive MKIDs. Current mechanical designs allow for up to three hexagonal arrays to be placed in each single instrument module. We present details on this first light detector array, including mechanical designs and cold readout plans, as well as introducing Mod-Cam as both a testbed and predecessor to Prime-Cam.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗