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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
NASA NTRS2023

Impact of Satellite Orbit Drift on Modis Earth Scene Observations Used in Calibration of the Reflective Solar Bands

After more than 20 years in orbit, NASA’s Terra and Aqua satellites have both started drifting away from their historically maintained orbits. The MODIS instruments on Terra and Aqua continue to collect valuable Earth observation data, but the changing orbits present a challenge for maintaining accurate calibration. The MODIS reflective solar bands (RSB), spanning the wavelength range from 412 nm to 2130 nm, are calibrated on orbit using a combination of regular data collections from an on-board solar diffuser, the Moon, and pseudo-invariant Earth scenes. Starting in the Collection 6 Level 1B (L1B) data products, the RSB calibration began using data from desert targets for a few of the visible bands to better track changes in the response versus scan angle that could not be captured by the on-board calibration. The use of Earth scene data has been extended recently for Terra MODIS calibration in Collection 6.1 (C6.1) and the upcoming Collection 7 (C7) L1B to also include data from ocean scenes and deep convective clouds (DCC). Drifts in both the orbit inclination and ground track of Terra and Aqua lead to changes in the solar illumination angles and satellite view angles of the Earth scenes. We discuss how these orbital changes impact the desert and DCC targets used for MODIS RSB calibration and present the accompanying changes made to our C6.1 and C7 calibration algorithms. We also discuss remaining future challenges, such as better characterization of bi-directional reflectance distribution functions, and possible alternative calibration strategies.

MODIS↗
NASA NTRS2007

Sensitive Quantitative Assessment of Balance Disorders

Computerized dynamic posturography (CDP) has become a standard technique for objectively quantifying balance control performance, diagnosing the nature of functional impairments underlying balance disorders, and monitoring clinical treatment outcomes. We have long used CDP protocols to assess recovery of sensory-motor function in astronauts following space flight. The most reliable indicators of post-flight crew performance are the sensory organization tests (SOTs), particularly SOTs 5 and 6, which are sensitive to changes in availability and/or utilization of vestibular cues. We have noted, however, that some astronauts exhibiting obvious signs of balance impairment after flight are able to score within clinical norms on these tests, perhaps as a result of adopting competitive strategies or by their natural skills at substituting alternate sensory information sources. This insensitivity of the CDP protocol could underestimate of the degree of impairment and, perhaps, lead to premature release of those crewmembers to normal duties. To improve the sensitivity of the CDP protocol we have introduced static and dynamic head tilt SOT trials into our protocol. The pattern of postflight recovery quantified by the enhanced CDP protocol appears to more aptly track the re-integration of sensory-motor function, with recovery time increasing as the complexity of sensory-motor/biomechanical task increases. The new CDP protocol therefore seems more suitable for monitoring post-flight sensory-motor recovery and for indicating to crewmembers and flight surgeons fitness for return to duty and/or activities of daily living. There may be classes of patients (e.g., athletes, pilots) having motivation and/or performance characteristics similar to astronauts whose sensory-motor treatment outcomes would also be more accurately monitored using the enhanced CDP protocol. Furthermore, the enhanced protocol may be useful in early detection of age-related balance disorders.

Paloski, Willilam H.↗
NASA NTRS2018

Preparing to Assure Mission Success

Space flight missions are inherently risky. The mission operations assurance discipline grew out of strategies to control error and evolved into what today is an independent technical authority dedicated to achieving mission success. After the Mars Climate Orbiter loss, NASA made a set of recommendations for missions. Two of those recommendations led to the creation of today’s Mission Operations Assurance Manager role: (1) require an independent Mission Assurance representative during the operational phase of every flight project, and (2) require all flight projects to report and track post-launch anomalies. Since then, the MOAM role has been continually refined by lessons learned from its practice on more than 20 concurrent missions. The MOAM role requires significant operations experience as well as an additional set of skills. In the interests of developing a cadre of potential MOAMs, the MOAM training program was developed. It is a 14-unit set of presentations/discussions covering the 11 categories of MOAM tasks. It is offered to new MOAMs and interested systems engineers with an eye to preparing both types of personnel for present and future assignments, as well as building relationships among personnel of different organizations. MOAM training sessions include presentations on the various tools and processes employed by MOAMs, interspersed with mindset lessons illustrated via “war story” discussions of previous missions.

Bryant, Larry↗
NASA NTRSDate not supplied

Investigating Risks Due to Artemis EVA Tempo Via Probabilistic Risk Assessment

Spaceflight operations pose unique challenges to crew health, safety, and resource management. As space agencies and private companies continue to push the boundaries of human exploration, it is essential to understand the risks associated with Extravehicular Activities (EVAs) and develop strategies to mitigate them. The tempo at which EVAs are conducted – the total number and frequency of these activities – can have a profound impact on medical risks, resource consumption, and overall mission success. Probabilistic risk assessment (PRA) provides a powerful framework for evaluating complex systems and identifying potential hazards. Our work employs the Medical Extensible Dynamic Probabilistic Risk Assessment Tool (MEDPRAT) [1] to simulate mission events, occurrence and treatment of medical conditions, and track the utilization of resources. Coupled with the Evidence Library [2], a medical evidence base for exploration-class missions developed by the Exploration Medical Capability within NASA’s Human Research Program, we can estimate these risks with increased fidelity and optimize medical kit contents to meet specific mission requirements. This presentation provides a detailed examination of how EVA tempo influences medical risk estimates for a lunar surface design reference mission. A comprehensive analysis is conducted to assess the additional mass and volume burden imposed on medical kits required to maintain adequate levels of risk mitigation. Furthermore, we estimate the distribution of the number of successful EVAs completed based on the level of task impairment imposed by medical events and flight rules related to specific medical events, such as decompression sickness.

Modeling↗
DOE OSTI2025

Graphene oxide gluing layer enabling macroscale tribology applications of pristine graphene

In recent studies of two-dimensional (2D) nanomaterial-based solid lubricants, the importance of durability has been emerging for real engineering-scale applications. To achieve this, a transfer layer formation is essential to prevent the wear of the mechanical systems. However, it has been challenging for pristine graphene (PG) to induce a material transfer due to chemical inertness. In this study, we suggest an easy-to-process strategy to promote the huge material transfer of the PG onto the counterpart contacting material. We utilized graphene oxide (GO) as a gluing layer between the PG film and the counterpart contact surface to realize the superior tribological performance. The high interaction energy of the GO from its functional groups makes a contribution to the material transfer of PG, which is unveiled by a systematic analysis of the counterpart contact surface and the wear track. The huge solid transfer layer not only makes a wear-resistant contact interface between the transfer layer and the underlying film by densification and oxidation, but also reduces surface interaction energies, finally resulting in a significant improvement in durability.

graphene oxide (GO)↗
DOE OSTI2025

Real-Time Wave Energy Converter Control Using Instantaneous Frequency

Wave Energy Converters (WECs) rely on effective Power Take-Off (PTO) control strategies to maximize energy absorption under dynamic sea conditions. Traditional hydrodynamic modeling techniques may require computationally intensive convolution calculations, making real-time control implementation challenging. This paper presents an alternative approach by leveraging instantaneous frequency estimation to dynamically adjust PTO damping in response to varying wave frequencies. Two real-time frequency estimation methods are explored: the Hilbert Transform (HT) and Phase-Locked Loop (PLL). The Hilbert Transform method provides accurate frequency tracking but introduces a delayed response due to its dependence on causal data. Conversely, the PLL approach demonstrates strong potential in frequency tracking but requires careful gain tuning, particularly in complex sea states. Comparative evaluations across multiple test cases—including sinusoidal variations, amplitude steps, frequency step changes, and real-world JONSWAP spectrum waves—highlight the strengths and limitations of each method. The two different PTO control techniques across the various frequency estimation methods were tested under real-sea states using a state-space model of a point-absorbing Wave Energy Converter. The Capture Width Ratio (CWR) is used as a performance metric, with results showing that the HT achieves a 10.6% improvement, while the PLL estimation yields a 0.9% improvement relative to the fixed parameter control baseline. These results highlight the effectiveness of real-time frequency estimation in improving energy absorption compared to static control parameters.

WEC control↗
NASA NTRS2016

Integrating Satellite and Surface Sensor Networks for Irrigation Management Applications in California

Satellite mapping of evapotranspiration (ET) from irrigated agricultural lands can provide agricultural producers and water managers with information that can be used to optimize agricultural water use, especially in regions with limited water supplies. The timely delivery of information on agricultural crop water requirements has the potential to make irrigation scheduling more practical, convenient, and accurate. We present a system for irrigation scheduling and management support in California and describe lessons learned from the development and implementation of the system. The Satellite Irrigation Management Support (SIMS) framework integrates satellite data with information from agricultural weather networks to map crop canopy development, basal crop coefficients (Kcb), and basal crop evapotranspiration (ETcb) at the scale of individual fields. Information is distributed to agricultural producers and water managers via a web-based irrigation management decision support system and web data services. SIMS also provides an application programming interface (API) that facilitates integration with other irrigation decision support tools, estimation of total crop evapotranspiration (ETc) and calculation of on-farm water use efficiency metrics. Accuracy assessments conducted in commercial fields for more than a dozen crop types to date have shown that SIMS seasonal ETcb estimates are within 10 mean absolute error (MAE) for well-watered crops and within 15 across all crop types studied, and closely track daily ETc and running totals of ETc measured in each field. Use of a soil water balance model to correct for soil evaporation and crop water stress reduces this error to less than 8 MAE across all crop types studied to date relative to field measurements of ETc. Results from irrigation trials conducted by the project for four vegetable crops have also demonstrated the potential for use of ET-based irrigation management strategies to reduce total applied water by 20-40 relative to grower standard practices while maintaining crop yields and quality.

Nemani, Ramakrishna R.↗
DOE OSTI2023

Risk Assessment of Industrial Microbes Using a Terrestrial Mesocosm Platform

Abstract Industrial microbes and bio-derived products have emerged as an integral component of the bioeconomy, with an array of agricultural, bioenergy, and biomedical applications. However, the rapid development of microbial biotechnology raises concerns related to environmental escape of laboratory microbes, detection and tracking thereof, and resultant impact upon native ecosystems. Indeed, though wild-type and genetically modified microbes are actively deployed in industrial bioprocesses, an understanding of microbial interactivity and impact upon the environment is severely lacking. In particular, the persistence and sustained ecosystem impact of industrial microbes following laboratory release or unintentional laboratory escape remains largely unexplored. Herein, we investigate the applicability of soil-sorghum mesocosms for the ecological risk assessment of the industrial microbe, Saccharomyces cerevisiae . We developed and applied a suite of diagnostic and bioinformatic analyses, including digital droplet PCR, microscopy, and phylogenomic analyses to assess the impacts of a terrestrial ecosystem perturbation event over a 30-day time course. The platform enables reproducible, high-sensitivity tracking of S. cerevisiae in a complex soil microbiome and analysis of the impact upon abiotic soil characteristics and soil microbiome population dynamics and diversity. The resultant data indicate that even though S. cerevisiae is relatively short-lived in the soil, a single perturbation event can have sustained impact upon mesocosm soil composition and underlying microbial populations in our system, underscoring the necessity for more comprehensive risk assessment and development of mitigation and biocontainment strategies in industrial bioprocesses.

09 BIOMASS FUELS↗
NASA NTRS2015

Tropospheric Emissions: Monitoring of Pollution Overview

TEMPO is now well into its implementation phase, having passed both its Key Decision Point C and the Critical Design Review (CDR) for the instrument. The CDR for the ground systems will occur in March 2016 and the CDR for the Mission component at a later date, after the host spacecraft has been selected. TEMPO is on schedule to measure atmospheric pollution for greater North America from space using ultraviolet and visible spectroscopy. TEMPO measures from Mexico City to the Canadian oil sands, and from the Atlantic to the Pacific, hourly and at high spatial resolution. TEMPO provides a tropospheric measurement suite that includes the key elements of tropospheric air pollution chemistry. Measurements are from geostationary (GEO) orbit, to capture the inherent high variability in the diurnal cycle of emissions and chemistry. The small product spatial footprint resolves pollution sources at sub-urban scale. Together, this temporal and spatial resolution improves emission inventories, monitors population exposure, and enables effective emission-control strategies. TEMPO takes advantage of a GEO host spacecraft to provide a modest cost mission that measures the spectra required to retrieve O3, NO2, SO2, H2CO, C2H2O2, H2O, aerosols, cloud parameters, and UVB radiation. TEMPO thus measures the major elements, directly or by proxy, in the tropospheric O3 chemistry cycle. Multi-spectral observations provide sensitivity to O3 in the lowermost troposphere, substantially reducing uncertainty in air quality predictions by 50 percent. TEMPO quantifies and tracks the evolution of aerosol loading. It provides near-real-time air quality products that will be made widely, publicly available. TEMPO provides much of the atmospheric measurement capability recommended for GEO-CAPE in the 2007 National Research Council Decadal Survey, Earth Science and Applications from Space: National Imperatives for the Next Decade and Beyond. Instruments from Europe (Sentinel 4) and Asia (GEMS) will form parts of a global GEO constellation for pollution monitoring later this decade, with a major focus on intercontinental pollution transport. TEMPO will launch at a prime time to be a component of this constellation.

Chance, Kelly↗
DOE OSTI2020

Energy Intensity Baselining and Tracking Guidance

Each company joining the U.S. Department of Energy’s (DOE’s) Better Buildings, Better Plants Program (Better Plants) commits to establishing an energy consumption and energy intensity (EI) baseline and to tracking its energy performance over a 10-year period against that baseline. The baseline must reflect a company’s energy consumption over a 12-month period, covering all its U.S.-based operations. Energy consumption is calculated by fuel type in terms of primary energy (also known as source energy). EI is broadly defined as the amount of energy consumed per unit of output produced. For this guidance document and for the program, the term energy performance represents an evaluation of a facility’s capacity to use energy efficiently. Metrics used to assess a facility’s energy performance can include EI, energy consumption, improvements in EI, etc. Establishing an energy baseline and tracking system is a critical first step in effectively managing energy use. Developing a baseline can help a company understand energy use within the corporation and give it a point of comparison to evaluate future efforts to improve energy performance. It can also support efforts to validate a company’s energy management activities, improve comparative analyses when using benchmarks, and help in predicting future energy needs. In addition, a company that normalizes its performance data can determine highly defensible measures of energy savings generated through implemented energy efficiency projects. Establishing a baseline and tracking energy performance is also a requirement for ISO 50001 certification. Although basic energy data can be collected through utility bills, most manufacturers will have to perform additional analyses to develop accurate and robust energy baselines and tracking systems. Energy is consumed in many ways within the manufacturing sector and can come from multiple sources. Energy is sometimes generated and sold to other parties or captured and reused on-site. External events can exert a significant impact on a facility or company’s energy use independent of any purposeful efforts to improve energy efficiency. Operational changes, such as production shifts—which may be inevitable for some companies over the 10-year period covered by the program—can also make a big difference in energy use. Since Better Plants asks companies to account for all their U.S.-based operations, mergers, acquisitions, and divestitures can also have significant implications for a company’s energy metrics. This document aims to demystify the sometimes complex baselining process. It devotes special attention to the task of normalizing and adjusting energy consumption to account for external factors, such as weather and production changes. A key recommendation is that companies use regression analysis to normalize their energy consumption data whenever possible. Regression analysis is a statistical technique that estimates the dependence of a variable (i.e., energy use in the context of Better Plants) on one or more independent variables such as ambient temperature, while controlling for the influence of other variables at the same time. A properly developed regression analysis can provide a reliable estimate of energy savings resulting from energy improvement strategies and projects by accounting for the effects of variables such as annual production levels and weather. DOE has developed a companion Energy Performance Indicator software tool (EnPI) to simplify the baselining process. This tool can run regression models, calculate changes in EI at the facility level, and automatically compile facility-level data into a corporate-wide metric. Note that although the relevant equations used to calculate EI are provided in this document, the EnPI tool will automatically perform most calculations for the user. Additionally, Better Plants Partners (Partners) can call on their Technical Account Manager (TAM) to help them establish a baseline and assist with the necessary calculations to track progress.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Towards Long‐Term Stable Perovskite Solar Cells: Degradation Mechanisms and Stabilization Techniques

It is certain that perovskite materials must be a game‐changer in the solar industry as long as their stability reaches a level comparable with the lifetime of a commercialized Si photovoltaic. However, the operational stability of perovskite solar cells and modules still remains unresolved, especially when devices operate in practical energy‐harvesting modes represented by maximum power point tracking under 1 sun illumination at ambient conditions. This review article covers from fundamental aspects of perovskite instability including chemical decomposition pathways under light soaking and electrical bias, to recent advances and techniques that effectively prevent such degradation of perovskite solar cells and modules. In particular, fundamental causes for permanent degradation due to ion migration and trapped charges are overviewed and explain their interplay between ions and charges. Based on the degradation mechanism, recent advances on the strategies are discussed to slow down the degradation during operation for a practical use of perovskite‐based solar devices.

14 SOLAR ENERGY↗
DOE OSTI2023

Pluminate: Quantifying aerosol injection behavior from simulation, experimentation and observations

Marine aerosol injections are a key component in further understanding of both the potentials of deliberate injection for marine cloud brightening (MCB), a potential climate intervention (CI) strategy, and key aerosol-cloud interaction behaviors that currently form the largest uncertainty in global climate model (GCM) predictions of our climate. Since the rate of spread of aerosols in a marine environment directly translates to the effectiveness and ability of aerosol injections in impacting cloud radiative forcing, it is crucial to understand the spatial and temporal extent of injected-aerosol effects following direct injection into marine environments. The ubiquity of ship-injected aerosol tracks from satellite imagery renders observational validation of new parameterizations possible in 2D, however, 3D compatible data is more scarce, and necessary for the development of subgrid scale parameterizations of aerosol-cloud interactions in GCMs. This report introduces two novel parameterizations of atmospheric aerosol injection behavior suitable for both 3D (GCM-compatible) and 2D (observation-related) modeling. Their applicability is highlighted using a wealth of different observational data: small and larger scale salt-aerosol injection experiments conducted at SNL, 3D large eddy simulations of ship-injected aerosol tracks and 2D satellite images of ship tracks. The power of experimental data in enhancing knowledge of aerosol-cloud interactions is in particular emphasized by studying key aerosol microphysical and optical properties as observed through their mixing in cloud-like environments.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2002

Orbit Determination Issues for Libration Point Orbits

Libration point mission designers require knowledge of orbital accuracy for a variety of analyses including station keeping control strategies, transfer trajectory design, and formation and constellation control. Past publications have detailed orbit determination (OD) results from individual notation point missions. This paper collects both published and unpublished results from four previous notation point missions (ISEE-3, SOHO, ACE and MAP) supported by Goddard Space Flight Center's Guidance, Navigation & Control Center. The results of those missions are presented along with OD issues specific to each mission. All past missions have been limited to ground based tracking through NASA ground sites using standard marine and Doppler measurement types. Advanced technology is enabling other OD options including onboard navigation using onboard attitude sensors and the use of the Very Long Baseline Interferometry (VLBI) measurement Delta Differenced One-Way Range (DDOR). Both options potentially enable missions to reduce coherent dedicated tracking passes while maintaining orbital accuracy. With the increased projected loading of the DSN, missions must find alternatives to the standard OD scenario.

Beckman, Mark↗
DOE OSTI2021

Application of electron backscatter diffraction techniques to quantify effects of aging on sub-grain and spatial heterogeneity in NMC cathodes

Identification and evaluation of structural heterogeneity in spent cathode materials is crucial to developing appropriate remediation strategies for novel recycling processes. Native heterogeneities may be exacerbated during the cell's operational lifetime, as sub-particle-scale variations induce anisotropic expansion and contraction upon cycling. Structural transformations resulting from repeated cycling and calendar aging predominantly occur at the secondary particle surface and at the grain boundaries (GBs) between primary particles. However, the diffusion and stress build up around and across GBs are poorly understood. In this study, electron backscatter diffraction (EBSD) is employed to track sub-grain lattice structure across a statistically relevant number of Li(Ni0.33Mn0.33Co0.33)O2 (NMC-111) particles. Specifically, differences in lattice misorientation – measured as the deviation from the grain's average orientation – are tracked as a function of position within the electrode (near current collector, middle, and near separator) and as a function of electrochemical cycling. Further, a novel method of structural analysis is developed, offering insight into sub-grain diffusion behavior by comparing lattice misorientation near the grain boundary versus in the grain bulk. The present results suggest that electrode-scale spatial heterogeneity in lattice structure is induced by initial manufacturing conditions, and that radial gradients in lattice misorientation evolve at the primary particle scale with repeated electrochemical cycling.

25 ENERGY STORAGE↗
NASA NTRS1990

A unified motion planning approach for redundant and non-redundant manipulators with actuator constraints

The term trajectory planning has been used to refer to the process of determining the time history of joint trajectory of each joint variable corresponding to a specified trajectory of the end effector. The trajectory planning problem was solved as a purely kinematic problem. The drawback is that there is no guarantee that the actuators can deliver the effort necessary to track the planned trajectory. To overcome this limitation, a motion planning approach which addresses the kinematics, dynamics, and feedback control of a manipulator in a unified framework was developed. Actuator constraints are taken into account explicitly and a priori in the synthesis of the feedback control law. Therefore the result of applying the motion planning approach described is not only the determination of the entire set of joint trajectories but also a complete specification of the feedback control strategy which would yield these joint trajectories without violating actuator constraints. The effectiveness of the unified motion planning approach is demonstrated on two problems which are of practical interest in manipulator robotics.

Chung, Ching-Luan↗
NASA NTRS2020

Reducing Errors in Velocity–Azimuth Display (VAD) Wind and Deformation Retrievals from Airborne Doppler Radars in Convective Environments

The present study describes methods to reduce the uncertainty of velocity–azimuth display (VAD) wind and deformation retrievals from downward-pointing, conically scanning, airborne Doppler radars. These retrievals have important applications in data assimilation and real-time data processing. Several error sources for VAD retrievals are considered here, including violations to the underlying wind field assumptions, Doppler velocity noise, data gaps, temporal variability, and the spatial weighting function of the VAD retrieval. Specific to airborne VAD retrievals, we also consider errors produced due to the radar scans occurring while the instrument platform is in motion. While VAD retrievals are typically performed using data from a single antenna revolution, other strategies for selecting data can be used to reduce retrieval errors. Four such data selection strategies for airborne VAD retrievals are evaluated here with respect to their effects on the errors. These methods are evaluated using the second hurricane nature run numerical simulation, analytic wind fields, and observed Doppler radar radial velocities. The proposed methods are shown to reduce the median absolute error of the VAD wind retrievals, especially in the vicinity of deep convection embedded in stratiform precipitation. The median absolute error due to wind field assumption violations for the along-track and for the across-track wind is reduced from 0.36 to 0.08 m s−1 and from 0.35 to 0.24 m s−1, respectively. Although the study focuses on Doppler radars, the results are equally applicable to conically scanning Doppler lidars as well.

Charles N Helms↗
DOE OSTI2026

Two-phase flow numerical analysis of electrode geometry for alkaline water electrolyzers

Hydrogen is a promising component of a future energy-secure and efficient economy, but its competitiveness depends on reducing production costs. One strategy is to operate alkaline water electrolyzers at higher current densities to increase output. However, this intensifies performance losses due to gas bubble accumulation, which blocks transport pathways and deactivates electrochemically active surfaces. Enhancing bubble evacuation through electrode design is therefore essential. Previous studies have explored various approaches — such as modifying surface morphology, applying sonication or pressure modulation, and introducing surfactants — but these efforts have addressed a limited range of conditions due to the complexity of two-phase flow and electrode geometries. Experiments have also largely been focused on either cell level improvements, which lack the information necessary to isolate each contributing factor, or on modified geometries that are not relevant to practical cell operation. From a modeling perspective, conventional Eulerian multiphase models do not track the complex gas–liquid interfacial dynamics and often neglect surface tension and contact angle effects, reducing their predictive accuracy. To provide insights on the effects of different electrode geometries on the performance of alklaine water electrolyzers this work employs an immersed boundary volume-of-fluid method to simulate bubble behavior in 3D porous electrodes. Multiple base electrode geometries, typically used in practice, with varying porosity are evaluated under a constant surface gas generation rate. Simulation data is analyzed to quantify electrode gas coverage, bubble size dynamics and other relevant metrics. Results show that porosity strongly influences bubble accumulation on electrode surfaces, with higher porosity reducing gas coverage, and its not strictly dependent on the electrode geometry. However, the electrode’s base geometry significantly affects gas accumulation at the separator gap, independent of porosity. A foam electrode geometry resulted in the lowest gas coverage of all electrodes with a median volumetric gas coverage of 11%, but at the cost of a 70% reduction in active area compared with the largest surface area electrode, while gyroid electrodes showed the best trade-off between gas coverage, particularly at the separator surface, and electrochemically active area. In conclusion, the results highlight the need for holistic electrode design strategies.

Alkaline↗
DOE OSTI2025

Directed energy deposition of functionally graded V-4Cr-4Ti to Fe-9Cr transition for fusion power systems

This study proposes a graded structure via additive manufacturing for divertor and first wall blanket applications in fusion reactors. Materials were selected based on thermodynamic calculations to operate from 1100 °C at the plasma-facing level to 550 °C at the structural steel level. Conventional joining methods often lead to failures due to discrete reaction layers with significant mechanical property differences. Using laser beam-directed energy deposition (LB-DED), this study demonstrates the fabrication of a VCrTi-Gr91 steel functionally graded component through a novel process parameter optimization framework. A systematic approach included powder characterization, single-track depositions, and construction of printability maps. Near full-density specimens of each interlayer were additively manufactured, and a transition from V-based alloys to reduced activation ferritic martensitic steels was achieved. Computational material selection of interlayer alloys and thermodynamic/diffusion kinetics simulations prevented most interface incompatibilities. A brittle intermetallic formed at one interface, causing cracking, which was not predicted by current thermodynamic models. Transition alloy design approach was updated with a more recent database and a mitigation strategy has been proposed to eliminate the formation of deleterious intermetallic phases. Ultimately, LB-DED has proven effective for producing multi-material graded systems for fusion applications, with the demonstrated process parameter optimization framework applicable to various materials.

Additive manufacturing↗