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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Development of a dynamical model and energy analysis for wheel loader

The objective of this paper is to develop a fully integrated model for the wheel loader, including the subsystem dynamics of the engine, drivetrain, working circuit, steering circuit, and vehicle. It leads to a high-order strongly nonlinear system, and all state variables are coupled together to form a Multi-Input and Multi-Output (MIMO) system. A control architecture is proposed to decouple the MIMO system into several Single-Input and Single-Output (SISO) systems. Here, a tracking problem has been formulated to validate this fully integrated model with the field test data. The accuracy of the model is verified by the 2.3% difference between the measured and simulated fuel consumption. Meanwhile, an energy distribution analysis is conducted to reveal the energy consumption and energy loss of each portion of the wheel loader. Such a model can be used to plan the working pattern, guide the driving habits of human operators, or refine the underlying architecture, leading to the ultimate goal of reducing total fuel consumption and improving productivity.

42 ENGINEERING↗
DOE OSTI2026

Feedback, physics, and forecasts: The emerging paradigm of machine learning-driven battery research

Machine learning (ML) is reshaping how we understand, predict, and optimize electrochemical systems. In batteries, ML accelerates discovery across chemistry, design, and operation by transforming massive experimental and simulated datasets into predictive, interpretable models. This review consolidates a decade of progress in ML-driven battery innovation, from early-cycle feature extraction to operando image analysis and physics-informed modeling. We categorize approaches by data domain and physical fidelity, emphasizing interpretable ML for diagnostics, reinforcement learning for control, and multi-objective optimization for lifetime extension strategies. Additionally, we demonstrate how integrated models accelerate discovery, reduce testing time, and guide sustainable design. Economic analyses furthermore illustrate how these advances can lower cost per cycle and improve circularity. Together, these developments chart a path toward self-optimizing, sustainable battery technologies.

artificial intelligence↗
DOE OSTI2021

Design rules for 316H nuclear components cladded with nickel or tungsten

The existing Class A metallic materials qualified in the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules for high temperature nuclear reactors are not ideally suited for long term molten salt corrosion resistance in high temperature molten salt reactors. Potentially, corrosion or corrosion driven environmentally assisted cracking could limit the design life of structural components in molten salt reactors. A solution to this limitation is the use of cladded components – overlay the Class A material with a thin layer of some non-qualified, corrosion-resistant material. However, this necessitates the development of design methods for cladded components that do not require long-term testing of clad materials in order to support the near-term deployment of molten salt reactors. This report develops such a methodology along with a complete set of rules presented in a format compatible with an ASME nuclear Code Case. These design rules are for 316H Class A components cladded with either nickel or tungsten. The report also discusses the development of a set of general criteria for selecting clad materials beyond the specific 316H/tungsten and 316H/nickel systems and general acceptance tests for checking the mechanical integrity of the clad/base metal interface. Finally, the report includes a set of fully-documented sample problems detailing the application of the rules to high temperature cladded components

36 MATERIALS SCIENCE↗
DOE OSTI2024

Fiscal Year 2024 Software Quality Assurance Activities for the ARC Software

The continued goal of the ARC SQA project in the Advanced Reactor Technologies program of DOE is to resolve the QA gaps for the ARC software that limit, or prevent, commercialization of the software for industry users. This project started in earnest in fiscal year 2023 which saw the entire code system moved from a SVN repository to a GitLab repository and an associated software quality assurance plan (SQAP) developed and ratified. Most of the QA gaps in the ARC software were identified in collaboration with industry partners and work begin in fiscal year 2023 and continued in 2024. The primary documentation that is missing includes user manuals, user guides, software verification reports, and code coverage assessments. The SUMMAR manual was completed this fiscal year and work was started on creating manuals for SE2ANL, SE2RCT, and DASSH. Software verification work was carried out for DIF3D and REBUS in a previous program and the current fiscal year saw the completion of software verification reports for GAMSOR, GAMSRC, VARPOW, EvaluateFlux, and SUMMAR. The goal for the next fiscal year is to complete the PERSENT software verification work and begin planning the software verification work for DASSH, SE2ANL, and SE2RCT. The code coverage reports for DIF3D and MC2-3 were completed in the previous fiscal year and the goal is to generate code coverage reports for REBUS, GAMSOR, PERSENT, and DASSH in the coming fiscal year. A considerable amount of effort was spent in the current fiscal year working on the continuous integration capability for automated regression testing in GitLab. The first version of the testing was created in the previous fiscal year and applied to DIF3D and its utility programs. That testing was extended this year to cover GAMSOR, REBUS, and PERSENT. To accomplish this, the first version of the new testing methodology had to be updated to make a single output checking methodology viable for all of the ARC software. This will result in a single document to detail the automated regression testing methodology and minor documents to detail the tolerance settings that have been applied to the output for each ARC code. The previous methodology put into place with SVN would have required a separate document for each ARC code to detail the output checking methodology and the tolerance settings for the output from each code. Because some of our industry partners are providing funds to add new capabilities to the ARC software to meet their needs, all of which must be reviewed and approved by the SQA program funded by this project, a summary of that development work is detailed in this report. Overall progress on resolving the QA gaps has been good this year with the most impactful improvement for our industry partners in capability being the creation of a threaded version of DIF3D-VARIANT that allows the DIF3D, REBUS, and GAMSOR run times to be reduced by a factor of 4-6. The most impactful QA gap that was resolved was the software verification of GAMSRC and VARPOW.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

ECE 4396 (Final Report)

In the summer of 2025, I was fortunate enough intern at Sandia National Laboratories in Albuquerque, New Mexico. I was hired into the Southwest Analysis Laboratories for Semiconductor Advancement (SALSA) intern program. In this internship, I applied my knowledge and skills in electrical engineering to conduct hardware failure analysis. I utilized various failure analyze techniques involving the use of Infrared Thermography (IRT) and Laser Scanning Microscopy (LSM) to test different Application-Specific Integrated Circuits (ASIC) chips that are available in the public market.

42 ENGINEERING↗
DOE OSTI2025

Cold Spray Field Deployment Evaluation for Double-Shell Tank 241-AN-105

This report highlights the documentation that supported Cold Spray field deployment in double-shell tank (DST) 241-AN-105 (AN-105) in July of 2025. This work was a collaborative effort between VRC Metal Systems (VRC), Robotic Technologies of Tennessee (RTT), the Hanford Tank Waste Operation and Closure (H2C) Chief Technology Office, H2C Tank Farm Projects Engineering, H2C Tank and Pipeline Integrity (TAPI) and H2C Ultrasonic Testing (UT) Operations & Support. Since 2019, the Chief Technology Office has been developing Cold Spray technology for refurbishing Hanford’s DSTs (RPP-RPT-65015). This technology is particularly relevant for addressing localized corrosion within the annulus of the DSTs by propelling metal powder particles at supersonic speeds to targeted areas. This process results in high-quality coatings characterized by high bond strength and low porosity result.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Numerical Modeling & Optimization of the iProTech Pitching Inertial Pump (PIP) Wave Energy Converter (WEC) (CRADA Final Report)

This project represents a continuation of the collaboration between iProTech and NLR to simulate, optimize and design the iProTech Pitching Inertial Pump (PIP) device. The objectives of this TEAMER project are twofold: 1. Refining the physical characteristics of the existing iProTech PIP WEC-Sim model to enhance the model’s fidelity and include controllable components. Key model enhancements target the inclusion of Coulomb friction, the introduction of a controllable bypass valve, and the replacement of traditional check valves with advanced motorized ones. 2. Exploring traditional and advanced control algorithms. From traditional methods like latching control to cutting-edge reinforcement learning (RL) algorithms, the goal is to ensure the PIP device's adaptability and optimal performance across a range of ocean conditions. NLR is tasked with augmenting the WEC-Sim model and implementing the control algorithms, culminating in performance comparison analyses. iProTech will update their existing 3D models, advise on model improvements, and determine crucial system metrics. WEC-Sim, developed in MATLAB/SIMULINK with Simscape Multibody, is the main piece of software that will be used in this project. Coupled with the MATLAB RL Toolbox, it offers a robust platform for in-depth simulation and optimization of the iProTech PIP device. Building on previous work to explore the PIP design space and optimize its geometry, mass distribution, center of gravity and other key parameters, this project aims to refine iProTech’s existing numerical models and develop effective control algorithms that can seamlessly integrate into their future hardware testing campaigns.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Long-term Dynamical Stability in the Outer Solar System. I. The Regular and Chaotic Evolution of the 34 Largest Trans-Neptunian Objects

We carried out an extensive analysis of the stability of the outer solar system, making use of the frequency analysis technique over short-term integrations of nearly 100,000 test particles, as well as a statistical analysis of 200 1 Gyr long numerical simulations, which consider the mutual perturbations of the giant planets and the 34 largest trans-Neptunian objects (we have called all 34 objects “dwarf planets,” DPs, even if probably only the largest of them are true DPs). From the frequency analysis, we produced statistical diffusion maps for a wide region of the a–e phase-space plane; we also present the average diffusion time for orbits as a function of perihelion. We later turned our attention to the 34 DPs, making an individualized analysis for each of them and producing a first approximation of their future stability. From the 200 distinct realizations of the orbital evolution of the 34 DPs, we classified the sample into three categories, including 17 stable, 11 unstable, and 6 resonant objects; we also found that, statistically, two objects from the sample will leave the trans-Neptunian region within the next gigayear, most likely being ejected from the solar system, but with a nonnegligible probability of going inside the orbit of Neptune, either to collide with a giant planet or even falling to the inner solar system, where our simulations are no longer able to resolve their continuous evolution.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

Use of Grid-Forming Medium-Voltage Power Electronics Hub in a Microgrid Setting: Preprint

This paper presents the application of a new design of a multiport, modular, medium-voltage power electronics hub (M3PE-HUB) in a microgrid setting. The M3PE-HUB system was modeled in a digital real-time simulator (DRTS) and integrated into the Banshee microgrid test system. This paper presents the preliminary DRTS simulation-based results of the M3PE- HUB system connected in a test microgrid system. Verification and validation of the M3PE-HUB architecture and controls in the test microgrid setting are the primary contributions of this work. The results of the operation during the islanding and resynchronization process indicate the feasibility of the proposed architecture in a microgrid setting. This paper also presents results for a system reconfiguration use case where the M3PE- HUB was used to reconfigure the system under a fault condition.

grid forming↗
DOE OSTI2024

Energy Efficiency Improvement Approaches in Ice Related Processes

Application and development of energy efficient techniques to separate ice from different surfaces and substrates is of significant value in the context of building equipment performance. A hybrid approach to help dislocate the ice layer using advanced materials and ultrasonic vibration to lower ice adhesion strength was investigated. Application of advanced polymer materials in lowering the adhesion strength of ice was confirmed where the measured strength was lowered by 50-70% depending on the material and geometry. Additionally, utilization of induced ultrasonic vibration in further lowering the ice harvesting energy was confirmed on multiple materials and geometries. Durability of the coating enhancement was also confirmed in a thermal cycling test under realistic operating conditions. Integration of these technical approaches was implemented and validated in commercial ice makers showing energy consumption reduction by ~ 15% to 30% depending on the technical enhancement.

Cheekatamarla, Praveen↗
DOE OSTI2025

Progress Towards the Validation of a new RELAP5-3D model of the High Temperature Test Facility

Validation is a key step in the development of any type of systems model. As the next generation of reactors approaches, the need for codes that have been validated for these new types of systems continues to grow. An example of a prominent option is the Reactor Excursion Leak Analysis Program (RELAP5-3D), developed by Idaho National Laboratory. This code was developed for the purpose of systems level thermal-hydraulic modeling of light water reactors (LWRS) and postulated transients that can occur in LWRS.RELAP5-3D has been substantially validated against LWR data. Due to its long history as a reactor safety analysis tool, there has been an effort to adapt RELAP5-3D for the purposes of advanced reactor concepts such as prismatic high-temperature gas-cooled reactors (HTGRs). However, RELAP5-3D has not nearly been validated and verified for HTGRs to the degree of LWRs, warranting verification and validation opportunities with computational benchmarks and existing experimental facilities. Examples of such facilities include the modular high-temperature gas-cooled reactor (MHTGR) 350 and the high temperature engineering test reactor (HTTR) from Japan. The MHTGR 350 is a benchmark design concept for code-to-code verification purposes; therefore, it does not provide any experimental data for validation opportunities The HTTR provides useful multiphysics validation data but does not have the in-core instruments to generate thermal-hydraulic experimental data to help with RELAP5-3D validation. Consequently, a facility that could provide key in-core temperatures for thermal-hydraulic validation was still needed. The High Temperature Test Facility (HTTF) is an integral effects facility for HTGR thermal hydraulics developed and operated by Oregon State University. HTTF represents ¼ length scale of the General Atomics MHTGR and is rated for a total power of 2.2 MW. Axially, the core consists of an upper and lower reflector and 10 blocks, numbered from bottom to top (Block 1 is right above lower reflector). The core is heated via graphite resistive heater rods, with respective channels distributed throughout the core. The primary coolant is helium and heat can radiate out of the core to the reactor cavity cooling system (RCCS), which is cooled by water. The primary purpose of the facility is to investigate pressurized conduction cooldown (PCC) and depressurized conduction cooldown (DCC) transients, which are also referred to as the pressurized and depressurized loss of forced cooling respectively. Two experiments were chosen to perform the validation study with a RELAP5-3D model of HTTF. These experiments are PG-27 (PCC) and PG-29 (DCC). These were chosen based off of the quality of available experimental data before and during the experiment which led to their inclusion in the HTGR Thermal Hydraulics Benchmark.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Damage of prismatic lithium‐ion cells subject to bending: Test, model, and detection

Abstract The mechanically induced internal short circuit (ISC) is one of the major safety concerns of lithium‐ion batteries. Mechanical abuse tests are often performed to evaluate the integrity and safety of lithium‐ion batteries under mechanical loadings. Except for the widely explored compression‐dominated indentation tests, bending is another typical real‐world loading condition that is tension‐dominated. To investigate the mechanical damage and ISC behavior of batteries under bending, we carried out controlled three‐point bending tests in four progressive steps on prismatic battery cells with maximum deflections ranging from 38% to 76% of the cell thickness. None of the tested cells experienced an ISC. We then conducted 3D X‐ray computed tomography (CT) scanning on the bent cells after unloading. X‐ray CT images showed three out of the four tested cells have extensive cracking in the electrode layers at the bottom side (opposite to the loading head). This indicates that cracking does not necessarily lead to an ISC under bending. Electrochemical impedance spectroscopy was also measured on the bent cells and substantial changes were observed. Both the bulk resistance and charge‐transfer resistance increased significantly after bending, which could influence the battery performance and lifespan. We then developed a detailed finite (FE) element model to further investigate the mechanical deformation and failure mechanisms. The FE model successfully predicts the load–displacement response and reproduces the deformation patterns. The findings and the FE model developed in the present study provide useful insights and tools for the battery structure and crash safety design. image

25 ENERGY STORAGE↗
DOE OSTI2025

Full Submersion Water Testing of SAVY-4000 Nuclear Material Storage Containers

SAVY-4000 (SAVY) containers are the primary container used at Technical Area (TA) TA-55 plutonium facility for the prevention of water ingress to mitigate against a criticality event. The basis for water resistance of these containers has long been attributed to the Polytetrafluoroethylene (PTFE) membrane that is assembled on the outermost surface of the filter assembly. On August 22nd a test of a container used inside of a glovebox was performed that brought into question this long-standing-basis. This test was performed by inverting a SAVY-lid onto a specialized piece of equipment for evaluating the integrity of the PTFE membrane. During the test water was observed passing through the filter indicating that the filter membrane was no longer preventing the ingress of water through the filter. The assumption after making this observation was that alpha-particles were rapidly degrading the membrane creating a leak path through the underlying aluminosilicate media (Fiberfrax®). The apparatus used was designed to only test the lid rather than the entire SAVY assembly. A test plan, PA-PLAN-01921, was developed to investigate whether a fully assembled container with a fully degraded PTFE membrane would be capable of meeting the criteria defined in PA-RD-1009 of not allowing more than 200 ml of water to enter the container with a water column of 6-inches applied over a 2-hour period. This report provides the results of the testing performed against PA-PLAN-01921.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Preliminary Plan to Inform Testing of a Heat Exchanger Test Article

This report presents a preliminary plan to guide the qualification testing of advanced heat exchanger (HX) components for nuclear-to-industrial heat transfer applications. The objective is to establish a defensible, physics-based methodology that integrates computational modeling, targeted experimentation, and in-service inspection considerations to demonstrate component performance and reliability under representative reactor conditions. The analysis identifies Sodium-cooled Fast Reactor (SFR) and High-Temperature Gas-cooled Reactor (HTGR) systems as reference configurations in terms of temperature, pressure, and chemical environment. Within these operating envelopes, dominant degradation mechanisms— including creep–fatigue interaction, flow-induced vibration, corrosion, and diffusion-bond deterioration—were evaluated to define test requirements. A comprehensive computationalexperimental framework is proposed to support life prediction and qualification activities. The framework couples high-fidelity structural-mechanics, thermal-hydraulic, and fluid-structure interaction models with accelerated degradation testing to produce a traceable linkage between microstructural evolution, mechanical performance, and remaining useful life (RUL). The approach adheres to established Verification, Validation, and Uncertainty Quantification (VVUQ) standards (ASME V&V 10/20; NUREG-2152) and incorporates a digital-twin architecture for continuous model refinement through data assimilation. The plan further outlines testing methodologies, including pre-test analyses, test-loop design parameters, and sensor placement strategies that maximize information yield while maintaining mechanistic fidelity. Complementary sections describe in-service inspection (ISI), on-line monitoring (OLM), and structural-health-monitoring (SHM) techniques applicable to compact HX geometries typical of advanced reactors. Collectively, these activities establish the technical foundation for demonstrating 40-60-year equivalent service life of advanced heat exchangers in support of the U.S. Department of Energy’s Advanced Reactor and Integrated Energy Systems programs. The forthcoming phase will execute the defined pre-test analyses, initiate hardware fabrication, and implement the integrated testing campaign to validate the proposed qualification methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

US HL-LHC cryo-assemblies at FNAL - testing and lessons learned

The U.S. High-Luminosity LHC Accelerator Upgrade Project (AUP) is fabricating ten cryogenic assemblies for the HL-LHC Q1/Q3 quadrupole optics at CERN, each integrating two Nb_{3}Sn-based magnets. Fermilab has tested three assemblies (LQXFA/B01–03) at its upgraded horizontal test stand under 1.9 K conditions. Overview of the test stand and the cryo-assembly tests is given along with main results. Challenges met and lessons learned are discussed. Successful testing validates the design and integration of U.S.-produced cryo-assemblies, keeping the project on track for timely delivery to CERN.

Stoynev, Stoyan [Fermilab] (ORCID:0000000345637702↗
DOE OSTI2020

Effect of Thermal Storage on the Emissions and Efficiency Performance of a Wood Pellet-Fired Residential Boiler

Wood pellet boilers for residential heating applications offer the promise of low emissions, high efficiency, and automatic operation. However, when operated in the field, these units operate often at very low loads causing them to cycle. In this study, the performance of a 25-kW modern pellet boiler under emulated field conditions and fixed nominal loads of 15% and 100% has been studied in a lab—with and without a buffer tank. A dilution tunnel approach was used for the measurement of particulate emissions, in accordance with U.S. certification testing requirements under EPA Methods 28 WHH and 28 WHH PTS. Results show that increasing the amount of thermal storage used decreases cycling rates leading to decreased emissions and increased efficiency. Without thermal storage, integrated efficiency over a 15% load test period was 57%, compared to 74% when thermal storage was used. Particulate emissions were 180 mg/MJ and 64 mg/MJ for the 15% load case without and with thermal storage, respectively.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

In-Cell Deployment and First Use of Digital Image Correlation for In-Situ Strain Analysis of Irradiated Nuclear Fuel Rods During LOCA Transient

Digital image correlation (DIC) is a noncontact, optical method increasingly used across industries and research environments for acquiring multidimensional strain data. At Oak Ridge National Laboratory’s (ORNL’s) Severe Accident Test Station (SATS), DIC has been extensively applied to study the thermomechanical response of nuclear fuel claddings, yielding fundamental insights into material behavior. However, these efforts have focused exclusively on unirradiated materials and relied on the SATS out-of-cell infrastructure. Efforts over the past two years have been made to extend these capabilities to ORNL’s Irradiated Fuels Examination Laboratory SATS system within the hot-cells to enable testing of irradiated fuel cladding materials. Integrating DIC into the hot-cell SATS infrastructure presents unique challenges, including enabling remote operation of optical equipment and adapting auxiliary hot-cell systems for DIC implementation. This report discusses design, stand-up testing, and application of DIC to an irradiated nuclear fuel cladding segment. A DIC testing rig was successfully built and validated out-of-cell through extensive surrogate tests and calibrations. The rig and specialized DIC furnace were installed in the hot-cell, and a DIC test was successfully conducted. Results from that test correspond to expectations for Zr-based alloys and showed similar uncertainties compared to out-of-cell tests.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗