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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 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Examining infrared thermography based approaches to rapid fatigue characterization of additively manufactured compression molded short fiber thermoplastic composites

A novel additive manufacturing (AM) methodology combined with a compression molding (CM) process has been developed to optimize the microstructure of short fiber thermoplastic composites (SFTs)with higher fiber alignment and lower porosity, yielding superior stiffness, strength, and structural integrity. Here, the current work examines the efficacy of the ‘passive’ infrared thermography (IRT) techniques for rapid fatigue characterization of SFTs that use the surface temperature evolution during cyclic loading due to self-heating as a fatigue indicator. A comparison of fatigue limits obtained from traditional stress-life (SN) (≈53.1%σ uts ) and IRT (≈54.1%σ uts ) shows a close match. However, the SN curve required 18 specimens and two weeks of continuous cyclic testing, while IRT used three specimens with 5 hours of testing. Thus, the IRT approach provides an accelerated testing framework for rapidly estimating the fatigue limit. Additionally, existing phenomenological approaches to IRT fatigue characterization have been examined.

42 ENGINEERING↗
DOE OSTI2024

A mean field homogenization model for the mechanical response of ceramic matrix composites

SiC/SiC composites offer exceptional mechanical stability at high temperatures and under irradiation. These ceramic matrix composites are therefore strong candidate materials for future nuclear energy applications. Their mechanical response, which exhibits pseudo-plasticity, is mediated by matrix cracking, fiber debonding, and fiber pull-out due to slip. Here, this study introduces a mechanistic model for the behavior of unidirectionally reinforced SiC/SiC composites. Specifically a mean field homogenization approach is proposed to account for all deformation and degradation modes during mechanical deformation. The homogenization scheme relies on a Mori Tanaka method that is extended to consider the effects of the coating’s elasto-plastic response on the development of micromechanical fields. Further, the model proposed introduces a method to effectively account for the role of localized damage (i.e., cracks) on mechanical fields within both the fiber and the matrix. Upon validating the model against experimental data, the roles of interface sliding, coating dimensions and intrinsic elastic response, as well as of microstructure (e.g. porosity, fiber volume fraction) are discussed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Isostatic pressing of multilayer pouch cells and its implications for battery manufacturing

Here, we report a comprehensive investigation into the impact of isostatic pressure (ISP) processing on multilayer pouch cells. The study compares baseline electrodes fabricated using conventional manufacturing processes with isostatically pressed counterparts under varying conditions. Extensive characterization is carried out to assess the differences between baseline cells and those that underwent the isostatic pressing process. The electrochemical performance of the isostatically pressed cathodes was evaluated through impedance spectroscopy and galvanostatic charge-discharge tests. The results indicated that ISP led to notable improvements in porosity, adhesion, and rate performance compared to the baseline cathodes. This work elucidates the microstructural changes induced by ISP in lithium-ion battery cathodes and highlights the technology’s promise for advancing battery manufacturing. The findings contribute to a better understanding of how ISP can be effectively integrated into cell assembly, fostering the development of more efficient and scalable battery manufacturing techniques for current Li-ion and solid-state batteries.

25 ENERGY STORAGE↗
DOE OSTI2025

Water reactive polyurethane grouting for deep vadose zone contaminant immobilization

Contaminants in the deep vadose zone (DVZ) pose a long-term threat to groundwater, human health, and the environment. Polyurethane grouting is a type of chemical grouting that is potentially advantageous in immobilizing contaminants in DVZs. Polyurethane resin has low viscosity that makes it feasible to penetrate and fill the pore space between fine particles. Here, in this study a series of laboratory pressure grouting and leaching tests were conducted to simulate and assess the effectiveness of polyurethane grouting for immobilizing contaminants in DVZs. Soil with fine particles was prepared with 127 I (as iodide) that served as a non-radioactive surrogate for radioactive 129 I. After grouting and curing, leaching tests were used to measure and compare contaminant diffusivity and leachability index values. Additionally, changes in porosity and saturated hydraulic conductivity of grouted soil were measured. X-Ray Computer Tomography (XCT) results showed that the cured polyurethane was distributed nearly homogeneously and approximately half of the voids were filled with cured polyurethane. Grouting reduced the saturated hydraulic conductivity of soil by 37 %. The effective diffusivity decreased by more than 80 % as compared with the ungrouted soil. The leachability index of the grouted soil was 6.5; meeting the criteria established by the U.S. Nuclear Regulatory Commission (NRC) standard. The results obtained in this study provide a valuable assessment of polyurethane grouting for iodide immobilization in the DVZ and indicate this approach may be a viable method for contaminant remediation in DVZ soils.

Contaminant Diffusion↗
DOE OSTI2026

Spatial and temporal characterization of municipal solid waste based on resource recovery pathways

This study presents a two-year, quarterly assessment of MSW across four source sectors (residential, schools, restaurants, and grocery stores) from sixteen sites across five U.S. states. MSW was manually sorted into 27 categories and aggregated into pathway fractions: high-moisture (HM) organics, low-moisture (LM) organics, recyclable (RC) materials, and residuals for disposal. Organics represented 89 % of the MSW stream. The largest fraction was HM organics consisting of food waste (31 %) and yard waste (3 %), with large coefficient of variations (CV), 79 and 278 %, respectively, reflecting high seasonal and site variability that varied significantly (p < 0.01) across sampling periods. The HM fraction showed properties favorable for anaerobic digestion, with moisture content ranging from 56 to 95 % and volatile solids ranges of 86-95 %. In contrast, the LM and RC fractions remained more stable (plastics CV = 41 %; paper CV = 53 %) with heating values up to 26.9 MJ/kg across sources, reflecting suitability for gasification. Microstructural analysis revealed less porosity in residential waste sampled at the landfill, which can influence preprocessing efficiency and microbial accessibility. Pathway informed allocations showed that 35 % of MSW is suitable for anaerobic digestion, 36 % for gasification, and 18 % for recycling, leaving 11 % requiring landfill disposal. These results provide quantitative evidence to determine feedstock allocation, waste-to-energy system design, and the development of data-driven sustainability and resource recovery strategies within a circular bioeconomy.

09 BIOMASS FUELS↗
DOE OSTI2025

Laboratory evaluation of cyclic underground hydrogen storage in the Temblor sandstone of the San Joaquin Basin, California

Underground Hydrogen Storage (UHS) in depleted oil and gas reservoirs could provide a cost-effective solution to balance seasonal fluctuations in renewable energy generation. However, data and knowledge on UHS at subsurface conditions are limited so it is difficult to estimate how effective this type of storage could be. In this study, we perform high pressure experiment to measure the effectiveness of cyclic hydrogen (H 2 ) storage in a specimen of Temblor sandstone retrieved from the San Joaquin Basin of California. Our experiment mimics reservoir pressure conditions to measure H 2 -brine relative permeability and fluid-rock interactions over the course of ten charging and discharging cycles. Initial gas breakthrough occurred at 15 % to 25 % H2 saturation in the specimen with 3 % NaCl brine as the resident fluid. Continuing injecting to 4 pore volumes (PV) of H 2 yielded an asymptotic H 2 saturation of 38 % to 41 %, a level often referred to as the irreducible gas saturation based on two-phase flow. The boundary condition in this study mimics the near wellbore region, which experiences bi-directional H 2 flow. This bi-directional flow led to evaporative drying of the specimen resulting in 94 % H 2 saturation at the end of 10th cycle. This indicates that cyclic flow and evaporative drying can lead to more efficient reservoir storage where a larger fraction of the reservoir porosity is usable to store H 2 . The produced gas stream consisted of H 2 mixed with 8 % to 22 % H 2 O, indicating formation dry-out by evaporation. Meanwhile, produced water chemistry indicated calcite and silicate dissolution, with calcite sourced from fossil fragments. This led to a loss of cementation and weakened the rock sample. Combined, our results indicate dry-out, compaction, increased H 2 saturation, rock weakening, and permeability loss during cyclic UHS. Overall, we anticipate that the combined effects should lead to higher than anticipated UHS storage efficiency per volume of sandstone reservoir rock.

08 HYDROGEN↗
DOE OSTI2025

Evolving physical and mechanical rock properties during exposure at Earth's surface

Rocks at Earth's surface experience progressive damage due to exposure to environmental conditions. Although environmental damage to rocks is recognized as being time-dependent, our quantitative understanding of its effects on physical and mechanical properties remains limited by field and laboratory studies constrained to short timescales. In this study, we aim to rigorously quantify how these properties evolve under longer natural environmental exposure spanning from the Holocene to the late Pleistocene. We conducted a ‘time series’ analysis of key physical and mechanical rock properties using multiple interior samples from 10 cogenetic granitoid boulders exposed for different amounts of time at two sites in Eastern California, USA. We find that over the late Pleistocene (~30 ka), rocks exhibit porosity increases of 40 ± 4 % and seismic velocity decreases of 7 ± 1 % at both sites. Similarly, over the same time period, rock tensile and compressive strengths declined by an average of 11 ± 4 %, and rock permeability increased on average by 104 ± 50 %. Microscopic analysis of thin sections of the same rocks indicates that microfracture density and intensity also progressively increased over the same timescales. These results suggest that time-dependent fracture propagation due to environmental exposure is likely a central contributor to the observed changes in rock properties. This study provides quantitative documentation that pronounced changes in the physical and mechanical properties of rock progressively occur within thousands of years of exposure.

Critical zone↗
DOE OSTI2026

Geomechanical properties of the Meletta sandstone - the high-temperature heat storage reservoir rock of DeepStor

The DeepStor project aims at storing excess heat at temperatures up to 140 °C in the depleted Leopoldshafen oil field at a depth of about 1300 m. In order to gain knowledge on the target horizons, the different layers of the Meletta sandstone, samples cored in a block retrieved in a quarry near Nussloch where the Meletta sandstone outcrops were studied. Several petrophysical properties were investigated including mineralogy, porosity, permeability, thermal conductivity, P- and S-wave velocities and quality factor. A mechanical study focused on compressive strength under uniaxial and triaxial stress conditions, tensile strength, critical pressure and stress-dependence of physical properties. Our results show that the Meletta sandstone is heterogeneous, anisotropic, mechanically weak, stress-sensitive and prone to water weakening. Petrophysical measurements on few Meletta sandstone cores retrieved in boreholes at about 1250 m depth showed that the outcrop samples are significantly less cohesive and weaker. Therefore, one should consider the Nussloch outcrop as a good reservoir analog only with great caution. Several models were applied to account for our experimental results on anisotropy, mechanical behavior and stress-dependence of the outcrop samples. Our study provides a valuable data set which can feed numerical models to simulate the behavior of the host formation during heat exchange operations in the DeepStor project.

Geomechanics↗
DOE OSTI2024

Microstructural effects on the rotating bending fatigue behavior of Ti–6Al–4V produced via laser powder bed fusion with novel heat treatments

The rotating bending fatigue (RBF) behavior (fully reversed, R = -1) of additively manufactured (AM) Ti–6Al–4V alloy produced via laser powder bed fusion (PBF-L) was investigated with respect to different microstructures achieved through novel heat treatments. The investigation herein seeks to elucidate the effect of microstructure by controlling variables that can affect fatigue behavior in Ti–6Al–4V, such as chemistry, porosity, and surface roughness. In order to control these variables, different hot isostatic pressing (HIP) treatments at 800 °C, 920 °C, and 1050 °C with a 920 °C temper were applied to three sets of Ti–6Al–4V cylinders that originated from the same PBF-L build, such that there were 30 tests per condition. After HIP treatment, the specimens were machined and tested. The highest runout stress was achieved after sub-β transus HIP at 800 °C for 2 h at 200 MPa of pressure. A significant drop in fatigue strength was attributed to large prior-β grains and grain boundary α resulting from super-β transus HIP treated specimens. In conclusion, for the sub-β transus HIP specimens, differences in fatigue strength were attributed to α lath thickness, relative dislocation density, and dislocation boundary strengthening.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Very high cycle fatigue characteristics of laser beam powder bed fused AlSi10Mg: A systematic evaluation of part geometry

This study explores the influence of geometry and part size on defect distribution, melt pool size, and mechanical characteristics in laser beam powder bed fused (LB-PBF) AlSi10Mg. Five distinct geometries—hourglass, small rod, small block, large block, and large rod—were fabricated under identical process parameters. Fully reversed ultrasonic fatigue testing, operating at a frequency of 20 kHz, was conducted to assess the very high cycle fatigue properties. The findings indicated that part geometry had a major impact on the fatigue properties of the material in the very high cycle fatigue regime. Specimens machined from large rods and large blocks had the lowest porosity and highest fatigue resistance. Microstructural analysis indicated that hourglass, small rod, and small block specimens had shallower melt pools and overlap depths compared to other geometries. This observation suggests a higher cooling rate in specimens with smaller cross-sectional areas, leading to the increased presence of entrapped gas pores and a lack of fusion defects. Understanding the relationship between part geometry and fatigue properties in LB-PBF components offers insights for optimizing design and manufacturing processes in additive manufacturing applications.

AlSi10Mg↗
DOE OSTI2026

Local convection characteristics of inline arrangement of Kagome-shaped unit cells in a square duct

Transient liquid crystal thermography experiments have been conducted to determine detailed convective heat transfer coefficients at the endwalls of lattice-frame configurations based on Kagome-shaped unit cells. Kagome unit cells with porosity of 0.88 were arranged in an inline manner, where two such arrangements were studied. In the first arrangement, a total of ten unit cells were placed next to each other along the streamwise direction resulting in a continuous configuration. In the 2nd arrangement, alternate unit cells from the continuous configuration were dropped, resulting in a discrete configuration which featured a total of 5 Kagome unit cells. Due to the asymmetric nature of the strut connections within the unit cell, the convective heat transfer coefficient maps were determined for the two opposite walls where the struts meet the endwalls. Transient liquid crystal experiments were conducted for Reynolds number ranging between 10,000 and 30,000. Here, the study was focused on the developing nature of flow along the streamwise direction and the local convection characteristics for continuous and discrete arrangement of unit cells. For the continuous configuration, the Nusselt number ratios (N u /Nu 0 ) varied between 3.15–3.46 and 2.75–2.89 for the two walls A and B, respectively. For the discrete configuration, convective heat transfer coefficients varied between 2.56–2.71 and 2.09–2.40 for the two walls. Kagome unit cells have the potential to be fabricated through inexpensive manufacturing routes such as wire-woven method and these unit cells find their applications in the areas which require different heat transfer levels on opposite walls.

Kagome↗
DOE OSTI2026

Continuum Correlations from CFD-DEM Modeling of Conduction Heat Transfer in Granular Flows

Heat transfer between a surface and flowing particles is analyzed to improve the accuracy of continuum models for wall-to-bed heat transfer in a fluidized bed. Discrete element modeling (DEM) is used to model a fluidized bed heat exchanger where heat enters the system through a heated wall. The DEM heat transfer predictions are validated against published experimental work (Brewster et al., 2024) with less than 15% error. In previous work by Morris et al. (2015), a continuum model was developed using data from high-fidelity DEM simulations of chute flows. In the current study, the continuum model is extended and validated for fluidized beds. The sensitivity of the continuum heat transfer model parameters, which was not quantified in previous studies, is also investigated. It is observed that for a given particle with specific properties, e.g. the particle size, roughness, and conduction lens radius, the continuum correlation developed for heat transfer from a heated boundary to the particle bed depends mainly on the solid fraction or porosity of the particle bed for a given fluid. The new continuum heat transfer model is then validated over a wide range of superficial velocities via comparisons to both discrete element and experimental data. It is shown that this correlation is valid for a large range of particle flow conditions from chute flows to fluidized beds with less than 10% error as compared to DEM predictions.

14 SOLAR ENERGY↗
DOE OSTI2025

Linking structure to performance: Characterization of porous transport layers for high-pressure water electrolysis

Proton exchange membrane (PEM) water electrolysis is a promising technology to produce cost-efficient hydrogen. PEM electrolyzers offer a large current density range and the ability to operate at differential pressure which can be used to minimize both capital and operational expenditures. However, directly producing pressurized hydrogen at the cathode results in pushing the membrane against the anode porous transport layer (PTL). This can lead to detrimental effects, such as membrane deformation or ruptures, which depend on membrane properties as well as PTL material properties such as pore size, structure, and morphology. In this work, a range of sinter and felt-based commercial PTLs are evaluated for their contributions to the cell's electrochemical and H 2 crossover performance at cathode pressures up to 30 bar. X-ray tomography and post-operando optical microscopy are used to assess the morphology of the PTLs, and the PTL induced deformation experienced by the catalyst coated membrane (CCM), respectively. PTL samples with lower porosity were found to reduce both the cell voltage and the amount of H 2 permeating from the cathode to the anode exhaust, which was ascribed to improved catalyst layer contact and reduced membrane deformation, respectively. The best performing PTLs improved electrolyzer efficiency by ~1.5 kWh/kg H2 . Specifically, 1 kWh/kg H2 was gained due to reducing membrane deformation and decreasing H 2 crossover. The remainder 0.5 kWh/kg H2 were achieved by improving the electrical contact at the electrode/PTL interface which decreased cell voltage.

08 HYDROGEN↗
DOE OSTI2026

Reservoir-scale model of geologic hydrogen production from serpentinization: Cyclic injection in a dual-permeability fracture-matrix system

Geologic hydrogen (GeoH 2 ) from serpentinization is a promising low-carbon resource, but its reservoir-scale behavior remains poorly understood. We develop a dual-permeability reactive transport model for an injector–producer well pair in ultramafic rock that couples multiphase flow, heat transfer, geochemistry, and porosity–permeability evolution. Here, the model is calibrated to olivine flow-through experiments and upscaled to two-year long simulations with continuous injection and cyclic injection with shut-in-to-injection ratios (SIR = 1, 0.5, 0.1). Olivine reacts along high-flux pathways to form lizardite and magnetite, increasing pH; H 2 (aq) and H 2 (g) peak early and then decline as exsolution and advective export outpace local generation. Continuous injection yields the highest cumulative H 2 but the lowest water-use efficiency (1.138 x 10 –6 mol/kgw). Cyclic injection increases this ratio to 1.35 x 10 –6 , 1.377 x 10 –6 , and 1.182 x 10 –6 mol/kgw for SIR = 1, 0.5, and 0.1, respectively; SIR = 0.5 provides a ~20% improvement over continuous injection and the best compromise for pilot design.

08 HYDROGEN↗
DOE OSTI2026

Zinc treatment to enhance nickel electrode performance for liquid alkaline water electrolyzers

Raney Ni treatment is introduced to the surface of Ni mesh anode electrodes, enhancing liquid alkaline water electrolyzer performance. The surface of the Ni mesh is alloyed with Zn, deposited by either an aqueous infiltration of Zn salt or direct reaction with Zn foil. The extent of alloying is controlled by a heat treatment step. For both processes, fine porosity and enhanced surface area are obtained after leaching the Zn out of the surface alloy layer. The observed electrode surface structure and performance is quite sensitive to the thermal treatment temperature. The enhanced surface area improves full cell performance by 90 mV for infiltrated Zn treated at 600 °C and by 185 mV for Zn foil reacted at 425 °C (at 2 A cm −2 and 80 °C). In conclusion, the Zn treatment methods produce stable operating performance, exhibiting no decay after 150 h for the infiltrated Zn treated at 600 °C, and a decay rate of 4.6 μV h −1 over 100 h for the Zn foil reacted at 425 °C (at 1 A cm −2 and 80 °C).

LAWE↗
DOE OSTI2026

High-Throughput Uniformity and Defect Monitoring in Low-Temperature Electrolysis Porous Transport Layers Using X-Ray Radiography

Effective quality control (QC) for manufacturing proton exchange membrane water electrolysis (PEMWE) components is critical to enabling widespread adoption of the technology for hydrogen generation. This study investigates X-ray radiography as a novel, high-throughput, potentially in-line QC technique for detecting defects and assessing material property distributions in titanium-based porous transport layers (PTLs) which constitute a crucial component of low temperature PEMWE stacks. We obtain radiographs of a set of fifteen PTLs and model their absorbance of the broadband radiation as a second-order polynomial to account for the non-monoenergetic radiation source used in this study. The resulting model serves as a basis for predicting the areal density and porosity distributions of the PTLs. We find radiography successful in detecting multiple instances of defects, including holes/depressions, cracks, and excess material on the surface or in the pores of the material, demonstrating its potential as a robust in-line QC tool for PTL manufacturing.

08 HYDROGEN↗
DOE OSTI2026

Synergistic cellulase–xylanase formulations for enhanced dewatering and fiber bonding toward energy-efficient and sustainable paper and packaging production

A mechanistic understanding of the synergistic effects of enzymes on cellulosic fibers dewatering and fiber bonding is essential for advancing energy-efficiency and lightweight production of paper and packaging materials. This study investigates the impact of varying cellulase and xylanase formulations on equilibrium moisture content (EMC) after pressing and tensile strength of cellulosic fiber webs using a factorial experimental design. Nine custom enzyme formulations were evaluated at controlled dosages ranging from ∼20 to 76 FPU/mL cellulase and ∼500–1130 IU/mL xylanase. Response surface modeling revealed a significant synergy, particularly at 20–40 FPU/mL cellulase combined with ≥ 1000 IU/mL xylanase. Under these conditions, EMC decreased by up to 3.6% compared with the untreated refined control, while tensile index gains of up to 16% were statistically significant for optimized blends (p < 0.05). The interaction between cellulase and xylanase was also significant for the tensile response (p = 0.010). Protein efficiency analysis showed that optimized formulations containing 30–40% less protein outperformed the commercial benchmark. The nonlinear synergy between cellulase and xylanase is attributed to their complementary substrate specificities. Endoglucanase- and β‑glucosidase‑rich cellulases hydrolyze internal β‑1,4‑glycosidic bonds in amorphous cellulose, loosening fiber walls and increasing flexibility, while xylanases target hemicellulose, primarily xylan-rich domains, enhancing porosity and improve cellulase accessibility. Tailoring enzyme formulations at low loadings overcomes traditional trade-offs between strength and dewatering, enabling cost-effective, energy-efficient, low-carbon solutions for sustainable packaging and hygiene products.

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

Upconversion of non-recycled MSW paper fractions into biochar via slow pyrolysis and life cycle analysis: Pathways to net negative GHG emission

This study presents an integrated and sustainable approach to valorizing non-recycled municipal solid waste (MSW), a heterogeneous and underutilized waste stream destined for landfilling, by converting it into valuable biochar resources. Specifically, we investigated the upcycling of nonrecycled paper waste based on compositional analysis into four major fractions: high cellulose, high lignin, high contamination, and high ash content papers. These fractions were then homogenized and subjected to slow pyrolysis. The high cellulose fraction (36.1 %) was the most abundant, and contained 66.7 % cellulose, while the high lignin fraction showed the highest lignin (12.1 %) and carbon content (44 %), resulting in highest energy value of 17.4 MJ kg −1 . Biochar yields ranged from 25.6 % to 35.6 %, with the high ash fraction producing the highest yield and alkalinity (pH ≈ 11.2) due to its higher mineral content. Elemental analysis revealed enhanced carbon content up to 76.9 % and reduced oxygen and hydrogen, confirming effective carbonization. The high lignin-derived biochar showed the highest aromatic carbon content (82.8 %) and greater structural stability, while contaminated and ash-rich fractions exhibited dense, low-porosity surfaces due to the presence of contaminants and minerals. Spectroscopic analysis revealed degradation of carbohydrates, disappearance of cellulose peaks and formation of aromatic and mineral derived phases. The scaled life cycle process yielded a global warming potential (GWP) of 119.3 kg CO 2 -eq per ton of dry paper waste, offset by soil carbon sequestration of − 556.41 kg CO 2 -eq, resulting in a net impact of − 427.36 kg CO 2 -eq. This represents a net carbon removal exceeding by ~186 % the emissions associated with landfilling paper waste with electricity generation.

09 BIOMASS FUELS↗