Search NASASearch

SEARCH · Search NASA

Results for “engineering process”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 91 records · Page 5

Engineering Microstructure in Dry-Processed Cathodes Via Calendering

Calendering serves as a multifunctional step in dry electrode processing that not only densifies the electrode but also induces polytetrafluoroethylene (PTFE) fibrillation and reorganizes the microstructure. These coupled effects are essential for achieving electrical connectivity and sufficient cohesion, yet they also introduce trade-offs, such as active material particle fracture, pore collapse, and excessive porosity loss, that can hinder ionic transport. This research systematically maps the calendering parameter space for LiNi0.6Mn0.2Co0.2O2 (NMC622) dry cathodes with a target thickness of ∼100 µm and porosity of ∼30% by varying roll gaps, roll temperature, roll speed, and the number of passes. A practical processing window for this formulation and electrode architecture is identified that achieves sufficient PTFE fibrillation and strong interfacial contact while minimizing particle fracture and preserving the porosity required for efficient ionic transport. In particular, gradual-gap calendering with moderate per-pass compression mitigates fracture and pore collapse while still reaching the target thickness with reasonable throughput, and slower roll speeds with modest roll temperatures further reduce mechanical damage. These results provide actionable guidance for scaling NMC622-based thick dry-processed cathodes.

Park, Hyunji

Influence of pre-existing defects on thermal transport in nuclear graphite

Nuclear graphite is a critical material in high-temperature nuclear reactors due to its superior thermal and mechanical properties. The manufacturing process leaves multi-scale ‘pre-existing’ defects that can affect thermal transport characteristics. Because these defects are remnant of graphitization temperature, they cannot be thermally annealed. This study employs a non-thermal electron wind force (EWF) annealing technique to avoid this obstacle. 2 min of EWF treatment of the as-received graphite IG-110 at temperatures below 100 °C led up to 67% increase in thermal diffusivity and ~ 35% decrease in electrical resistivity in average. Differential scanning calorimetry also showed similar outcome for specific heat. X-ray diffraction characterization was performed by fitting a bi-modal crystallite size distribution model to reveal the enhancement in crystallinity after the EWF treatment. The findings emphasize the potential of EWF annealing for optimizing thermal performance in nuclear graphite and its implications for reactor efficiency and safety.

Annealing

Business Opportunities in Clean Energy Supply Chains: Guidebook for Small and Medium-Sized Automotive Suppliers

This is the final report for the referenced TCF award which ran from Oct. 2019 through Jan. 2024 in conjunction with the industry partner Swift Solar. The long duration of the program was due to several factors including the pandemic and a technical work stoppage due to changes in the scope. Additionally, Swift’s business focus shifted during the course of the program. As a result of these factors, this program underwent two distinct modifications that dramatically changed the work scope. The following report is organized into three separate sections, each of which addresses a distinct work scope. Those scope changes, what necessitated them, and any new tasks/milestones are given, briefly, at the top of each section. The work performed was research on the hybrid halide perovskites (HHP), both the absorber material itself as well as other material layers that are required in a full device stack. At the start of the period of performance, there were two distinct challenges that we sought to address: (1) a wide band gap absorber (>1.6 eV), and (2) a recombination layer for tandem devices that provided good sequestration of the individual cell absorber materials in their respective device layers. NREL had previously published, and patented, advancements in both of these areas and they were the focus of much of the work throughout the program. The auto manufacturing space is evolving quickly. Sales of various electrified vehicles (xEVs) continue to grow steadily, which has medium to long-term ramifications for the thousands of U.S. manufacturers and hundreds of thousands of workers that contribute to the domestic automotive supply chain. In tandem with this growth in xEV sales, domestic clean energy manufacturing is surging (both for the xEV supply chain and other technologies), with public incentives spurring billions in private sector investment. Moreover, the next 2–3 years will see new and expanded industrial facilities come online to make products like hydrogen electrolyzers, solar panels, batteries, advanced electronics—and will create new supply chain needs and business opportunities as they do. DOE’s Office of Manufacturing and Energy Supply Chains (MESC) and Argonne National Laboratory developed this report to help automotive manufacturers—alongside various business support partners— understand these trends and their response options, and to make the most of current federal assistance programs for manufacturers. These market changes may create opportunities for small- and medium-sized manufacturers (SMMs) to expand production, grow profit margins, and diversify their businesses. For instance, SMMs could take advantage of engineering and process design similarities with new end-use industries that might enable greater business growth and stability as markets continue to change.

14 SOLAR ENERGY

Superstructure Optimization for Brine Valorization from Brackish Water Desalination

This poster presents preliminary results from a superstructure optimization framework developed to identify cost-optimal brine valorization configurations for brackish water desalination plants across diverse U.S. regional feed chemistries. The study uses brackish groundwater compositions from Arizona, California, Florida, New Mexico, and Texas. Using Pyomo Generalized Disjunctive Programming (GDP) within the WaterTAP modeling environment, the optimization framework simultaneously evaluates thousands of candidate treatment configurations, spanning nanofiltration, reverse osmosis, and chemical precipitation, to minimize the levelized cost of water (LCOW) while meeting water recovery targets and product recovery constraints. Results across eight representative feed clusters demonstrate water recovery rates of 57–87% and net LCOW values ranging from -$0.032/m³ (net revenue-positive) to $0.80/m. Notably, no single process configuration was optimal across all feed types, underscoring the necessity of feed-specific optimization. Products targeted include calcium carbonate (CaCO₃) at $0.01/kg and sodium chloride (NaCl) at $0.10/kg, both at 95% purity, with product revenues offsetting treatment costs in several scenarios. The work advances NAWI's process systems engineering capabilities for multi-configuration screening.

58 GEOSCIENCES

Vulcan-Forge: Architecture and Design of a Multi-Modal Forensic Analysis Plugin for CALDERA

Forge and VULCAN together describe an open-architecture cybersecurity analysis ecosystem that unifies forensic artifact processing, detection engineering, and vulnerability intelligence within integrated platforms. Forge operates as a plugin for MITRE CALDERA, ingesting diverse evidence formats—including EVTX, PCAP/PCAPNG, CSV, JSON, YAML, XML, binaries, and archives—to construct a unified artifact graph enriched with severity scoring, TLP classification, and audit trails. It provides subsystems for artifact parsing, streaming structured-data visualization, NetworkMiner-based packet inspection, PE/.NET binary analysis, and LLM-assisted triage and rule generation, with outputs validated against CCCS-YARA and pySigma schemas. VULCAN complements this by serving as a cybersecurity analyst platform that integrates a Neo4j knowledge graph, Qdrant vector retrieval, SSVC-based triage, and a local LLM to deliver CVE intelligence and forensic analysis through a multi-source ingest pipeline drawing from NVD, CISA KEV, EPSS, MITRE ATT&CK, and CAPEC. Together, they bridge structured threat intelligence with automated forensic analysis and detection workflows.

97 MATHEMATICS AND COMPUTING

Development of a High-Efficiency Hybrid Dry Cooler System for sCO 2 Power Cycles in CSP Applications

This project addressed a major gap in supercritical CO 2 (sCO 2 ) power cycle research by focusing on the pre-cooler, a component that had received little attention despite its significant impact on cycle efficiency and plant economics. The team developed a compact dry cooler using brazed/diffusion-bonded microchannel passages paired with formed air-side fins, advancing the technology from TRL-2 toward commercial readiness. Compared to conventional fin-tube coolers, the design cuts installation footprint by roughly half for 10+ MWth systems while achieving better heat transfer and lower approach temperatures, translating into a projected LCOE reduction from 6.04 ¢/kWh to between 5.85 and 5.94 ¢/kWh. While fabrication of an aluminum MW-scale prototype revealed brazing and sealing challenges at larger scales, lessons learned informed a subsequent 1 MWth unit that was successfully built and delivered for integration into Sandia's Gen3 Particle Pilot Plant, advancing the technology to TRL-7 with a path toward TRL-8 pending successful testing.

30 DIRECT ENERGY CONVERSION

Diol-enhanced natural deep eutectic solvents for efficient poplar pretreatment

Natural deep eutectic solvents (NDESs) are promising biomass pretreatment media, but their industrial application is often hindered by high viscosity. To address this limitation, diol-enhanced ternary DESs (TDESs) were prepared by incorporating 1,4-butanediol (1,4-BDO) or ethylene glycol (EG) into a choline chloride (ChCl) and 3,4-dihydroxybenzoic acid (DHBA) system. The applied TDESs maintained a liquid state at room temperature and had significantly reduced viscosity compared to the binary DES (BDES). In addition, the applied diols increased lignin solubility and suppressed lignin condensation by intercepting reactive carbocation intermediates. As a result, the recovered lignins from diol-induced TDES pretreatments showed better preservation of β-O-4 linkages and reduced condensation, improving their potential for downstream valorization. The diol-assisted DES systems showed a synergistic effect from the reduced viscosity, enhanced lignin solubility, and suppression of unwanted condensation, resulting in more effective biomass pretreatment performance, including the enhanced delignification and higher enzymatic digestibility compared to BDES. The 1,4-BDO-enhanced DES was also successfully applied to DHBA-enriched transgenic poplar, highlighting its potential for the processing of engineered biomass feedstocks.

3,4-dihydroxybenzoic acid

Algae Biofilm Produced from Anaerobic Digester Wastewater Demonstrated as Biofertilizer for Dwarf Wheat

Aims: To correlate yield of dwarf wheat fertilized with algae biofilm produced using anaerobic digester effluent (digestate) from a municipal water resource recovery facility as nutrient source and compare with yield using non-algae biofilm based fertilizers and a negative control. Study Design: Greenhouse testing for measurement of biomass yields and statistical analysis of wheat yield data results. Place and Duration of Study: Department of Biological Engineering Algae Processing and Products Facility greenhouse between March and June, 2024. Methodology: Yield of a dwarf cultivar of red spring wheat was measured as a function of four treatments including three fertilizers and a negative control: (1) algae biofilm cultivated on anaerobic digester effluent, (2) positive control of Osmocote commercial slow release fertilizer, (3) anaerobic digester biosolids, and (4) negative control with no fertilizer addition. Results: Average yield values (gm) for the four treatments were: (1) 1.25, (2) 0.99, (3) 0.72, and (4) 0.52, respectively. Algae biofilm fertilizer performed significantly better than Osmocote with P = .002, anaerobic digester biosolids with P = .05, and no fertilizer addition with P = .05. Struvite, a slow release fertilizer, was observed to be associated with the algae biofilm as a precipitate of the high concentrations of nutrients within the anaerobic digester water. Struvite (MgNH4PO46H2O) releases plant available nitrogen and phosphorus over time and is biologically precipitated due to the increase in solution pH as a result of photosynthesis by the algae biofilm. Conclusion: Algae biofilm cultivated on anaerobic digester wastewater can serve as a biofertilizer for recycling nutrients within the biosphere for sustainable nutrient management.

09 BIOMASS FUELS

Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report

The Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report outlines key insights and actionable recommendations for accelerating the scale-up of disruptive chemical manufacturing technologies. Convened in October 2024, the workshop brought together approximately fifty experts from academia, industry, national laboratories, and government agencies to address the barriers and solutions for maturing technologies from proof-of-concept to commercialization. The report identifies seven critical themes for enabling faster scale-up. These themes were explored through general discussions and breakout sessions focused on three specific chemical manufacturing technologies—electrochemical, thermochemical, and biological conversion processes. The findings emphasize the importance of interdisciplinary collaboration, robust funding mechanisms, and shared resources to overcome technical barriers and accelerate technology deployment. The report also highlights technology-specific challenges and opportunities, including the need for advanced materials, scalable manufacturing processes, and integrated testing environments. For electrochemical manufacturing processes, durability and material optimization are key priorities, while thermochemical processes require novel reactor designs and better supply chain integration. Biological conversion processes face hurdles in strain engineering, reactor design, and process integration. Across all technologies, the workshop emphasized the importance of leveraging computational tools, standardized protocols, and collaborative networks to address knowledge gaps and technical barriers. By acting on these insights, stakeholders can reduce the timeline for scaling up critical chemical manufacturing technologies, ensuring their timely impact on manufacturing competitiveness, and environmental sustainability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH

Simple Low-process Radiation Simulation For Unity Game Engine

This is a set of Unity components that use the Unity game engine's transform and collision systems to provide a reasonably representative approximation of any number of unique radiation sources and the collective dose they deliver to a user.

Dunker, Jack [Idaho National Laboratory (INL), Ida

Final Report: Process Intensification of Hydrogen Production through Sorption-Enhanced Gasification of Biomass

The University of Utah, in partnership with Idaho National Laboratory (INL), evaluated Sorption-Enhanced Gasification (SEG) as a transformative pathway for producing hydrogen with the potential for negative CO 2 emissions. SEG integrates gasification, water-gas shift, and in-situ carbon capture within a dual fluidized bed reactor to enable efficient clean hydrogen production. Key challenges related to biomass variability and process complexity were addressed through feedstock engineering, reaction optimization, and process validation. A co-pelletized biomass–limestone feedstock was developed to simplify feeding and introduction of makeup limestone. Kinetic and sorbent studies identified optimal operating conditions and confirmed the suitability of low-cost limestone, while catalysts were developed to reduce tar formation. Reactor modeling and techno-economic analysis indicated that SEG can achieve competitive hydrogen production costs, particularly when combined with carbon incentives, supporting its potential for scale-up and carbon-negative operation.

08 HYDROGEN

Technology Case Study: Economic, Sustainability, and Deployment Considerations for Sustainable Aviation Fuels Produced via Lignocellulosic Sugar Catalysis

This report presents a technology case study reflecting one exemplary representative pathway for the conversion of lignocellulosic sugars to sustainable aviation fuels (SAF) via aqueous phase reforming (APR) catalysis, considered within a broader integrated biorefinery framework based on biochemical processing operations. While far from the only option for converting sugars to SAF, this pathway was selected as a case study here based on its relatively high technology maturity and simplistic processing approach (avoiding complex separations or other equipment scalability challenges), coupled with the potential for high fuel yields and favorable costs/carbon intensities with opportunities for further near-term optimization. The report considers key process integration and engineering design considerations for a modeled hypothetical, nth-plant commercial biorefinery, reflecting a number of processing options and parameters envisioned to be achievable as future goals. Resultant outputs from Aspen Plus process simulations are evaluated through techno-economic and life cycle analyses (TEA and LCA), including implications for marginal cost of CO2 abatement and inclusion of currently-applicable policy incentives. Moving beyond base case configurations, a number of alternative scenarios are also evaluated for their ability to further improve economics, greenhouse gas (GHG) emissions, and marginal cost of abatement, highlighting a path to achieve deep decarbonization goals of more than 70% GHG reduction for SAF (with the potential to reach net-negative carbon intensities in some cases) under reasonable fuel production costs. The report also highlights future opportunities and gaps for further research on this technology pathway.

09 BIOMASS FUELS

Opportunities and challenges in process modeling and simulation of electrochemical systems

Electrochemical technologies have garnered intense interest in both academic research and industrial applications due to their potential to increase energy efficiency and reduce carbon footprint. However, electrochemical process fundamentals have been absent from the chemical process simulators available to millions of chemical engineers worldwide. To expedite process research and development of electrochemical technologies in the chemical industry, it is imperative that essential electrochemical process fundamentals be incorporated into process simulators to support modeling and simulation of electrochemical processes. Here, this study examines three process fundamentals key to the research and development of electrochemical processes: electrochemical reaction kinetics, electrolyte thermodynamics, and heat and mass transfer. It further illustrates application of these process fundamentals with a case study modeling an electrochemical process for the conversion of acrylonitrile to adiponitrile. The modeling example highlights the roles of applied voltage on reaction rates, and electron flow rates on the performance of electrochemical processes. It suggests that the applied voltage and electron flow rates are two unique concepts that should be included in simulators for electrochemical processes.

09 BIOMASS FUELS

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to fullscale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

36 MATERIALS SCIENCE

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to full-scale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

99 GENERAL AND MISCELLANEOUS

Magnetically Driven Neutron-rich Ejecta Unleashed: Global 3D Neutrino–General Relativistic Magnetohydrodynamic Simulations of Collapsars Probe the Conditions for r -process Nucleosynthesis

Abstract Collapsars—rapidly rotating stellar cores that form black holes—can power gamma-ray bursts and are proposed to be key contributors to the production of heavy elements in the Universe via the rapid neutron capture process ( r -process). Previous neutrino-transport collapsar simulations have been unable to unbind neutron-rich material from the disk. However, these simulations have not included sufficiently strong magnetic fields and the black hole (BH), both of which are essential for launching mass outflows. We present ν h-amr , a novel neutrino-transport general relativistic magnetohydrodynamic ( ν GRMHD) code, which we use to perform the first 3D global ν GRMHD collapsar simulations. We find a self-consistent formation of a weakly magnetized dense accretion disk, which has sufficient time to neutronize. Eventually, substantial magnetic flux accumulates near the BH, becomes dynamically important, leads to a magnetically arrested disk (MAD), and unbinds some of the neutron-rich material. However, the strong flux also hinders accretion, lowers density, and increases neutrino-cooling timescale, which prevents further disk neutronization. Typical collapsar progenitors with mass accretion rates, M ̇ ∼ 0.1 − 1 M ⊙ s - 1 , do not produce significant neutron-rich ( Y e < 0.25) ejecta. However, we find that MADs at higher mass accretion rates, M ̇ ≳ few M ⊙ s - 1 (e.g., for more centrally concentrated progenitors), can unbind M ej ≲ M ⊙ of neutron-rich ejecta. The outflows inflate a shocked cocoon that mixes with the infalling neutron-poor stellar gas and raises the final outflow Y e ; however, the final r -process yield may be determined earlier at the point of neutron capture freeze-out. Future work will explore under what conditions more typical collapsar engines become r -process factories.

Issa, Danat (ORCID:0009000524787631)

Rational Modulation of Plant Root Development Using Engineered Cytokinin Regulators

Achieving precise control over quantitative developmental phenotypes is a key objective in plant biology. Recent advances in synthetic biology have enabled tools to reprogram entire developmental pathways; however, the complexity of designing synthetic genetic programs and the inherent interactions between various signaling processes remains a critical challenge. Here, we leverage Type-B response regulators to modulate the expression of genes involved in cytokinin-dependent growth and development processes. We rationally engineered these regulators to modulate their transcriptional activity (i.e., repression or activation) and potency while reducing their sensitivity to cytokinin. By localizing the expression of these engineered transcription factors using tissue-specific promoters, we can predictably tune cytokinin-regulated traits. As a proof of principle, we deployed this synthetic system in Arabidopsis thaliana to either decrease or increase the number of lateral roots. The simplicity and modularity of our approach makes it an ideal system for controlling other developmental phenotypes of agronomic interest in plants.

Cell signaling