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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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DOE OSTI2025

A comprehensive academic and industrial survey of blockchain technology for the energy sector using fuzzy Einstein decision-making

The global energy sector is undergoing a significant transformation driven by decarbonization and digitalization, leading to the emergence of Distributed Ledger Technology (DLT) — particularly blockchain — as a promising tool for enhancing transparency, security, and efficiency in modern power systems. This study aims to provide a comprehensive academic and industrial survey of blockchain applications in the energy sector and develop a robust decision-making framework to identify and prioritize the most promising real-world use cases based on multidisciplinary criteria. A three-stage methodology was adopted: (i) a literature and market review encompassing over 300 academic publications and commercial blockchain initiatives in energy, (ii) an in-depth evaluation of the evolution and viability of blockchain initiatives in energy with the help of expert surveys, and (iii) a novel decision-making model using a q-rung orthopair fuzzy Multi-Attributive Border Approximation (q-ROF-MABAC) method under the Einstein operator. The results were compared with existing decision models to validate consistency and robustness. Nine key blockchain use case categories were identified and ranked based on technical, economic, and governance dimensions. The results demonstrated that integrating expert insights into a fuzzy logic framework helps filter out overhyped claims in the literature and prioritize realistic and high-impact applications such as green certificates, grid services, and peer-to-peer energy trading. The model’s rankings remained stable across varying weight configurations, confirming the robustness of the methodology. This study provides an evidence-based decision-support tool for researchers, industry stakeholders, and policymakers to better understand, evaluate, and adopt blockchain technologies in the energy sector.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

NSTTF Voucher Program RPPR-1 (Final Report)

Sandia issued a Request for Proposals (RFP) to solicit proposals from industry, academia, research laboratories, government agencies, and individuals on the use of the National Solar Thermal Test Facility (NSTTF) to increase CSP technology market adoption across the United States. The voucher funds will be used to cover the cost of NSTTF test facilities usage and technical staff support for analysis, design and test planning and execution. Sandia will collect submitted proposals, coordinate their review through DOE SETO, and work in partnership or under contract with the applicants to complete the funded research. Through this program, participants will be supported in their use of the world class facilities and expertise available at the NSTTF at Sandia in Albuquerque, NM to accelerate the advancement of CST technologies toward meeting 2030 SETO goals for CSP. The goals of this semi-annual reporting period were to complete all administrative tasks and contracting, begin testing on three of the vouchers, and report on initial findings. The fourth voucher (University of Michigan) is predicated on the results of an ongoing heat exchanger test that is expected to conclude by the end of FY22.

14 SOLAR ENERGY↗

DOE OSTI2024

T-Type Modular DC Circuit Breaker (T-Breaker) for Future DC Networks

The developed T-Type Modular DC Circuit Breaker (T-Breaker) technology offers an all-in-one solution to challenges in DC networks. This includes swift fault detection and protection, power transient stability, and power quality improvement, achieved through the utilization of wide bandgap (WBG) power semiconductors and energy storage devices. The T-Breaker not only facilitates rapid fault current detection and interruption but also implements fault current limiting through active insertion of storage devices or by operating WBG devices in the saturation region. Additionally, with the assistance of energy storage devices, potential overvoltage issues on power devices induced by control signal misalignment can be mitigated. The T-Breaker can be regulated to perform shunt current injection/absorption using the vertical arm and series voltage insertion via the horizontal arm, thereby enhancing DC system stability during voltage or load power fluctuation transients. The OSU team and Raytheon team actively worked together on designing, fabricating, assembling, and testing of two T-Breaker prototypes. The first prototype is rated at 1 kV, 500 A with half-bridge (unipolar) structure to validate the T-Breaker concept. The second prototype is rated at 20 kV, 50 A with full-bridge (bipolar) topology which can reach an efficiency of 99.977%, realize a power density of 60.2 MW/m3, and eliminate the 500-A fault current with a fault response time of around 20 µs. The prototypes show great feasibility of adopting this technology in multiple applications including electrified aircraft, super charging stations, data centers, etc.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2018

Physics of the Cosmos (PCOS) Program Technology Development 2018

We present a final report on our program to raise the Technology Readiness Level (TRL) of enhanced charge‐coupled‐device (CCD) detectors capable of meeting the requirements of X‐ray grating spectrometers (XGS) and wide‐field X‐ray imaging instruments for small, medium, and large missions. Because they are made of silicon, all X‐ray CCDs require blocking filters to prevent corruption of the Xray signal by out‐of‐band, mainly optical and near‐infrared (near‐IR) radiation. Our primary objective is to demonstrate technology that can replace the fragile, extremely thin, free‐standing blocking filter that has been standard practice with a much more robust filter deposited directly on the detector surface. High‐performance, back‐illuminated CCDs have flown with free‐standing filters (e.g., one of our detectors on Suzaku), and other relatively low‐performance CCDs with directly deposited filters have flown (e.g., on the X‐ray Multi‐mirror Mission‐Newton, XMM‐Newton Reflection Grating Spectrometer, RGS). At the inception of our program, a high‐performance, back‐illuminated CCD with a directly deposited filter has not been demonstrated. Our effort will be the first to show such a filter can be deposited on an X‐ray CCD that meets the requirements of a variety of contemplated future instruments. Our principal results are as follows: i) we have demonstrated a process for direct deposition of aluminum optical blocking filters on back‐illuminated MIT Lincoln Laboratory CCDs. Filters ranging in thickness from 70 nm to 220 nm exhibit expected bulk visible‐band and X‐ray transmission properties except in a small number (affecting ≲ 1% of detector area) of isolated detector pixels ("pinholes"), which show higher‐than‐expected visible‐band transmission; ii) these filters produce no measurable degradation in soft‐X‐ray spectral resolution, demonstrating that direct filter deposition is compatible with the MIT Lincoln Laboratory back‐illumination process; iii) we have shown that under sufficiently intense visible and near‐IR illumination, out‐of‐band light can enter the detector through its sidewalls and mounting surfaces, compromising detector performance. This 'sidewall leakage' has been observed, for example, by a previous experiment on the International Space Station during its orbit‐day operations. We have developed effective countermeasures for this sidewall leakage; iv) we developed an exceptionally productive collaboration with the Regolith X‐ray Imaging Spectrometer (REXIS) team. REXIS is a student instrument now flying on the Origins Spectral Interpretation Resource Identification Security - Regolith Explorer (OSIRIS‐REx) mission. REXIS students participated in our filter development program, adopted our technology for their flight instrument, and raised the TRL of this technology beyond our initial goals. This Strategic Astrophysics Technology (SAT) project, a collaboration between the MKI and MIT Lincoln Laboratory, began July 1, 2012, and ended on June 30, 2018.

PCOS↗

NASA NTRS2019

Overview of Heatshield for Extreme Entry Environment Technology (HEEET)

The objective of the Heatshield for Extreme Entry Environment Technology (HEEET) projects is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. Destinations that have extreme entry environments with heat fluxes > 3500 W/cm2 and pressures up to 5 atmospheres, entry environments that NASA has not flown since Pioneer-Venus and Galileo. The scope of the project is broad and can be split into roughly four areas, Manufacturing/Integration, Structural Testing and Analysis, Thermal Testing and Analysis and Documentation. Manufacturing/Integration covers from raw materials, piece part fabrication to final integration on a 1-meter base diameter 45-degree sphere cone Engineering Test Unit (ETU). A key aspect of the project was to transfer as much of the manufacturing technology to industry in preparation to support future mission infusion. The forming, infusion and machining approaches were transferred to Fiber Materials Inc. and FMI then fabricated the piece parts from which the ETU was manufactured. The base 3D-woven material consists of a dual layer weave with a high-density outer layer to manage recession in the system and a lower density, lower thermal conductivity inner layer to manage the heat load. At the start of the project it was understood that due to weaving limitations the heat shield was going to be manufactured from a series of tiles. And it was recognized that the development of a seam solution that met the structural and thermal requirements of the system was going to be the most challenging aspect of the project. It was also recognized that the seam design would drive the final integration approach and therefore the integration of the ETU was kept in-house within NASA. A final seam concept has been successfully developed and implemented on the ETU. The structural testing and analysis covers from characterization of the different layers of the infused material as functions of weave direction and temperature to sub-component level testing such as 4pt bend testing at sub-ambient and elevated temperature and culminates in testing of the ETU results from which will validate the structural models developed using the element and sub-component level tests. Given the seam has to perform both structurally and aerothermally during entry a novel 4pt bend test fixture was developed allowing articles to be tested while the front surface is heated with a laser. These tests are being utilized to establish the systems structural capability during entry.A broad range of aerothermal tests (arcjet tests) were performed to develop material response models for predicting the required TPS thickness to meet a missions needs and to evaluate failure modes and establish the capability of the system. The final aspect of the project is to develop a comprehensive Design and Data Book such that a future mission will have the information necessary to adopt the technology. This presentation will provide an overview for each of these areas and argue that HEEET has successfully achieved TRL 6.

HEEET↗

NASA NTRS2018

Overview of Heatshield for Extreme Entry Environment Technology (HEEET) Project

The objective of the Heatshield for Extreme Entry Environment Technology (HEEET) projects is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. Destinations that have extreme entry environments with heat fluxes up to 5000 watts per square centimeter and pressures up to 5 atmospheres, entry environments that NASA has not flown since Pioneer-Venus and Galileo. The scope of the project is broad and can be split into roughly four areas, Manufacturing/Integration, Structural Testing and Analysis, Thermal Testing and Analysis and Documentation. Manufactruing/Integration covers from raw materials, piece part fabrication to final integration on a 1-meter base diameter 45-degree sphere cone Engineering Test Unit (ETU). A key aspect of the project was to transfer as much of the manufacturing technology to industry in preparation to support future mission infusion. The forming, infusion and machining approaches were transferred to Fiber Materials Inc. and FMI then fabricated the piece parts from which the ETU was manufactured. The base 3D-woven material consists of a dual layer weave with a high density outer layer to manage recession in the system and a lower density, lower thermal conductivity inner layer to manage the heat load. At the start of the project it was understood that due to weaving limitations the heat shield was going to be manufactured from a series of tiles. And it was recognized that the development of a seam solution that met the structural and thermal requirements of the system was going to be the most challenging aspect of the project. It was also recognized that the seam design would drive the final integration approach and therefore the integration of the ETU was kept in-house within NASA. A final seam concept has been successfully developed and implemented on the ETU and will be discussed. The structural testing and analysis covers from characterization of the different layers of the infused material as functions of weave direction and temperature, to sub-component level testing such as 4-pt bend testing at sub-ambient and elevated temperature. ETU test results are used to validate the structural models developed using the element and sub-component level tests. Given the seam has to perform both structurally and aerothermally during entry a novel 4-pt bend test fixture was developed allowing articles to be tested while the front surface is heated with a laser. These tests are intended to establish the system's structural capability during entry. A broad range of aerothermal tests (arcjet tests) are being performed to develop material response models for predicting the required TPS thickness to meet a mission's needs and to evaluate failure modes. These tests establish the capability of the system and assure robustness of the system during entry. The final aspect of the project is to develop a comprehensive Design and Data Book such that a future mission will have the information necessary to adopt the technology. This presentation will provide an overview and status of the project and describe the status of the tehnology maturation level for the inner and outer planet as well as earth entry sample return missions.

Ellerby, Don↗

DOE OSTI2025

Evaluation of additive manufacturing side channels for nuclear nonproliferation applications

The nuclear industry is continuing to grow and adopt new technologies to manufacture components. One of the technologies under consideration is additive manufacturing (AM). AM could make production of components at lower cost and could lessen lead times significantly. However, AM could be prone to proliferation risks. AM machines give off signatures during the manufacturing process, and these signatures offer an alternative means of observing the component. Correlations between these signatures and the geometry being manufactured could be developed; enabling proliferators as they could take advantage of these correlations to steal AM manufacturing instructions relating to nuclear technology. This work pertains to preliminary work exploring the feasibility of tapping into AM side channels to predict geometries being manufactured on AM machines. The feasibility of utilizing vibration to draw geometric correlations will be assessed on an Ultimaker 2 + thermoplastic 3D printer.

Additive manufacturing↗

DOE OSTI2025

Integrated soft snake robot for gamma spectroscopy of radiologically contaminated ducting

Anticipated growth in the number and complexity of nuclear facilities entering the decommissioning phase of their lifespan requires innovative methods of mitigating radiological and safety hazards for workers. Advancements in robotics provide opportunities for remote characterization of radiologically contaminated ducts and pipes, reducing worker exposure. However, the nuclear decommissioning industry has shown a hesitancy in adopting new technology due to concerns regarding capital costs and a lack of demonstration data in representative environments. This work aims to leverage novel soft robotics to develop and demonstrate a sensor-integrated characterization tool for contaminated ducting systems. Two gamma spectrometers – one scintillation-based and one solid-state – were selected and integrated into a pneumatically-actuated snake-like soft robot using stretchable electronic cabling. The robot was then demonstrated at the Idaho National Laboratory’s Critical Infrastructure Test Range Complex. The robot maneuvered through a pseudo-constrained corridor containing several sealed sources and the integrated spectrometers collected spectra at various points along the path of travel. Both spectrometers successfully collected spectra with identifiable, isotope-specific peaks. To evaluate the effect of contamination buildup on the collected spectra, the robot with the integrated scintillation detector was tested using a liquid radioactive source. The resulting spectra showed little detection interference from the liquid contamination; however, a short-lived isotope was used which may not be representative of longer-lived contamination.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Influence of functional additives, fillers, and pigments on thermal and catalytic pyrolysis of polyethylene for waste plastic upcycling

Pyrolysis offers a relatively green and economical method to convert waste plastics into valuable chemicals and fuels without the need for harmful solvents, toxic chemicals, or costly high-pressure reactors. Despite its popularity among chemical upcycling technologies, industrial adoption suffers from feedstock heterogeneity, low-quality products, and catalyst deactivation. Most plastics in our daily lives are formulated with functional additives, fillers, and colorants. These additives remaining in end-of-life waste streams increase feedstock heterogeneity, creating a challenging issue in recycling plastics. Still, the potential impacts of additives on the chemical upcycling of plastics have been poorly understood. In this study, polyethylene compounded with a range of widely used additives (antioxidants, stabilizers, pigments, fillers, slip agents, and flame retardants) was subjected to both thermal pyrolysis and catalytic pyrolysis in different catalyst-to-feedstock contact modes. It showed that many inorganic additives, such as talc, kaolin, CaCO 3 , TiO 2 , carbon black, and zinc stearate, facilitated polymer decomposition during pyrolysis, increasing light hydrocarbons while also promoting aromatic and carbon residue formation. Conversely, antioxidants and stabilizers inhibited depolymerization, favoring heavier hydrocarbons. During catalytic pyrolysis with HZSM-5 zeolite, additives strongly enhanced aromatic and catalytic coke formation, especially when there was direct contact between plastics and catalysts. Although certain additives seem beneficial in the short term by promoting polymer cracking and improving the selectivity of aromatics, the transport of the additives and their degradation products and increased carbon coking can contaminate products, deactivate or modify catalysts, and foul reactors. These findings address a critical knowledge gap in effectively converting waste plastics via a greener route.

42 ENGINEERING↗

DOE OSTI2024

Decarbonizing the US Energy System

Recent rapid and unexpected cost reductions in decarbonization technologies have accelerated the cost-effective decarbonization of the US economy, with greenhouse gas (GHG) emissions falling by 20% from 2005 to 2020. The literature on US economy-wide decarbonization focuses on maximizing long-term GHG emissions reduction strategies that rely mostly on renewable energy expansion, electrification, and efficiency improvements to achieve net-zero GHG emissions by 2050. While these studies provide a valuable foundation, further research is needed to properly support decarbonization policy development and implementation. In this review, we identify key decarbonization analysis gaps and opportunities, including issues related to cross-sectoral linkages, spatial and temporal granularity, consumer behavior, emerging technologies, equity and environmental justice, and political economy. We conclude by discussing the implications of these analysis gaps for US decarbonization pathways and how they relate to challenges facing major global emitters.

08 HYDROGEN↗

DOE OSTI2025

Establishing model credibility for process-microstructure-property relationships in additive manufacturing using exascale computing

Additive Manufacturing (AM) of alloys holds significant promise as a disruptive technology in various industries, yet its adoption is often hindered by challenges in achieving consistent part quality. These issues are primarily due to the complex process-microstructure-property (PSP) relationships inherent to AM. Computational models can greatly aid in understanding these relationships, but their widespread impact and adoption has been limited by a lack of validated, open-source, and computationally efficient PSP modeling frameworks and hardware limitations. Here, this study leverages the ExaAM software suite and data from the AMBench-2018 series of laser powder bed fusion (LPBF) benchmark experiments to perform a comprehensive model assessment, including verification, validation, sensitivity analysis, and uncertainty quantification. The RADICAL-EnTK workflow manager was used to perform an ensemble of heat transport, solidification, and mechanical response simulations on the exascale computer Frontier, considering uncertainties in critical model inputs such as laser spot size and nucleation parameters, and consisting of 125 explicit grain structure simulations and 7875 crystal plasticity simulations. For a selected location within the Inconel 625 AMBench-2018 test artifact, sensitivity analysis and uncertainty quantification were performed using the predicted distributions of grain structure and mechanical properties. Qualitative agreement was found between the predicted grain size and texture and the observed AMBench-2018 microstructure, the mean predicted yield stress was within 5% of the experimental measurement mean, and the mean predicted engineering stress at 5% strain was within 10% of the experimental measurement mean. The insights gained from development and validation of the ExaAM PSP modeling framework will help guide future directions for enhancing the credibility and reliability of PSP models in AM, thereby accelerating the adoption of AM technologies in various industries.

Additive manufacturing↗

DOE OSTI2026

Evi-Pro Lite API

This application programing interface provides output from NLR's EVI-Pro model and is used to power the EVI-Pro Lite tool at https://afdc.energy.gov/evi-pro-lite. These endpoints provide daily (24-hour) fleet-level charging load profiles for a variety of customizable scenarios.