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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Using Large-Scale Additive Manufacturing for Wind Turbine Blade Core Structures

This report describes the techno-economic potential of using additive manufacturing technologies to design large wind turbine blade structures. After considering all additive technologies, the authors identified large-scale, polymer-based, material extrusion as the three-dimensional (3D) printing technology best suited to meet modern wind turbine blade manufacturing costs, cycle times, and geometric scale. Due to the lower structural performance requirements and the opportunity to reduce resin uptake mass penalties within the blade, the core material within the sandwich composite sections of the wind turbine blade is established as a logical entry point into advanced wind turbine blade manufacturing.

17 WIND ENERGY↗
DOE OSTI2023

Additive Manufacturing for Powering the Blue Economy Applications: A Tidal Turbine Blade Case Study: Preprint

As the marine renewable energy industry continues to expand, innovation in the manufacturing space must grow accordingly to reduce costs and ensure the economic feasibility of new technologies. Additive manufacturing, more commonly known as 3D printing, provides an alternative for rapid prototyping of marine hydrokinetic technologies, particularly supporting Powering the Blue Economy initiatives of the U.S. Department of Energy Water Power Technologies Office. This study explores the application of additive manufacturing in the development of marine hydrokinetic structures, focusing on material and printing method selection, design, and analysis of a 3D-printed spar for an axial-flow tidal turbine blade. Corrosion-resistant metals were deemed ideal due to the loads and harsh marine environment the blade would experience. Laser metal deposition methods were determined to be the most effective and scalable for the considered scale. The designed spar adapts its geometry to the blade - a feature uniquely suited to additive manufacturing - and is intended to serve as the blade's primary structural component. A finite element model was used to study stresses and deformations under loading conditions. The spar was manufactured using 316L stainless steel through direct energy deposition, and defects were assessed and recorded. Future efforts will include mechanical testing of the spar. This research establishes a benchmark process for using additive manufacturing in developing marine hydrokinetic structures, paving the way for future optimization and techno-economic analysis.

additive manufacturing↗
DOE OSTI2025

3D printable silicone compositions exhibiting high toughness and low durometer

3D printable silicones can be designed with varying crosslink density, network structures, and types of reinforcing additives. Within this design space, one may tailor the uncured material’s rheology and mechanical response to access a wide range of potential applications. However, printable, low modulus silicones, particularly those applicable to direct ink write, are underreported in published literature. To address the need for higher performance, low modulus silicones with demonstrated printability, a new set of ca. 20–50 Shore A hardness silicone elastomers exhibiting ca. 7 MPa ultimate tensile strength and ca. 400–1200% elongation at break is presented. Mechanical properties were analyzed, providing insight to the effects of formulation constituents on mechanical properties. Cyclic mechanical testing of the silicone formulations was also performed, and the energy loss and permanent set throughout cycling were determined. In conclusion, printed structures demonstrate the feasibility of these new silicones as durable frameworks for novel soft device applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Sulfonamidoboronic Acids as “Cross-Class” Inhibitors of an Expanded-Spectrum Class C Cephalosporinase, ADC-33, and a Class D Carbapenemase, OXA-24/40: Strategic Compound Design to Combat Resistance in Acinetobacter baumannii

Acinetobacter baumannii is a Gram-negative organism listed as an urgent threat pathogen by the World Health Organization (WHO). Carbapenem-resistant A. baumannii (CRAB), especially, present therapeutic challenges due to complex mechanisms of resistance to β-lactams. One of the most important mechanisms is the production of β-lactamase enzymes capable of hydrolyzing β-lactam antibiotics. Co-expression of multiple classes of β-lactamases is present in CRAB; therefore, the design and synthesis of “cross-class” inhibitors is an important strategy to preserve the efficacy of currently available antibiotics. To identify new, nonclassical β-lactamase inhibitors, we previously identified a sulfonamidomethaneboronic acid CR167 active against Acinetobacter-derived class C β-lactamases (ADC-7). The compound demonstrated affinity for ADC-7 with a K i = 160 nM and proved to be able to decrease MIC values of ceftazidime and cefotaxime in different bacterial strains. Herein, we describe the activity of CR167 against other β-lactamases in A. baumannii: the cefepime-hydrolysing class C extended-spectrum β-lactamase (ESAC) ADC-33 and the carbapenem-hydrolyzing OXA-24/40 (class D). These investigations demonstrate CR167 as a valuable cross-class (C and D) inhibitor, and the paper describes our attempts to further improve its activity. Five chiral analogues of CR167 were rationally designed and synthesized. The structures of OXA-24/40 and ADC-33 in complex with CR167 and select chiral analogues were obtained. The structure activity relationships (SARs) are highlighted, offering insights into the main determinants for cross-class C/D inhibitors and impetus for novel drug design.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Structure Sensitive Reaction Kinetics of Chiral Molecules on Intrinsically Chiral Surfaces

Enantiospecific heterogeneous catalysis utilizes chiral surfaces to resolve enantiomers via structure sensitive surface chemistry. The catalyst design challenge is the identification of chiral surface structures that maximize enantiospecificity. Herein, we develop data driven models for the enantiospecificity of tartaric acid reactions on chiral Cu(hkl) R&S surfaces. Measurements of enantiospecific rate constants were obtained by using curved Cu(hkl) R&S surfaces that enable kinetic measurements on hundreds of chiral surface orientations. One model uses feature vectors derived from generalized coordination numbers to capture the local structure around Cu atoms exposed by the Cu(hkl) R&S surfaces. The second model introduces the use of chiral cubic harmonic functions to capture the symmetry constraints of the face-centered cubic Cu structure. The model using 58 generalized coordination numbers has a fitting error similar to that of the model using only 5 cubic harmonic functions. The two models predict maxima in the enantiospecificity on surfaces with very similar surface orientations. The models developed in this work are applicable for any enantiospecific reaction happening on any chiral material with a cubic lattice structure, opening the way to understanding the surface structure sensitivity of the enantiospecific reaction kinetics.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

MPEX High Heat Flux Plasma Dump Design, Manufacture, and Articles Test

Here, the Material Plasma Exposure eXperiment (MPEX) device is a steady-state linear plasma device currently in the final design phase at the Oak Ridge National Laboratory. This device will reach ion fluences up to 10 31 m -2 and will be used to expose neutron-irradiated materials to divertor-relevant plasmas and to study the effects of plasma-material interactions. These studies will elucidate the complex effects of plasmas with divertor candidate materials capable of withstanding high heat flux and high fluences for next-generation fusion devices. Bidirectional plasma will be generated using a high-power (200 kW) helicon source. Plasma will be confined by superconducting magnets. The last plasma-facing component on the upstream side of the MPEX device is the dump, which has been designed to intercept plasma and energetic particles. The dump will have a total heat load of 9.2 kW. A copper alloy (Glidcop AL-15) was selected for use in the water-cooled flange design because of its high thermal conductivity, its retaining strength at elevated temperatures, and its ability to be used in the high-temperature braze joints used in this application. Titanium-zirconium-molybdenum (TZM) tiles are brazed to the Glidcop AL-15 flange using high-temperature braze alloy. External water-cooling channels are used on the dump flange to prevent water leakage inside the vacuum space. This article discusses the details of the high heat flux dump design, including the computational fluid dynamics (CFD) and structural analyses performed to validate the design to meet the operational requirements of the MPEX device.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Lattice design of 250 MeV version of PERLE

The PERLE (Powerful Energy Recovery LINAC for Experiment) collaboration is working on a high power energy recuperation linac facility with three acceleration (up to 500 MeV) and three deceleration passes through two cryomodules with an injection current of 20 mA. Here we present the lattice design of the first phase of this machine, which features a single cryo-module and demonstrates six-pass operation at a maximum energy of 250 MeV at a high current. This initial lattice design boasts a simpler structure with fewer elements, resulting in lower initial costs and faster construction and shorter commissioning time. Furthermore, all magnets and cryo-modules are designed to be compatible with both phases, keeping upgrade costs to a minimum.

Fomin, A.↗
DOE OSTI2023

Research Plan and Preliminary Results in Developing the Fabrication Parameters for Alloy 709 in Different Product Forms―Grain Coarsening Temperature Evaluation

The Advanced Reactor Technologies (ART) Program has established a multi-year plan to develop Alloy 709 advanced stainless steel (A709), generate the data package and develop material-specific design parameters in qualifying it as a new structural material for Class A component design in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors. In collaboration with material vendors, the Advanced Materials Development activities under ART have successfully scaled the A709 plate form production from a laboratory heat of 500 pounds to commercial heats totaling 133,000 pounds of A709 plate fabricated from three heats. The goal of the overall A709 development program is to establish the necessary microstructural and mechanical properties relationship for A709 to ultimately develop fabrication parameters for other product forms such as bars, piping and forging using the available ART A709 materials. The objective of this A709 development work at ORNL in FY2023 is to experimentally determine grain coarsening behavior for the A709 heats and to experimentally generate the continuous cooling precipitation (CCP) diagram for A709 using the as-rolled commercial heat plate materials. Integral to this work is the characterization of the as-rolled materials and the determination of an effective solution annealing process. This report summarizes the work performed to identify the grain coarsening temperature for commercial heat 58776-3RB fabricated by G. O. Carlson and heat 529900-02 fabricated by Allegheny Technologies Incorporated (ATI) Flat Rolled Products.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Generation IV Benchmarking of TRISO Fuel Performance Models Under Accident Conditions Final Report

The Generation IV International Forum (GIF) is a co-operative international endeavor of fourteen members organized to carry out the research and development needed to establish the feasibility and performance capabilities of the next generation nuclear energy systems. GIF selected six reactor technologies, amongst which is the Very High Temperature Reactor (VHTR) that is primarily dedicated to the cogeneration of electricity and hydrogen. The technical basis for VHTR is the tristructural isotropic (TRISO)-coated particle fuel, the graphite as the core structure, helium coolant, as well as the dedicated core layout and lower power density to removal decay heat in a natural way. At the heart of safety features of the VHTR concept lie the TRISO fuel particles that are designed to keep their structural integrity and retain fission products at temperatures up to 1600°C. As part as the design and future operation of VHTRs, a key aspect is the accurate prediction of fuel performance under irradiation and accident conditions. Modeling and simulation allow prediction of TRISO fuel behavior when subject to neutron flux and in high temperature accident scenarios. The refinement of the fuel performance models and codes is performed by comparison to in-pile and out-of-pile experimental data that reproduce the expected irradiation conditions in high temperature gas-cooled reactors (HTGRs). Historically, the International Atomic Energy Agency (IAEA) developed a benchmark dedicated to the validation of predictive methods for fuel and fission product behavior through the Coordinated Research Program CRP-2 (IAEA, 1997). CRP-2 was later updated to cover fuel fabrication, quality assurance, irradiation performance, safety testing, and spent fuel. The scope of the resulting CRP-6 benchmarks focused on HTGR fuel performance and fission product release (IAEA, 2012). Taking advantage of additional TRISO fuel fabrication, irradiation, and safety testing campaigns, GIF launched a Generation IV Benchmarking of TRISO Fuel Performance Models under Accident Conditions in late 2015. This GIF benchmark is a three-year program steered by Idaho National Laboratory (INL, USA). The other participants include the Japan Atomic Energy Agency (JAEA, Japan) and the Korea Atomic Energy Research Institute (KAERI, Korea). The objectives of the benchmark are to: follow on the IAEA CRP benchmarks, (2) model fission product release under accident conditions, (3) compare results obtained by the fuel performance modeling codes of the benchmark participants, and (4) compare these code predictions to experimental data. Safety tests chosen for modeling include the first and second experiments of the Advanced Gas Reactor program (AGR-1 and AGR-2) and the High Flux Reactor (HFR) EU1bis experiment. This report presents the results obtained by the three research institutions using their respective fuel performance modeling codes. Comparisons of the corresponding fission product release predictions are made with experimental data from AGR-1, AGR-2, and HFR-EU1bis. The benchmark results show good agreements between all participants but also show a general trend of over-prediction of the experimental release data, which is mainly attributed to the use of over-estimated diffusion coefficients.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Separation of alkane and alkene mixtures by metal–organic frameworks

The separation of alkane/alkene gas mixtures represents an important yet challenging process in the petrochemical industry to produce valuable chemical feedstocks with sufficiently high purity. These molecules have similar physical properties, making their separation difficult and capital-intensive. The current separation and purification technology relies largely on heat-driven distillations with a huge unit composed of hundreds of trays. Adsorptive separation using porous solids is capable of accomplishing the purification under ambient conditions, offering potential energy and environmental benefits. In particular, metal–organic frameworks (MOFs) hold enormous promise for this separation process in light of their highly tunable pore shape, pore size, and pore surface functionality. In this review article, we provide a comprehensive account of metal–organic frameworks that have been investigated for the separation of alkanes and alkenes with a focus on C 2 –C 3 hydrocarbons. Here, the material design rationale, separation mechanisms, and structure–property relations are highlighted. Finally, the existing challenges and possible design strategies for desirable materials are also discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Bifunctional Electrocatalysts with High-Entropy Alloys: Bridging Hydrogen Evolution and Oxygen Reduction

High-entropy alloys (HEAs) have emerged as a promising class of bifunctional electrocatalysts capable of simultaneously driving the hydrogen evolution reaction (HER) and the oxygen reduction reaction (ORR) with high activity and durability. Their near-equiatomic multicomponent compositions give rise to unique physicochemical characteristics, including lattice distortion, sluggish diffusion, high-entropy stabilization, and pronounced electronic heterogeneity, that collectively generate diverse and synergistic active sites inaccessible in conventional alloys. This review summarizes recent progress in HEA-based bifunctional electrocatalysis, with a focus on the fundamental mechanisms governing HER and ORR activity, stability, and selectivity. We discuss advances in synthesis strategies, ranging from confined growth and step-alloying to scalable continuous-flow methods, that enable precise control over composition, size, and surface structure. Complementary computational and data-driven approaches, including density functional theory, machine-learning-assisted screening, and descriptor development, are highlighted as essential tools for navigating the vast HEA design space and establishing structure−property relationships. Particular attention is paid to adsorption-energy distributions, multisite cooperativity, and environmental effects under realistic electrochemical conditions. Finally, we outline current challenges and future opportunities for integrating mechanistic understanding with AI-guided, closed-loop design frameworks to accelerate the discovery of next-generation HEA bifunctional electrocatalysts for sustainable energy conversion.

Alloys↗
DOE OSTI2025

Development of a Superconducting Adaptive Gap Undulator Prototype for NSLS-II

The photon flux and brightness of synchrotron radiation, crucial parameters for any light source, vary significantly depending on the type of source employed. Among the 23 Insertion Device (ID) sources at the National Synchrotron Light Source II (NSLS-II) at Brookhaven National Lab (BNL), the 12-year-old 3m-long In-Vacuum Undulator (IVU20) stands out for its superior performance, although it no longer represents the cutting edge of technology. Recently, there has been a shift in focus towards developing next-generation sources, particularly Superconducting Undulators (SCUs), characterized by smaller gaps, shorter periods, and maximum lengths. However, despite ongoing research and development efforts, SCUs have yet to surpass their predecessors, the Cryogenic Permanent Magnet Undulators (CPMUs), in terms of performance. This is largely attributed to the limitations posed by traditional superconducting wire, as well as challenges in the design of the magnetic structure and vacuum chamber. In this paper, we aim to overcome such limitations through the development of a unique prototype Superconducting Adaptive Gap Undulator (SC-AGU) magnet core and vacuum chamber design. This paper will outline a novel technical approach aimed at constructing a compact prototype magnet array utilizing state-of-the-art superconducting wire technology. This approach provides a more efficient magnetic structure, allowing for enhanced magnetic field strength and stability.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Epitaxial Regrowth and Hole Shape Engineering for Photonic Crystal Surface Emitting Lasers (PCSELs)

In the present research, epitaxial regrowth by molecular beam epitaxy (MBE) is investigated as a fabrication process for void-semiconductor photonic crystal (PhC) surface emitting lasers (PCSELs). The PhC is patterned by electron beam lithography (EBL) and inductively coupled plasma (ICP) etch and is subsequently regrown by molecular beam epitaxy to embed a series of voids in bulk semiconductor. Experiments are conducted to investigate the effects of regrowth on air-hole morphology. The resulting voids have a distinct teardrop shape with the radius and depth of the etched hole playing a very critical role in the final regrown void’s dimensions. We demonstrate that specific hole diameters can encourage deposition to the bottom of the voids or to their sidewalls, allowing us to engineer the shape of the void more precisely as is required by the PCSEL design. A 980 nm InGaAs quantum well laser structure is optimized for low threshold lasing at the design wavelength and full device structures are patterned and regrown. An optically pumped PCSEL is demonstrated from this process.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Network analysis uncovers the communication structure of SARS-CoV-2 spike protein identifying sites for immunogen design

The COVID-19 pandemic, caused by the SARS-CoV-2 virus, has triggered myriad efforts to understand the structure and dynamics of this complex pathogen. The spike glycoprotein of SARS-CoV-2 is a significant target for immunogens as it is the means by which the virus enters human cells, while simultaneously sporting mutations responsible for immune escape. These functional and escape processes are regulated by complex molecular-level interactions. Our study presents quantitative insights on domain and residue contributions to allosteric communication, immune evasion, and local- and global-level control of functions through the derivation of a weighted graph representation from all-atom MD simulations. Focusing on the ancestral form and the D614G-variant, we provide evidence of the utility of our approach by guiding the selection of a mutation that alters the spike’s stability. Taken together, the network approach serves as a valuable tool to evaluate communication “hot-spots” in proteins to guide design of stable immunogens.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

ACCELERATOR CHALLENGES OF THE LHeC PROJECT

The LHeC project studies the design of a future electron-proton collider at CERN that will run in parallel to the standard LHC operation. For this purpose, the existing LHC storage ring will be combined with an Energy Recovery Linac (ERL), to accelerate electrons up to kinetic energy of 50 GeV. This concept - also applicable to the FCC-eh collider and studied at the PERLE project as prototype version - allows a peak luminosity of 10³⁴ cm⁻² s⁻¹. A sophisticated design of the RF structures, linacs, arcs, and interaction region is required. The electrons are accelerated and, after the interaction point, their energy is recovered through the same RF structures. While this energy recovery concept is a very promising approach, severe challenges are set by the layout of the interaction region, the beam separation concept and the design of the linac and arc lattice for the highest possible momentum acceptance. Emittance control and beam-beam effect of both, electron and proton beams, have been studied in front-to-end simulations and will be presented. We summarise the design principles of the ERL, the optimization of the arc lattice, and the main parameters of the project.

Holzer, B. J.↗
DOE OSTI2020

Estimation of elastic properties of an additively manufactured lattice using resonant ultrasound spectroscopy

Development of improved approaches in the characterization of additively manufactured structures continues to be a topic of interest for the advanced manufacturing community. This article will investigate an approach using resonant ultrasound spectroscopy (RUS) to determine the effective elastic constants of an orthotropic lattice structure. The evaluation is performed on a cube shaped 316 L stainless steel test specimen, constructed using selective laser melting techniques. The approach uses RUS techniques in conjunction with the assumption that in the frequency regime of interest, the wavelength of the diagnostic ultrasound is greater than the discrete structural features of the unit cell of the lattice; thus, the AM structure can be treated as an anisotropic continuum with effective material properties and symmetry inherited from the unit cell. The RUS analysis estimates the nine elastic coefficients associated with orthotropic sample symmetry, which, in turn, are used to determine the elastic moduli and Poisson ratios. Current results show good agreement between experiments and modeled data. Comparisons to published results are also in good agreement, indicating the potential applicability of this characterization technique for estimating the linear elastic properties of innovative additive manufactured metal lattice structures.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Characterization and pulse-shape discrimination of a multi-stacked structure of ZnS: Ag/PMMA for fast-neutron detection in high-flux environments

The Micro-Layered Fast Neutron Detector (MLFD) is a proton-recoil scintillator that incorporates the basic concept of a Hornyak button detector with an improved design using a layered structure of ZnS:Ag and PMMA (polymethyl methacrylate). The MLFD was predicted to have low sensitivity to gamma rays, hence pulse shape discrimination was performed to determine the gamma-ray contribution. Presented in this paper are the pulse-shape discrimination characteristics of the MLFD. Additionally, the charge integration technique was employed to discriminate between the neutrons and gamma rays using a fast digitzer. The MLFD was found to exhibit excellent neutron/gamma-ray discrimination, with the highest Figure-of-Merit (FoM) being 4.56. With PSD, the neutron signal is distinct from gamma-ray, Ĉerenkov and electronic noise signals. This clear separation was achieved due to the large differences in decay times of the neutron and gamma-ray-induced pulses in the ZnS:Ag phosphor. The MLFD can be employed in high gamma-ray exposure fields, up to at least 1287.7 mR/hr, without appreciable degradation in PSD performance.

47 OTHER INSTRUMENTATION↗