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All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

First Annual Report on Pulsed Thermal Tomography Nondestructive Evaluation of Additively Manufactured Reactor Materials and Components: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Because of the geometry of metallic structures of interest for nuclear applications, which consist of planar primitives with no symmetry of revolution, limited options are available for nondestructive evaluation (NDE), either during or post manufacturing. Known material flaws in AM include low-density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. As a solution to NDE of AM, we are developing pulsed thermal tomography (PTT) models and depth inversion algorithms for 3D imaging. PTT has many advantages because the method is non-contact and allows for in-service, NDE of AM nuclear reactor parts. By analyzing transients of surface temperature response due to internal thermal resistances, one can obtain 3D reconstructions of material effusivity using a unique inversion algorithm developed at Argonne. This report provides results of preliminary performance evaluation of PTT capability in detection of flaws in metallic structures, as well imaging complex geometry AM structures. Performance of PTT was investigated through modeling and experiments, Computer models of PTT were developed using COMSOL Heat Transfer module. Defects were modeled as cylindrical flat bottom holes (FBH), which is a common model of calibrated material flaws in thermal tomography experiments. Materials considered in this study include stainless steel 316 (SS316), stainless steel 304 (SS304), and Inconel 718. Theoretical analyses were conducted to validate inversion of simulated PTT data with COMSOL for a plate. Subsequently, 3D reconstructions were performed on COMSOL simulations for FBH, revealing a decrease in spatial resolution over depth due to thermal diffusion. The results of this study show that the performance of the inversion algorithm for detecting smaller defects depends strongly on the depth of the defect as well as the incident heat flux. The size of detectable defect was estimated by fitting a Gaussian function to surface temperature profile. The criteria for detectability was taken as 20mK noise equivalent temperature difference (NETD), which is currently the sensitivity limit of high-performance infrared cameras. It was determined through computer simulations that the smallest detectable FBH in SS316 has a 50µm diameter and is located 0.5mm below the plate surface. Preliminary experimental studies were performed to evaluate PTT performance in detecting calibrated flaws using metallic specimens with AM defects simulated as drilled-in FBH’s. High strength Stainless Steel 316 and Inconel 718 alloys were considered, as well as lower grade Stainless Steel 304, Nickel 200, and Hastelloy C276. Specimens investigated in this report consisted of approximately 1/4in-thick plates made out of these alloys using conventional manufacturing methods. The diameters of FBH’s varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. The size of the smallest FBH was limited to 1mm because conventional mechanical drills were used for creating the holes. PTT imaging results have shown that 1mm-diameter FBH located 1mm and 2mm below the surface were detectable. Larger size FBH were detectable at greater depth. For example, 6mm-diameter FBH could be detected at 8mm depth. Image contrast varied slightly between the specimens, with the best reconstructions obtained in SS316 and C276 plates. Finally, PTT capability in imaging several AM structures fabricated from Inconel 718 (IN718) powder feedstock was investigated. The AM structures have complex geometry, but do not have calibrated internal defects. The objective is to determine PTT settings, such as the total integration time, for imaging of representative AM structures. A new FLIR X8500sc IR camera with higher spatial resolution (1280x1024 at 181Hz frame rate) was integrated into the PTT laboratory setup. Software tools were developed to ensure compatibility of new camera files with legacy effusivity reconstruction codes. The new camera was used to obtain 3-D reconstructions of AM IN718 nozzle plate and a particle filter plate. It was shown that PTT can scan through 2/3in-thick Inconel 718 plates in approximately 15s. Several modes of 3-D data visualization were explored, including using ImageJ and MATLAB software packages. The results demonstrate the capability of PTT in 3-D imaging of complex geometry AM structures. Intermediate results demonstrated in this report will be developed further to investigate detection of flaws in AM specimens.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2023

Numerical Study of Solidification Crack Susceptibility in Novel Refractory Alloy Systems

Calculation of Phase Diagrams (CALPHAD) -based solidification computa­tions, such as Scheil or equilibrium computations, have been utilized to propose crack solidification susceptibility indices (CSSIs) of cracking. These CSSIs have been proposed in order to predict the cracking susceptibility of an alloy in the solidification range, as a function of its solidification frac­tion and as dependent upon its wt.% elemental composition through the CALPHAD computation & via comparative methods between one composition & the next. Recently Kou at al. have proposed a novel CSSI where the gradient of the e.x. Scheil solidification curve is obtained in the critical solidification cracking region of greater than 0.95 fraction of solid. Therefore, a direct Temperature dependent metric is now available for the prediction, and presumably the control, of solidification cracking. In this TM, the researchers apply this Kou gradient method to refractory alloys for the first time & discuss justification for the approach via Spearman rank correlation with Varestraint cracking test data as well as by comparisons with Thermocalc based vulnerability time CSSI calculations. A Python Pycalphad module example of the approach is provided & can be utilized as an open-source resource that utilizes also open-source available thermodynamical databases, making the CSSI quantitative aspect of ICME more available and freely available to practitioners.

ICME integrated computational materials engineerin↗
DOE OSTI2021

Photonic Curing of Nickel Oxide Transport Layer and Perovskite Active Layer for Flexible Perovskite Solar Cells: A Path Towards High-Throughput Manufacturing

High-throughput roll-to-roll (R2R) manufacturing of perovskite solar cells (PSCs) is currently limited by thermal processes that take tens of minutes each, translating to impractically long annealing tools at high web speeds. In addition, PSCs are usually made with metal oxide transport layer materials that require high temperatures for thermal annealing. Here, we demonstrate the fabrication of PSCs using photonic curing, instead of thermal annealing, to convert NiO x directly from sol-gel precursors for hole transport layers and to crystallize methylammonium lead iodide (MAPbI 3 ) active layers on flexible Willow ® Glass substrates. Photonic curing uses short, intense pulses of light to process materials at a high speed, hence it is compatible with R2R manufacturing. We achieved power conversion efficiencies (PCEs) of 11.7% in forward-scan and 10.9% in reverse-scan for PSCs made with photonic cured NiO x and MAPbI 3 films. Furthermore, both NiO x and MAPbI 3 films could be processed with a single photonic curing pulse, with a web speed of 5.7 m/min, and still produce PCEs comparable to thermally annealed control samples. Based on the single-pulse photonic curing condition for each film, we project a web speed of 26 m/min, laying a pathway to high-throughput production of perovskite solar modules.

14 SOLAR ENERGY↗
NASA NTRS1989

Report of the committee on a commercially developed space facility

Major facilities that could support significant microgravity research and applications activity are discussed. The ground-based facilities include drop towers, aircraft flying parabolic trajectories, and sounding rockets. Facilities that are intrinsically tied to the Space Shuttle range from Get-Away-Special canisters to Spacelab long modules. There are also orbital facilities which include recoverable capsules launched on expendable launch vehicles, free-flying spacecraft, and space stations. Some of these existing, planned, and proposed facilities are non-U.S. in origin, but potentially available to U.S. investigators. In addition, some are governmentally developed and operated whereas others are planned to be privately developed and/or operated. Tables are provided to show the facility, developer, duration, estimated gravity level, crew interaction, flight frequency, year available, power to payload, payload volume, and maximum payload mass. The potential of direct and indirect benefits of manufacturing in space are presented.

Shea, Joseph F.↗
DOE OSTI2024

Systems and methods of adaptive two-wavelength single-camera imaging thermography (ATSIT) for accurate and smart in-situ process temperature measurement during metal additive manufacturing

A two-wavelength, single-camera imaging thermography system for in-situ temperature measurement of a target, comprising: a target light path inlet conduit for receiving a target light beam reflected from the target; a beam splitter installed in a splitter housing at a distal end of the target light path conduit, wherein the beam splitter divides the target light beam into a first light beam and a second light beam; a first light path conduit emanating from the splitter housing comprising a first aperture iris installed within the first light path conduit for aligning the first light beam; a first band pass filter installed within the first light path conduit for regulating the first light beam to a first wavelength λ1 and an optional half waveplate installed within the first light path conduit to modulate a polarization ratio of the first light beam of λ1 wavelength; a second light path conduit emanating from the splitter housing comprising a second aperture iris installed within the second light path conduit for aligning the second light beam; a second band pass filter installed within the second light path conduit for regulating the second light beam to a second wavelength λ2; a junction housing, wherein distal ends of each of the first and second light path conduits are connected to the junction housing; a polarizing beam splitter installed in the junction housing, wherein the polarizing beam splitter reflects the first light beam of λ1 wavelength along the same path or a parallel path of the second light beam of λ2 wavelength that passes directly through the polarizing beam splitter unreflected to create a merged light beam comprising light of λ1 and λ2 wavelengths; and a light path outlet conduit connected to the junction for directing the merged beam to a high-speed camera for imaging.

Zhao, Xiayun↗
DOE OSTI2018

A 3D-Printed Microresonator Based on the Quartz-Enhanced Photoacoustic Spectroscopy Sensor for Methane Detection

A 3D-printed microresonator based on a quartz tuning fork has been developed. The sensor performance is evaluated by detection of methane with a fiber-coupled distributed feedback diode laser. In combination with wavelength modulation spectroscopy, a minimum detectable concentration of 15.6 ppb by volume is achieved at atmospheric pressure with an 8-mW average optical excitation power and a lock-in amplifier time constant of 1 s, which corresponds to a 1σ normalized noise equivalent absorption coefficient of 5·10{sup –9} cm{sup –1}·W/Hz{sup 1/2}. An Allan variance analysis shows that the system has long-term stability and can serve as the basis for a portable gas analyzer. Approaches to improve the current sensor performance are also discussed. This design greatly reduces the time of manufacturing the microresonator.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

RD53A: A large-scale prototype chip for the phase II upgrade in the serially powered HL-LHC pixel detectors

The phase II upgrade of the HL-LHC experiments within the LHC intends to deepen the studies of the Higgs boson and to allow the discovery of further particles by adding an integrated luminosity of about 4000 fb -1 over 10 years of operation. This upgrade would overwhelm the installed pixel detector readout chips with higher hit rates and radiation levels than ever before. To match these extreme requirements the RD53 collaboration, a joint effort between ATLAS and CMS, developed RD53A, a new generation pixel detector readout chip prototype manufactured in a 65 nm CMOS technology. It is half the size of the final pixel chips and designed to meet requirements in the face of 3 GHz/cm 2 hit rate after irradiation to 500 Mrad. The detector is able to use 50×50 μm 2 or 25×100 μm 2 pixels with high readout speed of up to 4 links per chip with 1.28 Gbit/s each. Shunt–LDO regulators integrated on the bottom of the chip provide the required voltages to the two power domains, analog and digital. These regulators enable serial powering of the pixel modules, which is the only feasible, radiation hard scheme to ensure acceptable power cable losses and to stay within the material budget for the future pixel detectors. Finally, an overview of the status and challenges of serial powering and the Shunt–LDO regulator development will be given.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
NASA NTRS1991

Electrical Connectors

Betaflex connectors are sockets that connect multichip modules and high density ceramic packages to printed circuit boards. They incorporate shape memory alloy technology, developed under NASA contract. Aimed at computer, telecommunication, avionics and military markets, the connectors enable designers to gain up to 40 percent more board space and provide 100 signal lines to the inch. When the nickel titanium element in the connector is heated by a low voltage power supply, the connector's spring is opened allowing the circuit board to be inserted with zero force. This makes assembly easier and more reliable. Beta Phase was taken over by Mopex, BPS and currently manufactures these connectors.

Source record↗
DOE OSTI2018

Designing Phononic Crystals with Wide and Robust Band Gaps

Here, phononic crystals (PnCs) engineered to manipulate and control the propagation of mechanical waves have enabled the design of a range of novel devices, such as waveguides, frequency modulators, and acoustic cloaks, for which wide and robust phononic band gaps are highly preferable. While numerous PnCs have been designed in recent decades, to the best of our knowledge, PnCs that possess simultaneous wide and robust band gaps (to randomness and deformations) have not yet been reported. Here, we demonstrate that by combining the band-gap formation mechanisms of Bragg scattering and local resonances (the latter one is dominating), PnCs with wide and robust phononic band gaps can be established. The robustness of the phononic band gaps are then discussed from two aspects: robustness to geometric randomness (manufacture defects) and robustness to deformations (mechanical stimuli). Analytical formulations further predict the optimal design parameters, and an uncertainty analysis quantifies the randomness effect of each designing parameter. Moreover, we show that the deformation robustness originates from a local resonance-dominant mechanism together with the suppression of structural instability. Importantly, the proposed PnCs require only a small number of layers of elements (three unit cells) to obtain broad, robust, and strong attenuation bands, which offer great potential in designing flexible and deformable phononic devices.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Reliability history of the Apollo guidance computer

The Apollo guidance computer was designed to provide the computation necessary for guidance, navigation and control of the command module and the lunar landing module of the Apollo spacecraft. The computer was designed using the technology of the early 1960's and the production was completed by 1969. During the development, production, and operational phase of the program, the computer has accumulated a very interesting history which is valuable for evaluating the technology, production methods, system integration, and the reliability of the hardware. The operational experience in the Apollo guidance systems includes 17 computers which flew missions and another 26 flight type computers which are still in various phases of prelaunch activity including storage, system checkout, prelaunch spacecraft checkout, etc. These computers were manufactured and maintained under very strict quality control procedures with requirements for reporting and analyzing all indications of failure. Probably no other computer or electronic equipment with equivalent complexity has been as well documented and monitored. Since it has demonstrated a unique reliability history, it is important to evaluate the techniques and methods which have contributed to the high reliability of this computer.

Hall, E. C.↗
NASA NTRS2023

Elastic Modulus Testing for TriTruss Struts

The TriTruss is a novel structural module developed by researchers at NASA Langley Research Center (LaRC) that can be used in space to assemble large backing structures for a variety of applications. One such application is the metering truss and primary mirror backbone support structure of an in-space assembled telescope(iSAT). For the iSAT application, the TriTruss will be supporting mirror segments, payloads, and instruments, all of which require the TriTruss to have robust structural integrity. An accurate elastic modulus value is crucial to the finite element analysis(FEA) of the structure. Initial testing indicated that the equivalent elastic modulus provided by the manufacturer and used in the analyses did not accurately predict the behavior of the structure. In this paper, the in-house testing method developed at LaRC to accurately measure the equivalent elastic modulus of the composite struts for use in the analyses is described. A tensile and compressive equivalent elastic modulus was computed from the data obtained in this test. The testing resulted in a tensile equivalent elastic modulus of 24.6 Msi (standard deviation of 0.888 Msi) or 169 GPa (standard deviation of 6.20 GPa) and a compressive equivalent elastic modulus of 22.8 Msi (standard deviation of 0.780 Msi) or 157 GPa(standard deviation of 5.38 GPa) for the single wall thickness struts. For double wall thickness struts, the testing resulted in a tensile equivalent elastic modulus of32.1 Msi (standard deviation of 1.003 Msi) or 221 GPa (standard deviation of 6.91GPa) and a compressive equivalent elastic modulus of 31.9 Msi (standard deviation of 1.123) or 220 GPa (standard deviation of 7.74 GPa).1

TriTruss↗
DOE OSTI2020

The Role of Innovation in the Circularity of EV Lithium-Ion Batteries

This case study analysis highlights the role of innovations in EV battery design (cells, modules, and packs), reverse supply chain, and recycling processes in yielding value for the economics of recycling (and have the largest impact on the circularity of LIBs). Part of the assessment of value will be a semi-quantitative evaluation of the value of resilience in the rapidly evolving LIB market – i.e., there are a variety of risks that recyclers would face in making a financial commitment to a recycling facility including; the possibility that batteries would not be collected in sufficient quantities, the market for key constituents (e.g., cobalt) might decrease because of changes in battery chemistry, battery manufacturers may not be willing to pay as much for recycled material, etc. The analysis would be semi-quantitative in that two simple models would be used to assess 1. material flows using a previously developed excel-based reverse supply chain flows model, and 2. A LIB recycling process material and energy balance cost model that will be used to qualitatively assess the cost impacts of process innovations and changes in feed streams. Both sets of models are highly speculative in that they rely on a multitude of assumptions and input values (e.g., EV adoption rates) that vary widely in the literature. Additionally, the initial process flow diagrams and equipment lists for the recycling cost model are based on the Argonne EverBatt model, which is still under development. However, in combination with a critical review of the literature, economic modeling can yield valuable insights into the role of innovation in the circularity of LIBs and high-technology (“energy relevant”) products in general.

28 EE - Advanced Manufacturing Office (EE-5A)↗
DOE OSTI2024

LEED: A Lightwave Energy-Efficient Datacenter

The Lightwave Energy-Efficient Datacenter (LEED) program is a disruptive “green-field” approach that provides a quantum leap in the energy efficiency of datacenters. LEED’s fundamental value proposition is that a novel and re-architected optical network—RotorNet— can deliver “more bandwidth per buck” as well as unique system-level attributes that significantly improve overall datacenter energy efficiency and performance. LEED has developed three system-level testbeds. The first testbed uses calibrated hardware and software power measurements to determine server energy efficiency as a function of network bandwidth and workload. These measurements have shown that increasing network communications bandwidth dramatically increases server energy efficiency providing a realistic path to the overall ENLITENED program goal of doubling the number of transactions per joule. The second testbed demonstrates key hardware: a prototype low-loss, high-port count optical “selector switch”. This switch was fabricated, racked, and tested. Measured switch characteristics include loss, bandwidth, crosstalk, switch time, system-level switch time (including the transceivers), and bit error rate. The third testbed demonstrates a fully working and manufactured pinwheel design which dramatically lowers the cost of design, while delivering high switch radix and low reconfiguration times. The LEED project has tied these three novel photonic switch prototypes together with production servers and software through the development of a novel FPGA-based NIC platform called Corundum. Corundum ensures that the packet-switched protocols supported by commodity operating systems and devices can interface with the Rotor switch design. The LEED group has used this combined hardware and software prototype to characterize applications running at a commercially relevant scale. The project has used a combination of enhanced optical modulation amplitude (OMA) modulators, broadband multiplexers and demultiplexers, avalanche photodiodes, and a novel burst-mode receivers to enable the insertion of LEED-developed optical switches without the need for expensive optical amplification. Our modeling has shown that measured LEED-developed device characteristics can achieve link characteristics of 2 pJ/bit including both transceivers and the Rotor switch. In summary, the LEED program has demonstrated a credible and practical path, through novel hardware and software, to realize the program objectives of ENLITENED. The net result will ensure that the United States maintains its strength in the crucial sector of Information Technology, which is vital to both our economic security and our national security.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1991

Designing berthing mechanisms for international compatibility

The paper examines the technological issues regarding common berthing interfaces for the Space Station Freedom and pressurized modules from U.S., European, and Japanese space programs. The development of the common berthing mechanism (CBM) is based on common requirements concerning specifications, launch environments, and the unique requirements of ESA's Man-Tended Free Flyer. The berthing mechanism is composed of an active and a passive half, a remote manipulator system, 4 capture-latch assemblies, 16 structural bolts, and a pressure gage to verify equalization. Extensive graphic and verbal descriptions of each element are presented emphasizing the capture-latch motion and powered-bolt operation. The support systems to complete the interface are listed, and the manufacturing requirements for consistent fabrication are discussed to ensure effective international development.

Winch, John↗
NASA NTRS1999

In-Situ Production of Solar Power Systems for Exploration

Current proposals for developing an extended human presence, beyond space stations, on the Moon and Mars increasingly consider the processing of non-terrestrial materials essential for keeping the Earth launch burden reasonable. Utilization of in-situ resources for construction of lunar and Mars bases will initially require assessment of resource availability followed by the development of economically acceptable and technically feasible extractive processes. In regard to materials processing and fabrication the lower gravity level on the Moon (0.125 g) and Mars (0.367 g) will dramatically change the presently accepted hierarchy of materials in terms of specific properties, a factor which must be understood and exploited. Furthermore, significant changes are expected in the behavior of liquid materials during processing. In casting, for example, mold filling and associated solidification processes have to be reevaluated. Finally microstructural development and therefore material properties, presently being documented through on-going research in microgravity science and applications, needs to be understood and scaled to the reduced gravity environments. One of the most important elements of a human planetary base is power production. Lunar samples and geophysical measurements returned by the Apollo missions provide detailed data on the composition and physical characteristics of the lunar materials and environment. Based on this knowledge and extrapolations of terrestrial industrial experience it is clear that several types of solar-to-electric converters can be manufactured on the Moon. It is conceivable that well over 90% of a solar-to- electric power system could be made from lunar materials. Production and utilization of photovoltaic devices for solar energy production on Earth is primarily driven by the market economy. On Earth a production plant for photovoltaic devices is intimately linked to the planets massive industrial base. A selection of off the shelf refined materials are available as well as cheap fast transportation on demand. The processes takes place (except for the few seconds reprieve in shot towers etc.) under one gravity, with solar radiation significantly modulated by weather, and under conditions where one atmosphere is free and high vacuum is cumbersome and expensive. Off Earth, on lunar or Mars bases, the cost of photovoltaic power is driven by transport costs - Earth launch, deep space transport, landing on the planetary surface. Thus there is a premium for processes that are materials self-sufficient or for closed loop in-situ processes. The lack of differentiated ores on the Moon, and lack of explored minerals on Mars and interplanetary space give a premium to universal/non-ore-specific mineral extractive processes. Initially a semiconductor/photovoltaic production facility will build on no conveniently located industrial base, further increasing the premium on closed loop self sufficient processes.

Curreri, Peter A.↗
DOE OSTI2018

Insights into Magneto-Optics of Helical Conjugated Polymers

Materials with magneto-optic (MO) properties have enabled critical fiber-optic applications and highly sensitive magnetic field sensors. While traditional MO materials are inorganic in nature, new generations of MO materials based on organic semiconducting polymers could allow increased versatility for device architectures, manufacturing options, and flexible mechanics. However, the origin of MO activity in semiconducting polymers is far from understood. In this paper, we report high MO activity observed in a chiral helical poly-3-(alkylsulfone)thiophene (P3AST), which confirms a new design for the creation of a giant Faraday effect with Verdet constants up to (7.63 ± 0.78) × 10 4 deg T –1 m –1 at 532 nm. We have determined that the sign of the Verdet constant and its magnitude are related to the helicity of the polymer at the measured wavelength. The Faraday rotation and the helical conformation of P3AST are modulated by thermal annealing, which is further supported by DFT calculations and MD simulations. Our results demonstrate that helical polymers exhibit enhanced Verdet constants and expand the previous design space for polythiophene MO materials that was thought to be limited to highly regular lamellar structures. Here, the structure–property studies herein provide insights for the design of next-generation MO materials based upon semiconducting organic polymers.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Commercial Building Technology Demonstration (Final Scientific/Technical Report)

The background for this project was a unique and innovative concept that had been proposed and demonstrated by enVerid Systems, reducing the energy consumption in HVAC systems in commercial and public buildings by up to 50% at peak loads. The concept involves selective scrubbing of gas contaminants from indoor air as a practical substitute for outside air ventilation, the latter being the conventional practice today. This scrubbing enables recycling of most of the indoor air and significantly decreasing the amount of outside air, resulting in a reduced HVAC load and commensurate energy savings for the facility. Key to our approach is low cost scrubbing of all gas contaminants from indoor air using novel, efficient and regenerable sorbent materials. The total solution, labeled HLR (HVAC Load Reduction) is implemented by means of compact modules that can be retrofitted onto virtually any building, and utilizes novel sorbents that have been developed and brought to scale production by enVerid. Although the technology had been deployed and demonstrated, the US commercial building and HVAC markets, famously conservative with respect to innovation and new technologies, had yet to embrace the idea or the product. The overarching goal of the project was to help overcome market hesitancy and enable widespread adoption, by creating a critical mass of success stories across different regions and building types, all under oversight and verification of the DOE and NREL, to ensure credibility and accuracy. The project, overall, was a resounding success. Several installations were deployed and tested comprehensively for the impact on both energy consumption and indoor air quality, and results were not only excellent, but quantitatively in line with expectations. A total number of eight (8) installations were attempted, with 2 aborted due to building issues. Of the six successful installations, however, complete M&V was performed by NREL on 2 (Miami and NYC) and partial analysis on a third site (ArcBest), and these three, along with their results, were therefore presented from a financial and reporting standpoint. Although the number of case studies fell short of the original target of 10, we nevertheless had excellent demonstrations in vastly different climate zones: Southeast, Northeast and Midwest, and in very different building types. This included a modern high-rise office building in New York City and a University Campus health center in Miami, and a mid-rise high-density office in Arkansas. The cooling load reduction was shown to be significant, averaging 37% during the final cooling season in the Miami site. In the NYC site, the cooling energy savings were generally less, at around 12%, as expected. While this is a lower number for average/total savings, two comments are important to note: (i) the outside airflow (OA) reduction was not consistent during the data collection period, at least in part understating the attainable savings through incorrect measurement of the “high energy” reference state; and (ii) the peak impact in NYC is almost certainly as high as Miami, with critical ramifications for peak load reduction and equipment downsizing ability. Importantly, the measured energy savings in all locations were related to the outdoor climate conditions and the actual achievable reduction in outside air, very much in line with models and calculations; this leaves us with increased confidence in our understanding of the interaction between the technology and the building, and our ability to project the impact of this innovation in the future, through broad adoption. Simply put: the energy savings and load reduction impact of the HLR solution has been confirmed quantitatively. The results also confirmed the air quality objective. This may be even more significant, in that air quality is more complex and harder to measure and quantify, and the performance of the HLR as an air scrubber is the linchpin of the entire solution. In all sites, indoor air quality met or exceeded the required parameters, in terms of achieving the target (low) levels of indoor pollutants. Furthermore, the concentrations of outdoor sourced pollutants were markedly lower, as expected, mostly due to the reduction in outside air intake although in part also due to the scrubbing. The success was not immediate nor easy, and early challenges with the systems, especially (but not only) around controls and communication, caused delays in commissioning and undermined some of our M&V schedules. The good news is no fundamental issues were encountered and the number of such glitches was declining quickly by the end of the project. Other challenges had to do with coordinating the control of the building OA dampers, which the HLR needs to have in order to deliver the load reduction, but which the facility manager controls regularly and independently. This is not necessarily a problem for normal HLR operation but interferes with accurate M&V, where switching OA settings back and forth on a precise timetable is essential for clean data. The project provided valuable experience in retrofitting buildings that had been originally designed to operate with less recirculation and more outside air, and some key learnings related to the cyclical regeneration of the sorbents in the operational environment of the building. Some of these learnings gave already been incorporated into ongoing improvements in the design of the HLR module as well as the software that is used to control its operation. The cost and time of retrofit installations is much better understood; so is the test and balance procedure of the building that determines the available range of outside air reduction, which in turn determines the amount of load reduced. We had also implemented at least one annual cycle of sorbent cartridge replacement in the field, after which we tested the used sorbent to assess the rate of degradation of sorbent potency – an important factor affecting the long-term economics of HLR deployments. A notable shortfall of the project, other than the fact that the number of sites was below target, was that we had not (yet) completed testing to measure and verify (M&V) the winter energy savings. This is primarily due to late start on the NYC sites (Miami does not portend any heating savings associated with reduced outside air), combined with the issues of OA damper control. It is by no means suggested that such savings cannot be captured, only that the M&V with respect to winter in NYC has been incomplete. The value of this project and its interest to the general public are hard to overstate. The case studies created from Miami and especially from NYC have, without a doubt, opened up the interest of the broad HVAC industry to HLR in the past year. Major manufacturer reps have signed up to represent and promote the product, and dozens of top tier engineering consultants have introduced HLR as a base of design in upcoming construction and renovation projects – precisely the overarching goal of this project. These would not have happened without the highly visible installation in NYC and its ultimately satisfied customer. Furthermore, the DOE itself issued a report in late 2017 analyzing hundreds of candidate technologies for reducing energy consumption in HVAC; remarkably, the budding HLR solution ranked among the top 3(!); no doubt, its status as a viable and significant contender on this list is informed by the success of these demonstrations. And furthermore, in the wake of these demos, several major energy utilities, led by ConEdison in NYC, have endorsed the HLR solution and now routinely provide substantial cash rebates for customers choosing to incorporate the HLR in their buildings and reap the benefit of the reduced peak load as well as reduced cumulative energy demand. Last but not least, in January of 2019, as this report was being written, the HLR module won the AHR Expo Innovation Award for Green Buildings and, remarkably, the prestigious and only Product of the Year 2019, being selected by an independent professional panel of judges from AHR and ASHRAE. Given the confirmation of the enormous energy saving potential of HLR in widescale deployment, as well as ancillary but significant benefits in terms of equipment downsizing and indoor air quality, the benefit of this effort to the public speaks for itself. Accelerating adoption of HLR, without dependence on subsidies and driven by the private sector, is well under way. There is still much work to be done in terms of educating the HVAC and construction ecosystems and improving the product’s robustness and simplicity, to further facilitate the adoption of this technology and the capture of its potential value. But the American public will greatly benefit both directly and indirectly in the immediate future and beyond.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗