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

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Energy Saving Estimation of ASHRAE Guideline 36 Supervisory Setpoint Reset Controls in a Commercial Large Office Building

Designing, commissioning, and retrofitting HVAC control systems for energy efficiency is crucial, but the use of ad-hoc control sequences by designers and contractors, based on scattered information, results in diverse and sub-optimal sequences. ASHRAE Guideline 36 (G36) addresses the challenge by providing standardized, rule-based HVAC control sequences that prioritize energy efficiency. However, there is limited evaluation of their energy performance at the building level, with only a few studies primarily focused on HVAC airside systems in small-to-medium-sized commercial buildings. In this study, the energy performance of ASHRAE Guideline 36 control sequences was assessed using a large office building emulator in Chicago. The emulator features a central plant system with multiple chillers and boilers as well as multiple variable air volume (VAV) systems with terminal reheat. To achieve a high-fidelity representation, we developed a Spawn-of-EnergyPlus-based model for the large office building, maintaining the DOE prototype large office building setup but substituting the HVAC system with its Modelica counterpart. This substitution ensures that the building thermal load, HVAC system's dynamics, and detailed control sequences are all accurately represented. The study involved evaluating and implementing control strategies outlined in ASHRAE Guideline 36-2021 to replace conventional controls. These strategies include the demand-based supply air temperature and duct static pressure setpoint reset and the request logic for demand-based reset of chilled/hot water supply temperature setpoints and pipe static pressure setpoints. Energy performance was evaluated under various load conditions, including cooling, heating, and transitional seasons, both for individual control strategies and in combination. The results indicate that the collective control strategies retrofit yield greater energy savings than the sum of individual strategies, highlighting the synergistic benefits of incorporating both airside and plant-side control retrofits. Additionally, energy savings of up to 41% in the heating season, 18% in the shoulder season, and 20 % in the cooling season were observed compared to baseline control while maintaining the thermal comfort level.

ASHRAE Guideline 36, Commercial buildings, Control↗
DOE OSTI2024

Spatial control of perilacunar canalicular remodeling during lactation

Abstract Osteocytes locally remodel their surrounding tissue through perilacunar canalicular remodeling (PLR). During lactation, osteocytes remove minerals to satisfy the metabolic demand, resulting in increased lacunar volume, quantifiable with synchrotron X-ray radiation micro-tomography (SRµCT). Although the effects of lactation on PLR are well-studied, it remains unclear whether PLR occurs uniformly throughout the bone and what mechanisms prevent PLR from undermining bone quality. We used SRµCT imaging to conduct an in-depth spatial analysis of the impact of lactation and osteocyte-intrinsic MMP13 deletion on PLR in murine bone. We found larger lacunae undergoing PLR are located near canals in the mid-cortex or endosteum. We show lactation-induced hypomineralization occurs 14 µm away from lacunar edges, past a hypermineralized barrier. Our findings reveal that osteocyte-intrinsic MMP13 is crucial for lactation-induced PLR near lacunae in the mid-cortex but not for whole-bone resorption. This research highlights the spatial control of PLR on mineral distribution during lactation.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Understanding interfacial crystallization dynamics on carbon fiber reinforced polypropylene composite manufacturing

Reinforcing polymers with discontinuous fibers improves mechanical properties, such as strength and stiffness, and in some cases achieve isotropic properties, rendering them suitable for various engineering applications. Matrix materials are generally highly engineered thermosets (e.g. crosslinked epoxies), bonded to the fiber periphery by proprietary surface and sizing chemistries. Semicrystalline thermoplastic matrices are less utilized due to poor fiber-matrix bonding resulting in inefficient interfacial load-transfer in reinforced composites. However, flexibility with melt-processing or molding conditions can be leveraged to promote non-covalent interfacial bonding between matrix and fiber via crystallization of the matrix onto fiber surface. In the present study, we utilize a co-mingle chopped carbon and isotactic polypropylene fibers to form isotropic composites, tailoring interfacial immobilized matrix or interphase morphology to optimize performance through precise control of thermal processing/molding windows. Calorimetry and optical microscopy were employed to investigate the impact of carbon fiber at various volume fractions (10, 20, and 30 %) on isotactic polypropylene crystallization and mechanical performance. Variations in mechanical properties correspond to the structural evolution of the interfacial region and are correlated to underlying microstructural attributes using wide-angle X-ray scattering, thermal analysis, and low-field nuclear magnetic resonance spectroscopy. These results provide a practical framework for the manufacturing of thermoplastic matrix composites. In conclusion, the results presented provide a guide for the strategic optimization of interphase design, showcasing tailorable tensile strengths which outperform any isotactic polypropylene carbon fiber composites previously reported in literature.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Method for producing a crystalline film

A method is provided for coating a surface of a material with a film of porous coordination polymer. A first substrate having a first surface to be coated is positioned in a processing chamber such that the first surface is placed in an opposing relationship to a second surface. The second surface may be provided by a wall of the processing chamber, or in some cases the second surface may be provided by a second substrate to be coated. The first substrate is held such that a gap exists between the first and second surfaces, and the gap is filled with at least one reaction mixture comprising reagents sufficient to form the crystalline film on at least the first surface. A thin gap (e.g., less than 2 mm) between the first and second surfaces is effective for producing a high quality film having a thickness less than 100 μm. Confining the volume of the reaction mixture to a thin layer adjacent the substrate surface significantly reduces problems with sedimentation and concentration control. The size, shape, or average thickness of the gap may be adjusted during formation of the film in response to feedback from at least one film growth monitor.

Britt, David K.↗
DOE OSTI2025

FLEX-FUEL MIXING CONTROLLED COMBUSTION ENABLED BY PRECHAMBER IGNITION

There is an imminent need to displace fossil diesel fuel with cleaner burning, domestically produced, renewable fuels for use in heavy-duty engines. Bioethanol is a prime candidate as it widely adopted in the U.S. as a gasoline additive ranging in volume percentage from 10% (E10) up to 85% (E85). Direct substitution of market available ethanol-gasoline blends for diesel fuel is not plausible as the stark reactivity differences would not constitute the same ignition quality nor achieve auto-ignition at all. This work focuses on the development of prechamber enabled mixing-controlled combustion (PC-MCC) as an advanced combustion strategy to facilitate reliable ignition and diffusion style combustion ethanol-gasoline fuel blends. PC-MCC involves integration of an actively fueled prechamber (PC) into a conventional compression ignition combustion system. When ignited, the PC ejects hot turbulent jets into the main combustion chamber that then interact with the direct injected fuel, prompting immediate ignition. The PC jet flames provide a robust thermal ignition source that allows the engine to operate agnostic of fuel composition, or flex-fuel. Computational fluid dynamics (CFD) modeling was used to assess critical design features of the PC while garnering insights into the ignition strategies that facilitate robust performance. A key finding was the ignition performance benefits of fuel-rich PC operation which yield exothermic jets. Based on the numerical findings, a prototype igniter was tested experimentally on both single and multi-cylinder engine platforms at a variety of operating conditions. The experimental results indicate flex-fuel PC-MCC is well capable of diesel-like combustion processes by demonstrating matched or improved gross thermal efficiencies and load variability within 2%. Fuel grade ethanol (E98) exhibited consistently lower NOx and immeasurable soot across the load space. E98 also demonstrated a significant improvement in thermal efficiency at light loads.

Zeman, Jared↗
DOE OSTI2025

Learning the factors controlling mineral dissolution in three-dimensional fracture networks: applications in geologic carbon sequestration

We perform a set of high-fidelity simulations of geochemical reactions within three-dimensional discrete fracture networks (DFN) and use various machine learning techniques to determine the primary factors controlling mineral dissolution. The DFN are partially filled with quartz that gradually dissolves until quasi-steady state conditions are reached. At this point, we measure the quartz remaining in each fracture within the domain as our primary quantity of interest. We observe that a primary sub-network of fractures exists, where the quartz has been fully dissolved out. This reduction in resistance to flow leads to increased flow channelization and reduced solute travel times. However, depending on the DFN topology and the rate of dissolution, we observe substantial variability in the volume of quartz remaining within fractures outside of the primary subnetwork. This variability indicates an interplay between the fracture network structure and geochemical reactions. We characterize the features controlling these processes by developing a machine learning framework to extract their relevant impact. Specifically, we use a combination of high-fidelity simulations with a graph-based approach to study geochemical reactive transport in a complex fracture network to determine the key features that control dissolution. We consider topological, geometric and hydrological features of the fracture network to predict the remaining quartz in quasi-steady state. We found that the dissolution reaction rate constant of quartz and the distance to the primary sub-network in the fracture network are the two most important features controlling the amount of quartz remaining. This study is a first step towards characterizing the parameters that control carbon mineralization using an approach with integrates computational physics and machine learning.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Quantum sensing of paramagnetic analytes by nanodiamonds in levitated microdroplets and aqueous solutions

Nanodiamonds (ND) hosting negatively charged nitrogen-vacancy (NV-) color centers have received attention for applications in magnetic field, electric field, chemical, and bio-sensing. The versatility of these probes is their excellent room-temperature optical and spin properties, along with their small size, functionalized surfaces and resistance to bleaching, making them ideal as nanoscopic sensors in picoliter volumes (e.g. single cells, but also microcompartments and aerosols). For quantitative ND-NV- sensing of paramagnetic analytes in such contexts, however, there remains an incomplete understanding of how factors related to the aqueous phase environment control detection efficiency. To address this, optically detected magnetic resonance (ODMR) is measured in bulk macroscale solutions and single levitated microdroplets as a function of Gd+3 concentration (340 nM to 1.5 mM), nanodiamond size, pH, competitor ions, and ligands. The ODMR response to [Gd+3] is found to be nonlinear, and pH, ND and sample volume dependent; indicating the detection of Gd+3 requires efficient adsorption of the analyte to the diamond surface. Langmuir adsorption isotherms embedded in a quantitative photophysical model links the ODMR response to adsorption thermodynamics of Gd+3. The equilibrium constant for Gd+3 adsorption to a carboxylated ND surface is determined to be (1 ± 0.5) x 105 M-1 corresponding to a free energy of adsorption of (-28 ± 1) kJ mol-1. These results provide general insight into how complex aqueous and microscale environments impact nanodiamond based quantum sensing modalities, and portend their application as quantitative chemical sensors in microenvironments.

Brown, Emily K↗
DOE OSTI2026

Mechanically graded granular scaffolds for osteochondral tissue engineering

Engineered scaffolds designed to approximate the mechanical microenvironment of the osteochondral unit often address this complexity using discrete, two-phase architectures that introduce mechanical discontinuities and interfacial stress concentrations rather than a contiguous stiffness transition. To address this challenge, we created a photoannealed polyethylene glycol (PEG) granular scaffold with a spatially controlled stiffness gradient within a cell-permissive, macroporous architecture. Stiffness was dictated by photoannealing microgels using a photomask. We tuned void volume and available surface area by varying microgel diameter and tested how mesenchymal stromal cells (MSCs) interpret local mechanical environments. MSCs exhibited position-dependent differences in morphology, cytoskeletal structure, matrix deposition, and lineage-specific gene expression within the gradient scaffolds. Softer regions supported rounded cell morphology and deposition of a glycosaminoglycan-rich matrix, whereas stiffer regions promoted cell elongation, increased cytoskeletal tension, and expression of mineral-associated markers. Gradients formed from smaller microgels magnified these spatial responses by increasing cellular confinement and adhesion site availability. Disruption of actomyosin contractility eliminated these regional differences, demonstrating that MSCs rely on tension-dependent mechanotransduction to interpret the gradient. These findings reveal that coupling microgel architecture with continuous stiffness transitions provides a tractable platform to study multiscale mechanobiologic regulation and spatially guide osteochondral tissue formation.

Biological and medical sciences↗
DOE OSTI2024

Shifting groundwater fluxes in bedrock fractures: Evidence from stream water radon and water isotopes

Geologic features (e.g., fractures and alluvial fans) can play an important role in the locations and volumes of groundwater discharge and degree of groundwater-surface water (GW-SW) interactions. However, the role of these features in controlling GW-SW dynamics and streamflow generation processes are not well constrained. GW-SW interactions and streamflow generation processes are further complicated by variability in precipitation inputs from summer and fall monsoon rains, as well as declines in snowpack and changing melt dynamics driven by warming temperatures. Using high spatial and temporal resolution radon and water stable isotope sampling and a 1D groundwater flux model, we evaluated how groundwater contributions and GW-SW interactions varied along a stream reach impacted by fractures (fractured-zone) and below the fractured hillslope (non-fractured zone) in Coal Creek, a Colorado River headwater stream affected by summer monsoons. During early summer, groundwater contributions from the fractured zone dominated, but declined throughout the summer. Groundwater contributions from the non-fractured zone were constant throughout the summer and became proportionally more important later in the summer. We hypothesize that groundwater in the non-fractured zone is dominantly sourced from a high-storage alluvial fan at the base of a tributary that is connected to Coal Creek throughout the summer and provides consistent groundwater influx. Water isotope data revealed that Coal Creek responds quickly to incoming precipitation early in the summer, and summer precipitation becomes more important for streamflow generation later in the summer. We quantified the change in catchment dynamic storage and found it negatively related to stream water isotope values, and positively related to modeled groundwater discharge and the ratio of fractured zone to non-fractured zone groundwater. Importantly, we interpret these relationships as declining hydrologic connectivity throughout the summer leading to late summer streamflow supported predominantly by shallow flow paths, with variable response to drying from geologic features based on their storage. As groundwater becomes more important for sustaining summer flows, quantifying local geologic controls on groundwater inputs and their response to variable moisture conditions may become critical for accurate predictions of streamflow.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Unsupervised multimodal fusion of in-process sensor data for advanced manufacturing process monitoring

Effective monitoring of manufacturing processes is crucial for maintaining product quality and operational efficiency. Modern manufacturing environments often generate vast amounts of complementary multimodal data, including visual imagery from various perspectives and resolutions, hyperspectral data, and machine health monitoring information such as actuator positions, accelerometer readings, and temperature measurements. However, fusing and interpreting this complex, high-dimensional data presents significant challenges, particularly when labeled datasets are unavailable or impractical to obtain. This paper presents a novel approach to multimodal sensor data fusion in manufacturing processes, inspired by the Contrastive Language-Image Pre-training (CLIP) model. We leverage contrastive learning techniques to correlate different data modalities without the need for labeled data, overcoming limitations of traditional supervised machine learning methods in manufacturing contexts. Our proposed method demonstrates the ability to handle and learn encoders for five distinct modalities: visual imagery, audio signals, laser position (x and y coordinates), and laser power measurements. By compressing these high-dimensional datasets into low-dimensional representational spaces, our approach facilitates downstream tasks such as process control, anomaly detection, and quality assurance. The unsupervised nature of our method makes it broadly applicable across various manufacturing domains, where large volumes of unlabeled sensor data are common. We evaluate the effectiveness of our approach through a series of experiments, demonstrating its potential to enhance process monitoring capabilities in advanced manufacturing systems. This research contributes to the field of smart manufacturing by providing a flexible, scalable framework for multimodal data fusion that can adapt to diverse manufacturing environments and sensor configurations. The proposed method paves the way for more robust, data-driven decision-making in complex manufacturing processes.

Contrastive Learning↗
DOE OSTI2024

Performance Demonstration of an Occupancy Sensor-enabled Integrated Solution for Commercial Buildings

Traditionally, a single-loop fixed-gain controller is applied to supply fan (SF) and cooling coil (CC) valve controls while a fixed-damper position control is applied to outdoor air (OA) damper control at air handling units (AHUs) in commercial buildings. With the increasing application of occupancy sensors, the information generated by occupancy sensors is applied to not only reduce the electricity loads from lighting and controllable plug loads, but also reset OA intake and minimum supply airflow setpoints. Meanwhile, these intermittent operation actions greatly elevate the dynamics of AHU systems, which may introduce unstable SF and CC valve operations and inaccurate OA flow control at AHUs and consequently degrade maximum energy efficiency gains. With virtual fan and valve flow meter technologies, two advanced controls, including cascade control and gain scheduling control, can be implemented on both the SF and CC valve, and an advanced control using a virtual OA flow meter can be implemented on OA damper integrated with occupancy sensors. The goal of this project is to demonstrate the savings, cost, and performance of an integrated solution that integrates the three advanced HVAC controls with occupancy sensors to allow accurate and stable AHU operations in real buildings. The project objectives are to: 1) develop and validate an advance SF control algorithm; 2) develop and validate an advanced CC valve control algorithm; 3) validate an algorithm to implement a virtual OA flow meter; and 4) demonstrate the savings, cost, and performance of the integrated solution in real buildings. The technical approaches are to: 1) select a test system at the University of Oklahoma; 2) develop and implement the algorithms of advanced SF and CC valve controls and validate the performance; 3) develop and implement the advanced OA control using a virtual OA flow meter and validate the performance; 4) demonstrate the savings, cost, and performance of the proposed integrated solution with and without three advanced HVAC controls; and 5) disseminate the project results through publications and presentations. For the SF control, both the gain scheduling and cascade controls can improve the fan energy performance by reducing the fan power during the transient period and the fan control performance at lower speeds by reducing fan speed variation. Moreover, the gain scheduling control provides a simple and low-cost solution and is recommended. The fan power savings can reach 30% in a transient period. For the CC valve control, the gain scheduling control can considerably reduce the supply air temperature oscillation range and frequency under both higher and lower load conditions and the control valve response is much more stable. As a result, the gain scheduling control is recommended. The projected pump energy consumption can be reduced by 68.5%. With the developed virtual OA flow meter, the OA can be accurately controlled at its setpoint, which is determined based on the actual number of occupants in the building provided by occupancy sensors. The RMSE of the proposed OA control is 15.9 L/s. The energy data shows that the fan power and CC cooling energy were significantly reduced. On the other hand, the energy savings majorly results from the occupancy sensors and the energy savings by the advanced HVAC controls is minimal because that the controllers in the test AHU were tuned with very slow response. An annual technical savings potential is estimated as 0.5 quads in the commercial sector.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

New Tank Mapping Method Improves Waste Removal Process

Waste Tank Mapping Overview • Camera inspections are performed within available tank top risers and used to create waste tank maps – Several camera inspections are performed during waste removal transfers to verify the elevation of the visible salt/sludge mounds against the known elevation of the liquid surface • Tank mappings are used to evaluate the volume and distribution of saltcake or sludge that is present within the waste tank – Allows for refined operating strategies and process safety controls • New tank mapping process creates a standardized approach for accurately defining waste distribution within a waste tank while minimizing the required camera inspection footage – First utilized during the 2023 Tank 22 Sludge Removal Campaign

Mini, Melany [Savannah River Mission Completion (S↗
DOE OSTI2024

Thermal conductivity of 3D-printed block-copolymer-inspired structures

This study primarily focuses on examining the impact that geometric structure has on thermal conductivity of multi-phase constructs in different 3D-printed poly(lactic acid), PLA, samples. The investigated structures are inspired by morphologies formed by diblock copolymers: lamellae, hexagonally packed cylinders, and gyroid. This research also investigates how volume percentage and material combination influence the thermal conductivity of these structures. Further, the samples can be tailored to simulate various thermal management structures observed in practical applications, such as thermal interface materials in electronic devices. Thermal conductivity ratio is controlled using air, the least conductive material at 0.026 W/(m K), PLA at 0.136 W/(m K), and thermal paste at 5.11 W/(m K). Different models were tested against thermal conductivity measurements in order to capture the effect of material type (PLA-Air versus PLA-Thermal Paste), volume percentage, structure, and orientation. Simple, effective medium models were good predictions of thermal conductivity in lamellar structures, but it was necessary to develop models for conduction through cylindrical and gyroid structures. Finally, all results were normalized to find a universal model that is independent of structure and material. This approach provides a simple method to predict how to reduce or enhance transport properties and heat management capabilities of 3D printed objects.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Structure–performance relationships of lithium-ion battery cathodes revealed by contrast-variation small-angle neutron scattering

Lithium-ion battery cathodes are porous composites of active material, conductive carbon, and polymer binder. Controlling the cathode microstructure is key to achieving high energy density and cycling stability. Current characterization techniques lack the nanoscale resolution over representative volumes necessary to relate cathode microstructure to cycling performance. To address this challenge, we utilize contrast-variation small-angle neutron scattering to quantify the chemical and structural features of cathodes wet by dimethyl carbonate, representing a relevant solvent environment. Using neutron scattering measurements, we identify an expansion in carbon and polymer structures that arises after calendering and wetting with solvent. Further, we deconvolute the carbon and binder phases to obtain the solvent-accessible carbon black surface area, which we correlate to diminished capacity retention driven by electrolyte decomposition on exposed carbon. This technique provides nanoscale insight into composite cathode microstructures and resulting cycling performance, promising future applications to a broad range of porous materials that exist in energy storage systems.

25 ENERGY STORAGE↗
DOE OSTI2026

Topological Control of Triply Periodic Minimal Surfaces for Thermal Design and Advanced Manufacturing: A Gyroid Case Study

Recently, there has been a heightened interest in using triply periodic minimal surfaces (TPMSs) in the design of compact process engineering components. The benefits of high surface area per unit volume, modular form, and inherent periodicity provide a holistic self-supporting network and flow-conducive features. Applications of importance include thermal power management, biomimetic scaffolds and structures, and feasibility of advanced manufacturing. This study presents a novel approach to the manipulation of the characteristic Schwarz-G, or gyroid TPMS, for thermal design in the context of advanced manufacturing. The study presents relationships between design parameters and resulting surface area as a target response using the characteristic equation of a gyroid. Through parametric control, the characteristic equation is manipulated to produce a 20-fold increase in achievable area over a baseline design characteristic of 25.4 mm through controlled combinations of design parameters. A second relationship is presented as a function of the maximum area achieved and manipulated design parameters. Through the analysis, the study presents a framework to identify and maximize the achievable area of TPMSs for advanced manufacturing and thermal management applications.

gyroid↗
DOE OSTI2025

Fast-rate joining of thermoplastic composites using integrated additive manufacturing and compression molding process

The integration of additive manufacturing (AM) technology with compression molding (CM), has emerged as a high-performance composite manufacturing technology in recent years. In the AM-CM process, quickly deposited AM preform on a mold undergoes a rapid compaction cycle to fabricate structurally robust composite parts due to highly controlled fiber alignment (from AM) and reduced porosity (from CM). Currently, AMCM-based part size is limited by the size of the mold volume, thus posing a challenge to manufacture scalable parts. Here, this work focuses on joining techniques developed to enable fast rate joining of short fiber-reinforced thermoplastic composite parts using the AM-CM process. Acrylonitrile butadiene styrene resin reinforced with 20 wt% short carbon fiber composites was printed onto a flat mold and pressed under a hydraulic press. Fabricated panels were joined by the (a) mechanical impression at the joining interface and (b) over-molded continuous carbon fiber (CCF) sheet. Tensile tests were performed to characterize the joining strength of both mechanical impression-based joints and CCF over molded joints. Among the mechanical impression-based joints, a U-shape channel allowed the fibers to flow between two joint parts, and 280 % increased mechanical properties were observed. The continuous carbon fiber-based over molded joint CCF showed 350 % increase in tensile strength compared to the butt joints.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Demonstration of a Novel Phase-Space Painting Method in a Coupled Lattice to Mitigate Space Charge in High-Intensity Hadron Beams

Multiturn charge-exchange injection is the primary method of creating high-intensity hadron beams in circular accelerators, and phase space painting during injection enables tailoring of the accumulated phase space distribution. A technique we call eigenpainting allows injection of particles into a single mode of a coupled ring, providing full four-dimensional control of the phase space distribution. Under ideal conditions, uniform eigenpainting generates a linear-force equilibrium distribution in the transverse plane, with zero volume in four-dimensional transverse phase space, even including space charge. Here, we have implemented eigenpainting for the first time in the spallation neutron source accumulator ring. Injecting 8.8 μ⁢C of an 800 MeV beam, we obtain a final ratio of intrinsic transverse emittances of ≈2.4. We analyze the effect of space charge on the final distribution through comparison of the reconstructed phase space to particle-in-cell simulations.

Evans, Nicholas J. [Oak Ridge National Laboratory ↗