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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 OSTI2020

Bespoke, High-Purity Coal Tar with Microwave Plasma Pyrolysis

H Quest Vanguard, Inc is developing microwave plasma driven ultra-rapid (100-500 ms residence times) coal pyrolysis. In this innovative process, entrained in an oxygen-free gas stream, the coal particles enter a non-thermal plasma and are rapidly heated (~10 5 K/sec), resulting in a carbonized exterior and electrically conductive coal particles. Microwave radiation can then directly couple to entrained particles creating localized high energy regions. Aromatic and polyaromatic tar components are stripped from the macromolecular structure of coal and ejected into the gas stream leaving behind porous char particles

Viswanathan, Vignesh↗
DOE OSTI2021

One of These Things IS Like the Other: Pursuing a New Taxonomy of Industry for Improved Energy System Modeling

Industrial processes drive the exchange of materials, energy, and currency throughout the economy. These processes are powered by electricity and direct combustion, with variation in their operation even within the same industry. This heterogeneity makes it difficult for large models, including the National Energy Modeling System (US), to project their energy use while remaining tractable. Decarbonization and ensuing changes to the energy system require changes to industrial processes while offering opportunities for process innovation, but the extent and nature of changes are difficult to model with current classification schemes and corresponding data. The North American Industrial Classification (NAICS) is an economic taxonomy of industries, but its categories are less meaningful from an energy and material flow perspective. For example, a facility that makes steel from iron ore in a blast furnace/basic oxygen furnace is categorized under the same NAICS code as a facility that makes steel from scrap in an electric arc furnace despite the scale, use of recycled scrap versus iron ore, and energy use differences in the two facility types. Exploratory analysis is performed on a large dataset used for plant-level energy assessment in order to detect clusters that can aid in better modeling of industry for energy analysis in an evolving system with breakthrough technologies.

28 EE - Advanced Manufacturing Office (EE-5A)↗
DOE OSTI2021

Preliminary Cryogenic Cold Test Results of the First 9-Cell LSF Shape Cavity

Following successful prototyping and testing of single- & 5-cell LSF shape cavities *, **, the first 9-cell LSF shape cavity LSF9-1 was successfully constructed using an innovative process at JLab with the in-house facilities. The cavity was then shipped to KEK for post-fabrication mechanical adjustment and ILC TDR style treatment and surface processing. Cold testing was carried out at the JLab VTA facility, instrumented with a suite of Kyoto instruments. Favorable values for the bath pressure detuning sensitivity and Lorentz force detuning coefficient were experimentally measured, validating the design improvement in cell stiffeners. Pass-band measurements indicate 4 out of 9 cells reaching gradient capability of > 45 MV/m, including 2 cells reaching 51 MV/m. Cornell OST detectors identified the cell and location responsible for the current hard quench limit. Multipacting-like barriers observed in end cells are investigated both analytically and numerically. The cavity was shipped to FNAL and received a light EP at the joint ANL/FNAL facility for further cold testing at Jlab. Two new 9-cell LSF cavities are being constructed including one made of large-grain niobium material.

Geng, Rong-Li↗
DOE OSTI2025

Predicting Initial Trans-Membrane Pressure for Optimized Operations in UF Unit Using Random Forest

With the growing scarcity of freshwater, innovative process design mechanisms like Reverse Osmosis (RO) are increasingly gaining attention among water treatment utilities to address the rising demand. Ensuring reliable water production necessitates efficient resource utilization, minimizing downtime in (ultra-filtration) UF systems. Recent advancements in machine learning (ML) have enabled the development of accurate data-driven models for Model Predictive Control (MPC), often requiring minimal prior knowledge of underlying physical processes. In this study, we present predictive regression models based on Random Forest (RF) and Auto-Regressive (AR) approaches to forecast the initial Trans-Membrane Pressure (TMP) for each filtration cycle in data generated by Direct Potable Reuse (DPR) systems. The proposed RF-based model demonstrates superior performance compared to baseline methods, including historical mean, Last Observation Carried Forward (LOCF), and naïve AR models, across various forecasting horizons in terms of root mean square error (RMSE) metric. To evaluate how different classes of process variables contribute to TMP dynamics over time, we examine the feature importance of independent covariates across multiple forecast horizons. This analysis provides insight into the temporal relevance of operational and sensor-derived features, guiding control and monitoring strategies. Additionally, the impact of hyperparameter tuning on TMP prediction performance is studied for both direct and recursive RF modelling approaches across increasing forecast horizons. Accurate prediction of initial TMP is critical for optimizing RO operations, as it enables the development of robust modelling frameworks by accurately estimating membrane fouling trends, thereby enhancing process efficiency and long-term reliability. The demonstrated efficacy of the RF-based approach highlights its potential as a tool for real-time decision-making in water treatment systems, paving the way for advanced process optimization and sustainable water resource management.

Mukherjee, Subrata [ORNL] (ORCID:0000000309930338)↗
DOE OSTI2025

Predicting Initial Trans-Membrane Pressure for Optimized Operations in UF Unit Using Random Forest

With the growing scarcity of freshwater, innovative process design mechanisms like Ultra-filtration(UF) units are increasingly gaining attention among water treatment utilities to address the rising demand. Ensuring reliable water production necessitates efficient resource utilization, minimizing downtime in UF systems. Recent advancements in machine learning (ML) have enabled the development of accurate data-driven models for Model Predictive Control (MPC), often requiring minimal prior knowledge of underlying physical processes. In this study, we present predictive regression models based on Random Forest (RF) and Auto-Regressive (AR) approaches to forecast the initial Trans-Membrane Pressure (TMP) for each filtration cycle in data generated by Direct Potable Reuse (DPR) systems. The proposed RF-based model demonstrates superior performance compared to baseline methods, including historical mean, Last Observation Carried Forward (LOCF), and naïve AR models, across various forecasting horizons in terms of root mean square (RMSE) metric. Accurate prediction of initial TMP is critical for optimizing CCRO operations, as it enables the development of robust modelling frameworks that enhance process efficiency and reliability. The demonstrated efficacy of the RF-based approach highlights its potential as a tool for real-time decision-making in water treatment systems, paving the way for advanced process optimization and sustainable water resource management.

Mukherjee, Subrata [ORNL] (ORCID:0000000309930338)↗
DOE OSTI2024

Evaluation of Dissolvable Additively Manufactured Molds and Supports for Electroimpacts Innovative Additive Manufacturing Process

Electroimpact inc. has developed a new additive manufacturing process involving continuous fiber reinforcement along with high-strength thermoplastics. A unique part of this process includes using additive manufacturing to print a base geometry that is then used as a tool for continuous fiber placement. Ideally the tool should be disposable and cost effective. After printing the base tool, continuous fiber is printed on top of the tool using a secondary additive head on the same system to create the final printed part. After continuous fiber printing is completed, the tool is removed and disposed of to leave only the final desired structure. Materials used for the base tool have several requirements that must be met in order to complete this process. First, the material must be rigid and strong enough to support the loads from the secondary printing operation (continuous fiber printing). In addition, the material must be able to adhere to the secondary process material as well be capable of being removed such that the only remaining structure is continuous fiber composite. Using innovative soluble materials allows for parts to be produced through additive with molds that are produced as non-reusable one-off shapes and sizes.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Traveling Molten Zone Refining Process Development for Innovative Fuel Cycle Solutions

Considering the phase diagrams of metallic spent fuel constituents, the melting and solidifying of spent metallic fuel causes three immiscible layers (actinide-rich, lanthanide-rich, and Group II-rich) and the condensate phase (Group I) to form. We believe this anticipated immiscibility offers an untapped opportunity for innovative fuel cycle solutions. Through the proposed project, we anticipate confirming the expected phase behavior and develop a thermal treatment process to rapidly extract actinides from spent metallic fuels. The prime apparatus for both purposes is a traveling molten zone system with induction heating. We envision that one rapid pass of the molten zone from the bottom to the top of the metallic rod incorporating species of spent metallic fuels should produce the expected immiscible layer formation and provide species partitioning data effectively and cleanly. It will also demonstrate an actinide extraction process by concentrating the impurities at the top segment of the rod and leaving the actinide species behind as the bulk rod. The successful execution of the project will demonstrate proof of concept for a transformative process path for used metal fuels in terms of economics and safeguards.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Process control integration requirements for advanced life support systems applicable to manned space missions

An overview of recent developments in process-control technology which might have applications in future advanced life support systems for long-duration space operations is presented. Consideration is given to design criteria related to control system selection and optimization, and process-control interfacing methodology. Attention is also given to current life support system process control strategies, innovative sensors, instrumentation and control, and innovations in process supervision.

Spurlock, Paul↗
DOE OSTI2025

Innovative Polyhydroxyalkanoates (PHA) Production with Microbial Electrochemical Technology (MET)

The project “Innovative Polyhydroxyalkanoates (PHA) Production with Microbial Electrochemical Technology (MET)” addressed food waste disposal challenges by successfully converting food waste to bioplastics (known as PHAs). The novel process created by our team of researchers from universities, national labs, and industry substantially enhanced overall carbon conversion efficiency of food waste processing (> 50%), while reducing disposal costs (> 25%). The project showed economic viability potential at community scale through pilot-scale demonstration at a relevant scale (50 L reactor volume) with more than 100 hours of PHA production using realistic conditions. The project goal was to valorize food waste by shunting traditional anaerobic digestion processing and creating a value-added PHA processing route that improves the economics and sustainability of local, community-scale, wet organic waste treatment. First, the food waste undergoes microbial-based, dark fermentation to break down the food to small carbon chains known as volatile fatty acids (VFAs). Instead of microorganisms converting the VFAs into methane using normal anaerobic digestion processing, our innovative process inhibits methane production. This preserves the produced VFAs for extraction and use by a novel Haloferax mediterranei (HM) archaea, which effectively converts the VFAs to bioplastics. The project added microbial electrochemical cells (MEC) to the dark fermentation process to enhance the VFAs produced and optimize the type of bioplastics formed.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Experimental Comparison of Hydrogen Refueling with Directly Pressurized vs. Cascade Method

This paper presents a comparative analysis of two hydrogen station configurations during the refueling process: the conventional “directly pressurized refueling process” and the innovative “cascade refueling process.” The objective of the cascade process is to refuel vehicles without the need for booster compressors. The experiments were conducted at the Hydrogen Research and Fueling Facility located at California State University, Los Angeles. In the cascade refueling process, the facility buffer tanks were utilized as high-pressure storage, enabling the refueling operation. Three different scenarios were tested: one involving the cascade refueling process and two involving compressor-driven refueling processes. On average, each refueling event delivered 1.6 kg of hydrogen. Although the cascade refueling process using the high-pressure buffer tanks did not achieve the pressure target, it resulted in a notable improvement in the nozzle outlet temperature trend, reducing it by approximately 8 °C. Moreover, the overall hydrogen chiller load for the two directly pressurized refuelings was 66 Wh/kg and 62 Wh/kg, respectively, whereas the cascading process only required 55 Wh/kg. This represents a 20% and 12% reduction in energy consumption compared to the scenarios involving booster compressors during fueling. The observed refueling range of 150–350 bar showed that the cascade process consistently required 12–20% less energy for hydrogen chilling. Additionally, the nozzle outlet temperature demonstrated an approximate 8 °C improvement within this pressure range. These findings indicate that further improvements can be expected in the high-pressure region, specifically above 350 bar. This research suggests the potential for significant improvements in the high-pressure range, emphasizing the viability of the cascade refueling process as a promising alternative to the direct compression approach.

08 HYDROGEN↗
NASA NTRS1989

An innovations approach to decoupling of multibody dynamics and control

The problem of hinged multibody dynamics is solved using an extension of the innovations approach of linear filtering and prediction theory to the problem of mechanical system modeling and control. This approach has been used quite effectively to diagonalize the equations for filtering and prediction for linear state space systems. It has similar advantages in the study of dynamics and control of multibody systems. The innovations approach advanced here consists of expressing the equations of motion in terms of two closely related processes: (1) the innovations process e, a sequence of moments, obtained from the applied moments T by means of a spatially recursive Kalman filter that goes from the tip of the manipulator to its base; (2) a residual process, a sequence of velocities, obtained from the joint-angle velocities by means of an outward smoothing operations. The innovations e and the applied moments T are related by means of the relationships e = (I - L)T and T = (I + K)e. The operation (I - L) is a causal lower triangular matrix which is generated by a spatially recursive Kalman filter and the corresponding discrete-step Riccati equation. Hence, the innovations and the applied moments can be obtained from each other by means of a causal operation which is itself casually invertible.

Rodriguez, G.↗
NASA NTRS2001

Proceedings of the 4th Conference on Aerospace Materials, Processes, and Environmental Technology

The next millennium challenges us to produce innovative materials, processes, manufacturing, and environmental technologies that meet low-cost aerospace transportation needs while maintaining US leadership. The pursuit of advanced aerospace materials, manufacturing processes, and environmental technologies supports the development of safer, operational, next-generation, reusable, and expendable aeronautical and space vehicle systems. The Aerospace Materials, Processes, and Environmental Technology Conference (AMPET) provided a forum for manufacturing, environmental, materials, and processes engineers, scientists, and managers to describe, review, and critically assess advances in these key technology areas.

Griffin, D. E.↗
NASA NTRS2015

Printing Outside the Box: Additive Manufacturing Processes for Fabrication of Large Aerospace Structures

To achieve NASA's mission of space exploration, innovative manufacturing processes are being applied to the fabrication of propulsion elements. Liquid rocket engines (LREs) are comprised of a thrust chamber and nozzle extension as illustrated in figure 1 for the J2X upper stage engine. Development of the J2X engine, designed for the Ares I launch vehicle, is currently being incorporated on the Space Launch System. A nozzle extension is attached to the combustion chamber to obtain the expansion ratio needed to increase specific impulse. If the nozzle extension could be printed as one piece using free-form additive manufacturing (AM) processes, rather than the current method of forming welded parts, a considerable time savings could be realized. Not only would this provide a more homogenous microstructure than a welded structure, but could also greatly shorten the overall fabrication time. The main objective of this study is to fabricate test specimens using a pulsed arc source and solid wire as shown in figure 2. The mechanical properties of these specimens will be compared with those fabricated using the powder bed, selective laser melting technology at NASA Marshall Space Flight Center. As printed components become larger, maintaining a constant temperature during the build process becomes critical. This predictive capability will require modeling of the moving heat source as illustrated in figure 3. Predictive understanding of the heat profile will allow a constant temperature to be maintained as a function of height from substrate while printing complex shapes. In addition, to avoid slumping, this will also allow better control of the microstructural development and hence the properties. Figure 4 shows a preliminary comparison of the mechanical properties obtained.

Babai, Majid↗
DOE OSTI2022

Integrated CO 2 -facilitated Hydrometallurgical and Electrochemical Technology for Sustainable Mining and Recovery of Critical Elements from Wastes and Ashes

The availability of critical materials and other metals is very important for our national security and economic growth since they are widely used in defense and energy applications including batteries and wind turbines. Unfortunately, high grade ores have become scarce and their productions is dominated by limited countries. Thus, there is a strong need to obtain these materials from domestic sources. Municipal wastes are great candidates since they often contain high concentrations of metals. Since the metals in wastes and waste ashes are not in the form found in natural ores and contain a wide range of impurities, conventional extraction processes would not be effective. Thus, our project has developed an innovative MIDAS process based on the integrated CO2-facilitated hydrometallurgical and electrochemical technology that can effectively recover critical materials and metals from waste ashes while minimizing the environmental impacts. We have (i) characterized waste ashes to understand their physico-chemical properties, (ii) developed green solvent systems for hydrometallurgical extraction of critical elements and metals from waste ashes, (iii) explored electrochemical interfaces to refine the extracted metals.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Optimization of prefabricated component installation using a real-time evaluator (RTE) connection locating system

Prefabrication promises to industrialize the construction industry. By constructing elements within a manufacturing environment, producers can better control quality and maximize production efficiency. Since the major adoption of prefabrication, a wide variety of prefabricated components have been produced for varying applications such as new construction and exterior wall retrofits. While the production processes of these prefabricated components have seen much innovation, the installation process has remained relatively unchanged for decades. To innovate the installation process with modern technologies, a real-time evaluator (RTE) has been developed to reduce the installation cost of prefabricated components by reducing installation time, decreasing rework, and improving accuracy. The RTE uses developed software solutions with off-the-shelf hardware to assist erectors in completing an installation by measuring the real-time positions of connections and prefabricated components, providing installation guidance through a graphical user interface, and monitoring the accumulated installation errors. An overview of the RTE and proposed workflow is presented. A connection locating system that guides users in expediting the installation of connections is introduced. Laboratory experiments were conducted to determine the accuracy improvement and time savings of the RTE in installing connections for prefabricated components. RTE enabled a time saving of up to 37% compared to traditional connection installation methods using handheld measurement tools.

Hayes, Nolan↗