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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 OSTI2026

Estimation of radiation fields generated by injected beam losses at the EIC's RCS

This technical note provides a general estimate of radiation fields generated by injection fault events at the electron-ion collider´s (EIC) Rapid Cycling Synchrotron (RCS), calculated with the Monte Carlo particle transport and interaction code FLUKA. Calculations were performed for two major injection loss scenarios that involve iron targets and featured different electron beam energy and current values. The results presented here constitute a first order assessment of several radiological quantities associated with these electromagnetic showers and their potential effect on environmental safety and health (ESH) systems in the vicinity of injection areas.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Dark Energy Survey Year 6 Results: Synthetic-source Injection Across the Full Survey Using Balrog

Synthetic source injection (SSI), the insertion of sources into pixel-level on-sky images, is a powerful method for characterizing object detection and measurement in wide-field, astronomical imaging surveys. Within the Dark Energy Survey (DES), SSI plays a critical role in characterizing all necessary algorithms used in converting images to catalogs, and in deriving quantities needed for the cosmology analysis, such as object detection rates, galaxy redshift estimation, galaxy magnification, star-galaxy classification, and photometric performance. We present here a source injection catalog of 146 million injections spanning the entire 5000 deg 2 DES footprint, generated using the Balrog SSI pipeline. Through this SSI sample, we demonstrate that the DES Year 6 (Y6) image processing pipeline provides accurate estimates of the object properties, for both galaxies and stars, at the percent-level, and we highlight specific regimes where the accuracy is reduced. We then show the consistency between SSI and data catalogs, for all galaxy samples developed within the weak lensing and galaxy clustering analyses of DES Y6. The consistency between the two catalogs also extends to their correlations with survey observing properties (seeing, airmass, depth, extinction, etc.). Lastly, we highlight a number of applications of this catalog to the DES Y6 cosmology analysis, such as estimates of the redshift distribution and lens magnification. This dataset is the largest SSI catalog produced at this fidelity and will serve as a key testing ground for exploring the utility of SSI catalogs in upcoming surveys such as the Vera C. Rubin Observatory Legacy Survey of Space and Time.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Machine Learning-Based Process Control for Injection Molding of Recycled Polypropylene

The increased interest in artificial intelligence in manufacturing has driven the adoption of machine learning to optimize processes and improve efficiency. A key challenge in injection molding is the variability of recycled materials, which affects part quality and processing stability. This study presents a novel closed-loop process control approach for injection molding, leveraging machine learning to adaptively predict processing inputs and quality outcomes. The methodology was tested on five blends of recycled polypropylene (rPP), using artificial neural networks (ANNs), linear regression, and polynomial regression to model the relationships between material properties and process parameters. The dataset was split 80/20 into training and testing sets. The ANN model was implemented using TensorFlow and Keras, with six hidden layers of 32 neurons per layer, ReLU activation, and an Adam optimizer. Empirical tuning and early stopping were used to optimize performance and prevent overfitting. Predictions were evaluated based on mean absolute error (MAE), mean squared error (MSE), and percentage error. The results showed that yield stress, ultimate elongation, and part weight were accurately predicted within a 5% error for linear and polynomial regression models and within a 10% error for the ANN. However, modulus predictions were less reliable, with errors of ~11% for ANN and linear regression and ~40% for polynomial regression, reflecting the inherent variability of this property in rPP blends. Predictions of processing inputs had errors ranging from 3% to 25%, depending on the model and response variable. No single modeling approach was consistently superior across all responses, highlighting the complexity of the relationship between material properties, process parameters, and quality metrics. Overall, the work demonstrates that closed-loop process control, powered by machine learning, can effectively predict key quality parameters in injection molding of recycled materials. The proposed approach can improve process stability and material utilization, facilitating increased adoption of sustainable materials.

Krantz, Joshua↗
DOE OSTI2026

The Role of Three-dimensional Effects on Ion Injection and Acceleration in Perpendicular Shocks

Understanding the conditions that enable particle acceleration at nonrelativistic collisionless shocks is essential to unveil the origin of cosmic rays. We employ 2D and 3D hybrid simulations (with kinetic ions and fluid electrons) to explore particle acceleration and magnetic field amplification in nonrelativistic perpendicular shocks, focusing on the role of shock drift acceleration and its dependence on the shock Mach number. We perform an analysis of the ion injection process and demonstrate why efficient acceleration is only observed in 3D. In particular, we show that ion injection critically depends on the “porosity” of the magnetic turbulence in the downstream region near the shock, a property describing how easily the postshock region allows particles to traverse it and return upstream without being trapped. This effect can only be properly captured in 3D. Additionally, we explore the impact of numerical resolution on ion energization, highlighting how resolving small-scale turbulence—on scales below the thermal ion gyroradius—is essential for accurately modeling particle injection. Overall, our results emphasize the necessity of high-resolution 3D simulations to capture the fundamental microphysics driving particle acceleration at perpendicular shocks.

Orusa, Luca [Princeton Univ., NJ (United States); ↗
DOE OSTI2025

Fracture Network Quantification during CO2 Injection

This is the conference paper accompanying an oral presentation at the ARMA 2025 (59th US Rock Mechanics/Geomechanics Symposium) Conference held in Santa Fe, New Mexico, June 8-11, 2025. Accurate mapping and quantification of these networks are essential to ensure the integrity of CO2 storage reservoirs, understand and reduce potential leakage, and maintain long-term environmental safety. This study presents a novel machine learning-driven approach, integrated with geomechanical analysis, to quantify fracture networks and assess their spatial distribution during CO2 injection. This paper combines microseismic monitoring data with principles of hydraulic diffusivity and geomechanical analysis to characterize reservoir scale fracture network. The novelty of our approach lies in its capacity to assimilate time-dependent pressure data and microseismicity into a cohesive framework, which not only identifies microseismic triggering fronts but also tracks fracture distribution during active injection. Besides, leveraging image log data and analysis our approach also provides another angle of the insights to solidate the fracture networks understanding and geomechanical impacts. Key results from our study include the detection of over 100 distinct fracture clusters across the injection site, with fracture orientations strongly correlated with the prevailing in-situ stress field.

CO2 storage and sequestration↗
DOE OSTI2025

Injection simulations of space charge dominated proton beams in IOTA

A 2.5 MeV proton injector is being constructed for the IOTA ring at Fermilab to study the interaction of nonlinear integrable optics (NIO) with high space charge beams. Space charge in the transport line from the RFQ to the injection location has a significant current dependent effect on the phase space. Simulation studies to support efficient injection of intense bunches into IOTA are presented, included schemes to inject directly into NIO lattices.

Wieland, J. [Fermilab; Michigan State U.] (ORCID:0↗
DOE OSTI2025

Development of fiber orientation in injection molding: Comparison of glass fiber, carbon fiber and their hybrid composites

Fiber orientation distribution (FOD) in injection-molded panels with respect to distance from the gate was analyzed using X-ray computed tomography (X-CT) for glass fiber (GF), carbon fiber (CF), and hybrid CF/GF (CGF) reinforced nylon 66. To understand the reason behind the FOD with different fiber types, computational fluid dynamics (CFD) and rheology were performed. Samples were extracted at three locations: near the gate, center, and opposite end. Thickness of the layers of typical skin-shell-core type FOD varied with fiber type and location. GF achieved flow direction alignment (in shell) earlier than viscous CF and CGF near the gate, whereas CF showed the highest flow-direction alignment at the center due to shear induced orientation. At the opposite end, GF experienced more backflow than others indicating faster mold filling owing to its lower viscosity. Hybrid CGF exhibited GF-dominated center and CF-dominated end region. The numerical model used to obtain FOD and rheological predictions for the CF and GF composites served to corroborate the trends observed in the experimental trials. The FOD responses across fiber types and location were reflected in their longitudinal and transverse properties. Only GF showed higher longitudinal modulus over transverse modulus near the gate attributed to rapid alignment, whereas CF and CGF exhibited opposite trend. However, fountain flow enhanced the longitudinal modulus over transverse modulus with the distance for all, particularly for CF. This study offers insights into mold filling behavior of different fibers which are critical in optimizing injection molding conditions for tailored final properties.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A comprehensive numerical investigation on spray models for Direct-Injection Spark-Ignition engines

Gasoline direct-injection spark-ignition (DISI) engines generate a large portion of their unburned hydrocarbon (UHC) and soot emissions during the cold-start phase. A predictive computational fluid dynamics (CFD) modeling framework can be used to understand the physical processes that characterize fuel spray evolution and fuel-film formation at cold start conditions, which can help to reduce engine-out particulate emissions. This study systematically evaluated spray submodels and developed a set of simulation best practices for physical-numerical submodels with the goal of enabling accurate simulations of liquid spray behavior in a DISI engine. Three comprehensive experimental datasets containing free-spray projected liquid volume (PLV), liquid volume fraction (LVF), and near-field X-ray radiography data were used to validate the simulation results and evaluate the spray submodels. Systematic analysis delved into injected parcel distribution, droplet collision, spray breakup, and evaporation via a detailed assessment of the relevant spray submodels. Moreover, the effects of turbulence models and the initial turbulent flow properties on the liquid spray evolution were examined. Based on extensive calibration efforts, a set of simulation best practices for the free spray was developed and validated against the PLV/LVF data. Simulation results indicated that the uniform distribution for parcel initialization, coupled with appropriate droplet collision submodels, provides an improved spray morphology compared to the cluster distribution. The findings also underscored the importance of calibrating the Kelvin-Helmholtz Rayleigh-Taylor (KH-RT) breakup model constants and droplet heat transfer coefficient scaling factor to achieve favorable agreement regarding measured liquid penetration and spray widths. In conclusion, this study marks a substantial stride towards accurately predicting fuel film evolution and soot formation within DISI engine performance.

ECN Spray G↗
DOE OSTI2024

Multicycle large-eddy simulations of a direct-injection hydrogen-fueled optical engine

Hydrogen (H 2 ) is a carbon-free chemical energy carrier and one promising solution for achieving effective decarbonization of the transportation sector, particularly for internal combustion engines (ICEs). With a focus on ICEs, and compared to port-fuel injection, direct injection (DI) of gaseous H 2 during the compression stroke offers potential advantages, which include backfire avoidance and reduction of preignition occurrence. In these last two decades, much research, experimental and numerical, has been devoted to understanding H 2 's mixing and combustion processes in ICEs. Computational fluid dynamics modeling efforts commonly rely on unsteady Reynolds-averaged Navier Stokes (URANS) turbulence frameworks, mostly due to their computational affordability. However, many authors have pointed out the opportunity to perform large-eddy simulations (LESs) to investigate the cyclic variability of H 2 engines and assess potential advantages of using LES in place of URANS, especially for lean operation. This study addresses this knowledge gap and presents a computational fluid dynamics (CFD) study of the H 2 DI process in an optical engine operating at relatively low tumble conditions, using multicycle LESs. In conclusion, the manuscript presents a thorough validation of the results against experimental data available from the literature as well as direct comparison with URANS, demonstrating the feasibility of multicycle LESs for CFD modeling of DI H 2 -fueled ICEs.

Direct injection↗
DOE OSTI2024

Numerical modeling of impurity powder injection in W7-X

In this work, we present numerical simulation results of powder injection in W7-X using the EMC3-EIRENE and DIS codes. First, we model powder injection experiments performed in W7-X with the Probe Mounted Powder Injector. The simulation results qualitatively agree with visible imaging measurements. Secondly, we perform predictive simulations to guide the installation of an Impurity Powder Dropper in W7-X, allowing to choose in between several available non-vertical ports to maximize the amount of powder penetrating into the plasma, as well as the verticality of the port, to minimize sticking of the powders in the in-vessel stainless steel guiding tube. Port AEM41 is selected as the best candidate for IPD installation. The robustness of the simulation results has been verified for different plasma densities, powder materials and sizes, powder friction coefficient and changes in the plasma flow.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Enhanced passivation and stability of negative charge injected SiN x with higher nitrogen content on the boron diffused surface of n-type Si solar cells

This paper explores the potential of the negatively charged SiN x using plasma charge injection technology to passivate the front textured boron-diffused emitter of n-type Si solar cells. The high-x value single SiN x layer with x ≥ 1.30 (x = N/Si) previously developed for the planarized rear-side passivation of p-type silicon solar cells, with an excellent passivation and charge stability, was found to be unacceptable for the passivation on the front textured boron emitter of n-type cells due to a severe bulk lifetime degradation issue. Therefore, in this study, we investigated a new concept of depositing a dual-x SiN x with a low-x SiN x layer (x~1.01) on top of a high-x SiN x layer (x~1.30) for passivation of the front textured rough surface of boron diffused emitter in n-type cells. Here, the optimized dual-x SiN x stack reveals the promise of charge retention for more than 25 years in field operation as well as excellent passivation of boron-doped emitter without bulk lifetime degradation. N-type cells with the optimized dual-x SiN x after charge injection show comparable cell performance to Al 2 O 3 passivated reference cells. The results of cell-level light stability tests using one-cell minimodules exhibit cell performance decay characteristics similar to the traditional Al 2 O 3 /SiN x passivated reference module.

14 SOLAR ENERGY↗
DOE OSTI2024

Simulation of triggering and evolution of ELM by pellet injection in EAST under BOUT++ framework

A BOUT ++ three-field magnetohydrodynamic model is employed to study the triggering and evolution of edge localized mode (ELM) by Li pellets injected along the outer mid-plane in the EAST configuration. The linear simulation shows that compared with a large deposition on the pedestal top (scenario I), a smaller deposition within the steep-gradient pedestal region (scenario II) can stimulate much larger linear growth rates of all-n peeling-ballooning modes (PBMs). The nonlinear simulation shows that there exists a pellet size threshold for ELM triggering for two deposition locations; the threshold for scenario I predicted in the present study matches the EAST observation well. Comparison of the two scenarios reveals that a smaller deposition is sufficient to trigger an ELM in a much shorter time in scenario II, whose ELM size is comparable to that in scenario I. This conclusion confirms previous DIII-D and ASDEX-Upgrade observations, suggesting that the steep-gradient pedestal region is a favorable deposition location for ELM triggering with minimum pellet size. Simulation analyses also find that the positive radial gradient of the hump-like pressure profile in the outer mid-plane induced by the pellet deposition plays a different role in the two scenarios. In scenario I, the force resulting from the gradient hinders the outflow of core plasmas and in return, the perturbation is suppressed from spreading inwards after ELM crashes. In scenario II, with a sizable deposition, the gradient results in another competitive perturbation growth region during the linear phase, thus dispersing the free energy and reducing the efficiency of destabilizing PBMs by pellet injection. The suppressing effect of saturated zonal flow on other modes, the short ELM fast crash phase, and the restricting transport effect of the positive radial pressure gradient work together to constrain the pedestal energy loss, especially when the pellet deposition amount is high.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Extended-MHD simulations of disruption mitigation via massive gas injection in SPARC

Recent developments to the M3D-C1 code enable higher fidelity modeling of disruptions, and can be applied in the design verification of reactor-scale tokamaks. Among these new capabilities is a method to mesh conducting vessel structures such as coils and passive plates, packing of the toroidal mesh around gas injectors, as well as anisotropic resistivity inside the vessel structures. We present extended-magnetohydrodynamic (MHD) simulations of disruption mitigation via massive gas injection (MGI) in SPARC. The goal of this study is to inform the disruption mitigation layout of SPARC and aid in the design of an effective gas injector configuration. Fully three-dimensional simulations with M3D-C1 are carried out for various injector configurations with the primary goal of determining the effect of different MGI parameters on heat loads and vessel forces. The simulations include a model for impurity ionization, recombination, advection and radiation, as well as spatially resolved conducting structures around the plasma. A localized mixture of deuterium and neon with a small toroidal and poloidal width is injected in up to six locations. We demonstrate that M3D-C1 can model a rapid shutdown via MGI using narrow and more realistic gas plumes than in previous simulations. As a result of the q = 1 surface in the SPARC baseline case a sawtooth is observed early in the simulations. Despite the sawtooth and the onset of edge MHD instabilities, the impurity distribution remains localized around the injector locations, but enables a radiative shutdown of the plasma. We find that using the maximum of six gas injectors results in a lower peaking factor and leads to a more even distribution of radiation toroidally than using two injectors.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Multi-device analysis of energy loss duration and pellet penetration with implications for shattered pellet injection in ITER

A robust disruption mitigation system (DMS) requires accurate characterization of key disruption timescales, one of the most notable being the thermal quench (TQ). Recent modeling of shattered pellet injection (SPI) into ITER plasmas, using JOREK and INDEX, suggests long TQ durations (6–10 ms) and slow cold front propagation due to the large plasma size. If validated, these predictions would have an impact on the desired pellet parameters and mitigation strategies for the ITER DMS. To resolve these questions, a database of SPI experiments from several small-to-large sized devices (J-TEXT, KSTAR, AUG, DIII-D, and JET) has been compiled under the auspices of the International Tokamak Physics Activity MHD, disruptions, and control topical group. Analysis of the energy loss duration (proxy for the TQ duration) with machine size is presented for both mixed neon/deuterium (Ne/D) SPI and pure deuterium (D) SPI. Several metrics for the energy loss onset (e.g. soft x-ray signal drop, I p dip, and radiation flash) were considered as the conventional metric, electron cyclotron emission, is often cut-off during SPI. Several scalings with different onset metrics showed an increase in energy loss duration with machine size. The energy loss duration was additionally shown to be a function of the ratio between the number of SPI neon atoms injected and the stored energy. Analysis of the pellet shard position relative to the cold front found that in larger devices, pellets are typically found inboard of the q = 2 surface at the energy loss onset. Lastly, the delay between the pellet shards hitting the q = 2 surface and the energy loss onset was additionally found to increase with machine size. This suggests that the pellet shards in large devices will penetrate faster and further than the cooling front.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Validation of 3D MHD simulations of Ne/D 2 mixed shattered pellet injection in JET

Nonlinear 3D magnetohydrodynamic (MHD) modeling of shattered pellet injection (SPI) in JET tokamak plasmas is performed with the JOREK code. The study focuses on the validation of simulation result with respect to experimental observations, addressing in particular figures of merit for the efficiency of the SPI, as a technique to mitigate thermal loads by injecting radiative impurities like neon during the thermal quench (TQ) phase of disruptions. A set of JET pulses with neon/deuterium atomic mixture ratio in the shattered pellet varying from 10% to 100% provides the experimental data to be compared with. Simulations using different models for the ablation of solid fragments and the radiation of neon impurities are considered. Synthetic diagnostics are employed for a direct quantitative comparison with key JET diagnostic systems providing in particular radiation, electron temperature and density, and magnetic measurements. 3D radiation structures from MHD simulations are analyzed to estimate the toroidal asymmetry of radiation, which is difficult to measure in JET due to the presence of only two toroidally displaced multi-channel bolometry systems. JOREK simulations show that, before the TQ, the bulk of the radiation is concentrated in a toroidal region enclosing the radiating fragments that is missed by both multi-channel bolometers, suggesting a possible underestimation of the total radiation by such diagnostic systems in the pre-TQ phase. On the other hand, JOREK predicts that during the TQ the radiation becomes more toroidally symmetric, with positive implications for the heat load to plasma facing components.

JOREK↗
DOE OSTI2025

Design of the EIC hadron storage ring stripline injection kicker with a novel impedance tuning capability

The Electron-Ion Collider (EIC), to be built at Brookhaven National Laboratory, will be a high luminosity (~10 34 cm –2 s –1 ) nuclear science facility. To facilitate EIC experiments, the existing yellow ring of the Relativistic Heavy Ion Collider (RHIC) will be reconfigured to serve as the Hadron Storage Ring (HSR). Designing a stripline injection kicker for the HSR beams, with high magnetic rigidity (~ 82 Tm), poses some technical challenges due to the required large pulsed voltage with long flattop duration, very fast rise time, expected shorter bunch spacing, and potential heating due to higher peak current. In addition, minimizing impedance mismatch in the transition region between the feedthrough and the stripline electrode is challenging. This paper focuses on the mechanical design and optimization of the HSR injection kicker, highlighting a novel impedance tuning capability achieved through an innovative kicker aperture adjustment mechanism. We comprehensively cover the design, including impedance optimization (both beam coupling and characteristic), beam-induced heating, and thermal analysis, and investigation of the maximum electric field due to high voltage signal excitation to ensure safe and reliable operation.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Data and figures for "Integrated modeling of boron powder injection for real-time plasma-facing component conditioning"

This dataset contains raw and processed data, as well as supplementary figures used in the paper titled "Integrated modeling of boron powder injection for real-time plasma-facing component conditioning." The data includes simulation results for boron transport and deposition in DIII-D tokamak scenarios, and processed plots. It provides insights into the effects of boron powder injection on plasma-facing component conditioning and surface composition.

ablative particle injection↗
DOE OSTI2026

Cost-Benefit Assessment of Additive Manufacturing for Injection Molds

This report presents an additive-manufacturing (AM) technology, where AM Cyclic Olefin Resin (COR) molds would be used for injection molding. The National Laboratory of the Rockies (NLR) team has focused on the costs and economics of this developing technology. This report presents a cost-benefit analysis of using the polySpectra AM COR molds made of COR, at the start of the project (Present') and the potential lifetime, cost-effectiveness, and performance by the end of the project period (Period 3'). The analysis of the AM COR molds is compared to traditional Computer Numerical Control (CNC) machined aluminum molds across the time periods. A cost-benefit model framework has been developed to evaluate AM COR molds. This model accounts for mold delivery to customers, current and future levels of technology readiness, the type of material injected, and various business cases. AM COR molds offer a major advantage in lead time, reducing production setup from weeks or months (with CNC machining) to as little as two to five days. This enables faster prototyping, quicker design cycles, and accelerated time-to-market, critical in industries like electronics, aerospace, medical devices, and automotive. Even modest improvements in the durability of polySpectra AM COR molds show the potential for these molds to complement traditional tooling. With further development, AM COR mold technology could provide significant time and cost savings while supporting increased domestic manufacturing capacity.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗