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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

Reassessing early-age strength development of high-volume fly ash concretes for precast buildings

Increasing beneficial use of fresh or landfilled fly ash as a replacement for Portland cement can be more challenging for the construction of precast buildings or similar applications requiring rapid strength development. Therefore, the framework presented in this paper aims to reassess high-volume fly ash concretes but in the context of facilitating more sustainable precast buildings. More specifically, the framework was used to characterize strength development of concrete mixes with a target minimum 24-hour compressive strength of 24.1 MPa (3500 psi), selected as an example strength development metric to demonstrate the framework, and comprised of 40% Class C, Class F, and landfilled (harvested) fly ash – as a high-volume replacement of Type III or Type IL cement. High-early strength was driven by optimized dosages of commercial grade gypsum and accelerating admixtures, in addition to optimal aggregate packing and mix proportioning strategies. Early-age mechanical properties including compressive strength, modulus of rupture, and modulus of elasticity were reevaluated within 24 hours of batching with respect to common precast production demands. Simple data analyses were then used to highlight cases where currently accepted design provisions for the aforementioned properties are either overly-conservative or unconservative with respect to test data. Furthermore, the framework and demonstration of example mixes presented herein aim to promote confidence for using larger fractions of fresh or landfilled fly ashes for precast buildings to further enhance environmental benefits without sacrificing pertinent early-age structural performance.

42 ENGINEERING↗
DOE OSTI2026

Accelerating Laboratory-Based, All-Solid-State Battery Research and Development: Industrially Relevant Small-Batch Dry-Processing, Small and Low-Cost Test Fixtures, and Short-Tolerant Separators

This work presents improvements to mixing (for dry-processed electrodes), separator robustness, and cell testing jigs for all-solid-state batteries (ASSBs). These developments combine synergistically to enable rapid research and development of ASSB catholytes. A mechanical "kneader" is designed and built which emulates the mixing and fibrillation of poly-tetrafluoroethylene binder that occurs in industrially relevant twin-screw extruders. A modest improvement in the mixing and dispersion catholyte materials is observed using micro-resolution X-ray computed tomography (X-ray CT). Catholytes are paired with an In-metal anode and separated by a novel, dual-layer, polyaramid-fiber-supported, sulfide-solid electrolyte (Li6 PS5 Cl) separator. This separator achieves high short tolerance which enabled a 95% success rate across 20 attempted cells and to date over 100 successful cells have been built. ASSBs were tested in a 2032 coin-cell format. Simultaneous cycling of a large number of cells is further enabled by a compact and low cost (~ 38 USD per jig) pressure application jig of which 100 have been constructed to date. The utility of these advances is demonstrated through a brief study on the effect cathode-side conductive carbon and current collector type has on capacity and rate performance.

25 ENERGY STORAGE↗
DOE OSTI2026

Rapid Electrochemical Carburization of Mild Steel

Next-generation iron production generates iron with 0 wt.% C, in contrast to contemporary blast furnace production of iron with 1 - 5 wt.% C. This makes new iron feedstocks difficult to use as a drop-in replacement in current steelmaking. We report results of an emissions-negative approach of carburizing iron or mild steel using molten salt electrochemistry and CO2. Electrochemical carburization of mild steel via molten carbonate salt electrolyte and CO2 bubbling shows rapid carbide development tunable by applied electric potential. Mild steel rods, serving as the cathode, show pearlite development at the surface after exposure to applied voltage in a LiKCO3 molten carbonate salt bath at 715 degrees C. The thickness of the pearlitic layer could be varied by changing the applied potential, with a strong difference in microstructure observed between an applied potential of -1.8 V and -2.4 V. This rapid carburization has multiple applications for enhancing steel production by upgrading the carbon content of low-carbon feedstocks.

36 MATERIALS SCIENCE↗
DOE OSTI2025

LandScan Mosaic

The LandScan program at Oak Ridge National Laboratory (ORNL), in collaboration with the National Geospatial-Intelligence Agency (NGA), continues to deliver the most accurate and up to date global, high resolution gridded population data. Additionally, the latest advancements in the LandScan HD methodology led to reduced latency in development of rapid updates for geopolitical events. With momentum towards reporting more up to date population estimates, feedback from the user community expressed interest in reporting population estimates in ranges - whether to express a level of uncertainty or confirm to leadership and stakeholders the modeled data are estimates. Building upon the need to understand uncertainty or confidence in the modeled data and report ranges at the global scale, LandScan Mosaic was developed. LandScan Mosaic represents the next generation of high-resolution population modeling, building upon the established success of previous LandScan HD iterations. While LandScan HD employed a deterministic big data fusion approach, LandScan Mosaic enhances this methodology by integrating advanced machine learning techniques to impute missing, yet crucial, population model parameters. This advancement allows for probabilistic modeling of building occupancy and population distribution, incorporating uncertainty quantification through Monte Carlo sampling methods. By combining big data fusion with machine learning-driven imputation and stochastic modeling, LandScan Mosaic provides a more comprehensive and robust representation of population dynamics. LandScan Mosaic will be following the in the footsteps of its longstanding counterpart LandScan Global and releasing a global gridded population raster, at the 3-arcsecond resolution. This technical report documents the current stage of development of LandScan Mosaic, detailing the methodologies and data sources behind the modeling. Stakeholders are encouraged to use this document as an authoritative reference for insight into Mosaic’s data development processes. However, readers should note that LandScan Mosaic remains in a late-stage research and development phase, and methodologies and data presented here are subject to refinements ahead of the anticipated global release in Summer 2025. Feedback and inquiries from users and stakeholders are welcomed as we continue to refine and enhance this important population resource.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

An updated technique to obtain explosive kinetics data on microsecond timescales

There are few techniques available for chemists to obtain time-to-explosion data with known temperature inputs at the early stages of the design and synthesis of new explosives. In the 1960s, a technique was developed to rapidly heat milligram-quantities of confined explosives to ~1000 K on microsecond timescales. Wenograd loaded explosives inside stainless steel hypodermic needles, connected them to a fireset and rapidly discharged a capacitor through the steel. He obtained the temperature by measuring the needle resistance in a Wheatstone bridge arrangement and the time to explosion from a needle rupture. However, owing to the narrow-gauge needles used in the original research, the experiment was only possible with melt-castable explosives; it was never replicated, and modern diagnostics are now available with advances beyond the 1960s. Here, we report the development of the High Explosives Initiation Time (HEIT) test, which utilizes a 250 J pulsed power system to heat the needles. This work extends the Wenograd approach by using optical diagnostics, computational modeling, and advanced techniques to measure needle resistance and needle rupture. Preliminary rate information for pentaerythritol tetranitrate (PETN) will be presented.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2025

Microstructure & Mechanical Properties of Scaled Thermally Aged LPBF 316H SS Builds

As part of the US Department of Energy’s Advanced Materials and Manufacturing Technologies program’s mission to accelerate qualification of advanced manufacturing pathways for nuclear applications, laser powder bed fusion (LPBF) 316H stainless steel (SS) has been selected as a model system to develop a rapid code case framework. This effort directly addresses the grand challenges of (1)expanding the limited portfolio of materials currently codified for elevated-temperature nuclear structural service under Section III, Division 5of the American Society of Mechanical Engineers’ Boiler and Pressure Vessel Code; and (2) significantly reducing qualification timelines that traditionally exceed a decade. The strategic importance of LPBF 316H lies in its immediate industrial relevance, existing data foundation from wrought 316H, and alignment with ongoing code case development for LPBF 316L.Prior work revealed accelerated precipitation of deleterious secondary phases and reduced creep ductility in as-printed LPBF 316H. Building on that prior research, FY2025activities focused on establishing an understanding of the key failure mechanisms of crept 316H specimens to aid in code case development and on evaluating stress relief (SR) parameters on the high-temperature performance and thermal aging-induced degradation of tensile and fracture behavior in LPBF316H.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Microstructure and Mechanical Properties of Scaled Thermally Aged LPBF 316H SS Builds

As part of the US Department of Energy’s Advanced Materials and Manufacturing Technologies program’s mission to accelerate qualification of advanced manufacturing pathways for nuclear applications, laser powder bed fusion (LPBF) 316H stainless steel (SS) has been selected as a model system to develop a rapid code case framework. This effort directly addresses the grand challenges of (1) expanding the limited portfolio of materials currently codified for elevated-temperature nuclear structural service under Section III, Division 5 of the American Society of Mechanical Engineers’ Boiler and Pressure Vessel Code; and (2) significantly reducing qualification timelines that traditionally exceed a decade. The strategic importance of LPBF 316H lies in its immediate industrial relevance, existing data foundation from wrought 316H, and alignment with ongoing code case development for LPBF 316L. Prior work revealed accelerated precipitation of deleterious secondary phases and reduced creep ductility in as-printed LPBF 316H. Building on that prior research, FY 2025 activities focused on establishing an understanding of the key failure mechanisms of crept 316H specimens to aid in code case development and on evaluating stress relief (SR) parameters on the high-temperature performance and thermal aging induced degradation of tensile and fracture behavior in LPBF 316H.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Cluster Dynamics Modeling Needs for the Advanced Materials and Manufacturing Technologies Program

This milestone report aims to identify and assess the cluster dynamics (CD) modeling requirements within the Department of Energy's Office of Nuclear Energy (DOE-NE) Advanced Materials and Manufacturing Technologies (AMMT) program and to communicate these needs to the DOE-NE Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. The goal is to ensure NEAMS is well-informed about the CD modeling requirements to support AMMT's mission of accelerating the development, qualification, demonstration, and deployment of advanced structural materials and manufacturing for nuclear energy applications. CD modeling is an essential tool for predicting the degradation of structural materials under irradiation, which is a key component of AMMT's accelerated qualification process. The AMMT program focuses on both additively manufactured and wrought structural alloys, such as laser powder-bed fusion 316H austenitic stainless steel, alloy 709, Haynes 244, and alloy 617. These materials require a generalized CD modeling framework to facilitate rapid model development and computational simulation. A flexible, generalized CD software, similar to the Multiphysics Object-Oriented Simulation Environment (MOOSE) finite element framework, would enable modeling of various cluster types, including defect clusters, defect-solute clusters, and multicomponent clusters, incorporating thermodynamics and kinetics parameters. Radiation effects, microstructural feature evolution, and multi-dimensional modeling are critical considerations for the CD model. The usability of the CD code should allow for easy modification and coupling with MOOSE-based simulations. Additionally, the software should adhere to Nuclear Quality Assurance-1 standards, include a testing suite for verification and validation, and be version-controlled within a national laboratory-managed Git repository. Benchmark problems are needed to assess code predictions and performance.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Online collection of LC effluent as droplets for automatic injection into ICP-MS

A sample introduction technique was developed to allow for online, dropwise injection of effluent into a mass spectrometer (MS). This allowed for the coupling of chromatography systems that were not driven by pumps without altering the set-up or separation performance. This capability combined the benefits of coupling separation and measurement while also enabling accurate chromatographic evaluation that would generally be performed offline. The incorporation of a flowing rinse into the system made dropwise resolution possible for any liquid capable of forming drops under ambient conditions. The technique was demonstrated utilizing gas pressurized extraction chromatography (GPEC) and inductively coupled plasma-time-of-flight mass spectrometry (ICP-TOFMS) to illustrate the qualitative applications for rapid separation development and procedure evaluation. This method's quantitative applications were evaluated using single and double isotope dilution mass spectrometry (IDMS) with an external mass bias correction to measure analytes across entire elutions including volumes as small as single drops. In conclusion, the total neodymium values afforded by both single and double IDMS were within the uncertainty of the calculated value for evaluation of full elution peaks and for most of the single drops analyzed that reached above 10k cps Nd-144.

GPEC↗
DOE OSTI2024

Direct numerical simulation of a high-pressure hydrogen micromix combustor: Flame structure and stabilisation mechanism

A high-pressure hydrogen micromix combustor has been investigated using direct numerical simulation with detailed chemistry to examine the flame structure and stabilisation mechanism. The configuration of the combustor was based on the design by Schefer et al., using numerical periodicity to mimic a large square array. A precursor simulation of an opposed jet-in-crossflow was first conducted to generate appropriate partially-premixed inflow boundary conditions for the subsequent reacting simulation. The resulting flame can be described as an predominantly-lean inhomogeneously-premixed lifted jet flame. Five main zones were identified: a jet mixing region, a core flame, a peripheral flame, a recirculation zone, and combustion products. The core flame, situated over the jet mixing region, was found to burn as a thin reaction front, responsible for over 85% of the total fuel consumption. The peripheral flame shrouded the core flame, had low mean flow with high turbulence, and burned at very lean conditions (in the distributed burning regime). It was shown that turbulent premixed flame propagation was an order-of-magnitude too slow to stabilise the flame at these conditions. Stabilisation was identified to be due to ignition events resulting from turbulent mixing of fuel from the jet into mean recirculation of very lean hot products. Ignition events were found to correlate with shear-driven Kelvin-Helmholtz vortices, and increased in likelihood with streamwise distance. At the flame base, isolated events were observed, which developed into rapidly burning flame kernels that were blown downstream. Further downstream, near-simultaneous spatially-distributed ignition events were observed, which appeared more like ignition sheets. The paper concludes with a broader discussion that considers generalising from the conditions considered here.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Fabrication of porous transport electrodes: Development of quantitative approach for quality control

This work focuses on porous transport electrodes (PTEs), which integrate the anodic catalyst with the adjacent Ti porous transport layer (PTL). Challenges in catalyst deposition on PTLs, particularly at low loadings, motivated this study to evaluate various fabrication methods and characterization approaches. This work investigated Pt-treated PTLs coated with Ir-based catalysts using several common methods, including airbrush coating, rod coating, ultrasonic spray coating, electrodeposition, and sputter deposition, with catalyst loadings ranging from 2.9 to 0.1 mg/cm 2 , providing the opportunity for comparisons across a large set of samples produced by different methods. Two widely accessible characterization techniques: X-ray computed tomography (XCT) and scanning electron microscopy energy dispersive X-ray spectroscopy (SEM-EDS) were explored. Initial evaluation of selected samples with XCT provided qualitative insights into catalyst distribution, however comprehensive quantitative analysis was limited. SEM-EDS enabled detailed information on the catalyst distribution both qualitatively and quantitatively using two metrics. Atomic and surface area % ratios of Pt:Ir and Ti:Ir revealed trends in catalyst loading and losses into the PTL pores, as well as evaluating the homogeneity of catalyst coatings. The analysis demonstrated that ultrasonic spray coating, electrodeposition, and sputter coating produced the most homogeneous coatings, with minimal catalyst losses observed for electrodeposition and sputter coating. By adapting common techniques with novel, standardized methodologies, this work establishes a universally applicable framework for cross-study comparison of PTEs. The SEM-EDS approach provides a practical, accessible tool for PTE characterization and contributes a reference dataset supporting both research development and rapid quality control.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

A Deep Learning Based Framework to Identify Undocumented Orphaned Oil and Gas Wells from Historical Maps: A Case Study for California and Oklahoma

Undocumented Orphaned Wells (UOWs) are wells without an operator that have limited or no documentation with regulatory authorities. An estimated 310,000 to 800,000 UOWs exist in the United States (US), whose locations are largely unknown. These wells can potentially leak methane and other volatile organic compounds to the atmosphere, and contaminate groundwater. In this study, we developed a novel framework utilizing a state-of-the-art computer vision neural network model to identify the precise locations of potential UOWs. The U-Net model is trained to detect oil and gas well symbols in georeferenced historical topographic maps, and potential UOWs are identified as symbols that are further than 100 m from any documented well. A custom tool was developed to rapidly validate the potential UOW locations. We applied this framework to four counties in California and Oklahoma, leading to the discovery of 1301 potential UOWs across >40,000 km 2 . We confirmed the presence of 29 UOWs from satellite images and 15 UOWs from magnetic surveys in the field with a spatial accuracy on the order of 10 m. This framework can be scaled to identify potential UOWs across the US since the historical maps are available for the entire nation.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

The Influence of Land‐Surface Conditions on the 2020–2021 Western US Drought

Abstract In summer 2021, 90% of the western United States (WUS) experienced drought, with over half of the region facing extreme or exceptional conditions, leading to water scarcity, crop loss, ecological degradation, and significant socio‐economic consequences. Beyond the established influence of oceanic forcing and internal atmospheric variability, this study highlights the importance of land‐surface conditions in the development of the 2020–2021 WUS drought, using observational data analysis and novel numerical simulations. Our results demonstrate that the soil moisture state preceding a meteorological drought, due to its intrinsic memory, is a critical factor in the development of soil droughts. Specifically, wet soil conditions can delay the transition from meteorological to soil droughts by several months or even nullify the effects of La Niña‐driven meteorological droughts, while drier conditions can exacerbate these impacts, leading to more severe soil droughts. For the same reason, soil droughts can persist well beyond the end of meteorological droughts. Our numerical experiments suggest a relatively weak soil moisture‐precipitation coupling during this drought period, corroborating the primary contributions of the ocean and atmosphere to this meteorological drought. Additionally, drought‐induced vegetation losses can mitigate soil droughts by reducing evapotranspiration and slowing the depletion of soil moisture. This study highlights the importance of soil moisture and vegetation conditions in seasonal‐to‐interannual drought predictions. Findings from this study have implications for regions like the WUS, which are experiencing anthropogenically‐driven soil aridification and vegetation greening, suggesting that future soil droughts in these areas may develop more rapidly, become more severe, and persist longer.

Jiang, Yelin [Lamont‐Doherty Earth Observatory Col↗
DOE OSTI2024

Electrothermal mineralization of per- and polyfluoroalkyl substances for soil remediation

Abstract Per- and polyfluoroalkyl substances (PFAS) are persistent and bioaccumulative pollutants that can easily accumulate in soil, posing a threat to environment and human health. Current PFAS degradation processes often suffer from low efficiency, high energy and water consumption, or lack of generality. Here, we develop a rapid electrothermal mineralization (REM) process to remediate PFAS-contaminated soil. With environmentally compatible biochar as the conductive additive, the soil temperature increases to >1000 °C within seconds by current pulse input, converting PFAS to calcium fluoride with inherent calcium compounds in soil. This process is applicable for remediating various PFAS contaminants in soil, with high removal efficiencies ( >99%) and mineralization ratios ( >90%). While retaining soil particle size, composition, water infiltration rate, and cation exchange capacity, REM facilitates an increase of exchangeable nutrient supply and arthropod survival in soil, rendering it superior to the time-consuming calcination approach that severely degrades soil properties. REM is scaled up to remediate soil at two kilograms per batch and promising for large-scale, on-site soil remediation. Life-cycle assessment and techno-economic analysis demonstrate REM as an environmentally friendly and economic process, with a significant reduction of energy consumption, greenhouse gas emission, water consumption, and operation cost, when compared to existing soil remediation practices.

Science & Technology - Other Topics↗
DOE OSTI2024

Robust wind farm layout optimization

Wake interactions in wind farms cause losses in annual energy production (AEP) on the order of 10%. Wind farm designers optimize the layout of the farm to mitigate wake losses, especially in the dominant site-specific wind directions. As wind turbines and wind farms grow in scale, optimization becomes more complex. Offshore wind farms regularly comprise more than 100 wind turbines and are characterized by complex boundaries due to shipping lanes, neighboring wind farms, and other constraints. Layout optimization methods are broadly split between gradient-based and gradient-free approaches. Gradient-based approaches can converge quickly and perform well for smaller, academic problems but are often sensitive to initial conditions and tuning parameters and require expert knowledge to use. On the other hand, gradient-free approaches can be more robust to problem complexities. We present a robust layout optimization approach based on a random search algorithm. The algorithm is intended for those who are not optimization experts and has few tuning parameters that need specification to achieve satisfactory results. Unlike off-the-shelf methods, which use generally available, non-domain-specific optimization routines that accept as inputs an optimization function and constraint definitions, this approach takes advantage of the relative computational costs of the different evaluations by evaluating cheaper computations first (boundary and minimum distance constraints) and running expensive AEP evaluations only if all other checks pass. Moreover, an outer genetic algorithm allows multiple solutions to evolve in parallel, enabling rapid solution development on high-performance computers. We discuss the relative ease of selecting necessary tuning parameters and demonstrate the efficacy of the genetic random search on a complex layout problem consisting of placing 70 turbines in a nonconvex and unconnected boundary region.

17 WIND ENERGY↗
DOE OSTI2024

Advanced Distributed Optical Fiber Sensor Systems for Pipeline Integrity Monitoring

Distributed fiber optic sensors allow the measurement of structural parameters such as static/dynamic strain, temperature, pressure, and vibrations at thousands of locations along a single fiber cable. Deep neural network (DNN) algorithms were developed for rapid data processing speed and vibration event classification.

Lalam, Nageswara↗
DOE OSTI2025

Chelation ion chromatography as an automated, and cost-effective analytical technique for REE determination: method development and applications

Rare earth elements (REEs), as critical minerals, have important uses in modern energy and technologies, yet are vulnerable to potential supply chain disruptions. To establish domestic REE supply chain, efficient REE detection methods for resource characterization and mineral processing will be needed to accelerate innovations for domestic REE recovery. This study developed a rapid, novel, and cost-effective for REE detection method using ion chromatography (IC) for aqueous samples. Various REE-targeted eluent gradients and post-column agent compositions were tested on the chelation ion chromatography (CIC) with UV-vis detector for optimal separation and quantification of REEs within approximately 20 min. The single-channel pump to deliver the post-column solution to UV-vis detector was replaced with a 4-channel gradient pump, to increase operation and maintenance efficiencies. After method optimization, resulting calibration curves for more than ten REEs achieved high coefficients of determination (R2>0.999) and low relatively standard deviations (below 3.24%), demonstrating sub-ppm level detection limits (0.0897 to 0.1149 mg/L). The reliability of the CIC method was validated through comparison with inductively coupled plasma mass spectrometry (ICP-MS), showing strong agreement in REE recovery from certified standards. The impact of metal ions and salts on REE recovery using CIC was also systematically investigated. CIC consistently exhibited reliable performance in the presence of salt solutions such as NaCl and Na₂SO₄ (up to 10,000 mg/L). Our study also found the presence of high concentrations of Al ions (at 10,000 mg/L) significantly influenced REE determination, and elevated concentrations of Ca ions affected the recovery of specific REEs, including La, Ce, and Pr. The CIC method was further tested on REE-containing eluents from solvent extraction tests out of fly ash leachates. REE detection from these real processing fluids were reported to achieve 90% to 100% recovery rate from our IC method, compared to ICP-MS results. This study underscores the potential of CIC as a reliable and efficient alternative for REE determination in complex matrices. It also highlights the importance of minimizing select interfering metal ions in solutions to ensure accurate results. The REE CIC method presents a promising, low-maintenance, salt-tolerant, and cost-effective alternative to traditional analytical methods for REE analysis.

detection of rare earth elements (REE)↗
DOE OSTI2024

Situated Visualization of Photovoltaic Module Performance for Workforce Development: Preprint

The rapid growth of the solar energy industry requires advanced educational tools to train the next generation of engineers and technicians. We present a novel system for situated visualization of photovoltaic (PV) module performance, leveraging a combination of PV simulation, sun-sky position, and head-mounted augmented reality (AR). Our system is guided by four principles of development: simplicity, adaptability, collaboration, and maintainability, realized in six components. Users interactively manipulate a physical module's orientation and shading referents with immediate feedback on the module's performance.

augmented reality↗