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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Towards Prospective LCA Using Life-Cycle Assessment Integration into Scalable Open-Source Numerical Models (LiAISON) Framework for Analyzing Emerging Low-Carbon Technologies

Decarbonizing the industrial sector is a significant challenge in achieving a net-zero greenhouse gas (GHG) emissions economy by 2050 and the Paris Agreement, i.e., a global climate change mitigation target of achieving a maximum average temperature change potential of 1.5 Degrees Celsius or less by 2100 with respect to pre-industrial levels. In the United States (US), the industrial sector accounts for 23% of total GHG emissions and is home to a number of hard-to-electrify activities. The chemicals subsector has the single largest subsector emissions profile after direct emissions from fossil fuel combustion and leakage from fossil fuel distribution systems. Within the chemicals subsector, many processes depend on hydrogen or ammonia precursors. Decarbonizing these two commodities would contribute significantly to decarbonizing the industrial sector as hydrogen could also be used for low carbon steel production (e.g., hydrogen-based direct reduction of iron) and other industrial applications. Emerging technologies require the application of prospective life cycle assessment (LCA), which can account for technology (foreground) scaling and process improvements via learning-by-doing, among others. In many cases, the future system context (background) in which the technologies are assumed to operate in is equally relevant. Background scenarios generated by integrated assessment models (IAM) can coherently incorporate potential future dynamics of the energy-climate-human-land system. Further, IAM scenarios are harmonized across socioeconomic and climate change mitigation pathways, which facilitates the comparability of prospective LCAs using different IAMs. We introduce an open source prospective LCA framework, the Life-cycle Assessment Integration into Scalable Open-source Numerical models (LiAISON), to analyze the non-linear relationships between technology foreground and the future energy system background across a series of midpoint and resource use metrics The integration of LCA and IAM data is achieved using prospective environmental Impact assessment (PREMISE). We showcase it by assessing two Power-to-Hydrogen (PtH2) processes, namely Solid Oxide Electrolysis (SOE) and Polymer Electrolyte Membrane Electrolysis (PEME). We compare the technologies to a baseline of hydrogen production via natural gas-based Steam Methane Reforming (SMR) in a US context of multiple energy system and climate change mitigation futures. Besides providing an analysis that specifies the LCA results ranges with temporal and geospatial explicitness across the two technologies, metrics, and impact assessment methods, this research also aims to establish a base framework that can be expanded to use other IAM generated scenarios and US open-source life cycle inventory (LCI) databases. We find that the temporal environmental performance of either technology or their difference to SMR is directly influenced by the underlying background dynamics. Additionally we compare our results by linking two other prospective models with LiAISON - GCAM(Global Change Assessment Model) and ReEDS (Regional Energy Deployment System) to analyze the effect of changing background scenarios using varying predictions in life cycle analysis.

emissions↗
DOE OSTI2024

Catalyzing deep decarbonization with federated battery diagnosis and prognosis for better data management in energy storage systems

Industrial data analytics methods play a central role in improving energy storage performance and efficiency, impacting the future of electrified transportation and renewable electricity generation. However, significant challenges hinder the large-scale deployment of batteries. Conventional methods rely on centralized collection and processing of fleet-level data, leading to database size issues and privacy concerns due to potential data breaches. To enable scalable deployment of battery management systems, this article proposes a federated battery diagnosis and prognosis model, which distributes the processing of battery standard current-voltage-time-usage data in a privacy-preserving manner. Instead of transferring the raw data, this approach communicates only the locally processed parameters, thus reducing communication load and preserving data confidentiality. The federated model offers a paradigm shift in battery health management through privacy-preserving distributed methods for battery data processing and lifetime prediction, ensuring the reliable and sustainable deployment of lithium-ion batteries in a rapidly evolving world.

asset health management↗
DOE OSTI2025

srlife : A software tool for estimating the life of high temperature concentrating solar receivers. Part II – Ceramic receivers

As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat demands, high-temperature metallic materials, including nickel-based superalloys, face challenges in maintaining structural integrity. Advanced ceramics offer a promising alternative due to their superior high-temperature strength. However, accurately assessing the performance of ceramic components requires a fundamentally different approach from that used for metallic components. This Part II of a two-part paper describes the integration of ceramic statistical failure models within srlife – an open-source tool for predicting the life of high-temperature CSP receivers. These models account for the inherent variability in ceramic strength, as well as the effects of subcritical crack growth (SCG) under high temperature cyclic loads. Here, the paper includes an example problem that demonstrate the process of evaluating ceramic receivers using srlife. Part I details the life estimation process for metallic receivers (i.e. creep-fatigue life) along with input and output data structure, thermohydraulic analysis, and structural analysis. The complete tool is available as open-source software at https://github.com/srlife-project/srlife and can be installed via the PyPi package manager (https://pypi.org). By supporting both ceramic and metallic receiver analyses, srlife facilitates fair comparisons between competing metallic and ceramic designs, enabling accurate evaluations of plant efficiency and the economic benefits of ceramic solar receivers and other components.

High temperature ceramic receivers↗
DOE OSTI2024

Multivariate prognosis of battery advanced state of health via transformers

De-risking energy storage investments necessary to meet CO 2 reduction targets requires a deep understanding of the connections between battery health, design, and use. The historical definition of the battery state of health (SOH) as the percentage of current versus initial capacity is inadequate for this purpose, motivating an expanded SOH consisting of an interrelated set of descriptors including capacity, energy, ionic and electronic impedances, open-circuit voltages, and microstructure metrics. In this work, we introduce deep transformer networks for the simultaneous prognosis of 28 battery SOH descriptors using two cycling datasets representing six lithium-ion cathode chemistries, multiple electrolyte/anode compositions, and different charge-discharge scenarios. The accuracy of these predictions for battery life (with an unprecedented mean absolute error of 19 cycles in predicting end of life for a lithium-iron-phosphate fast-charging dataset) illustrates the promise of deep learning toward providing enhanced understanding and control of battery health.

25 ENERGY STORAGE↗
DOE OSTI2022

Effects of applied stress and grain size on creep-rupture lifetime prediction for Haynes 282 alloy

A multiple-heat set of tensile and creep-rupture data generated from a single laboratory was used to establish and evaluate predictive equations for the average creep-limited lifetime of an aged wrought Haynes 282 alloy using two different time- and temperature-compensated parametric models (those of Larson and Miller and Wilshire et al.). The range of temperatures and stresses used to produce the creep-rupture data used in the analyses revealed that two distinct regimes, above and below the proportional limit, were necessary for more accurate predictions of creep lifetimes over the range of conditions studied. Furthermore, a 2x difference in grain size amongst the three heats revealed a breakdown in the relationship between ultimate tensile strength and creep-rupture time, thus impacting the predictive ability of the Wilshire model. Finally, lifetime predictions based on the formulations from the respective models were compared to other available Haynes 282 datasets and found to reasonably replicate the experimental trends established in other studies.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Quantitative Non-Destructive Evaluation of Fatigue Damage Based on Multi-Sensor Fusion

Based on sensor fusion and machine learning, this project developed a novel non-destructive evaluation (NDE) methodology, which consists of a remaining useful life (RUL) prediction framework and regression models for predicting residual stress and full width at half maximum (FWHM). A series of fatigue testing experiments were conducted using 5052-H32 aluminum alloy specimens. All specimens were measured using linear ultrasonic (LU) and nonlinear ultrasonic (NLU) testing methods non-destructively. Machine learning models were developed to use LU and NLU measurements to predict loading condition, fatigue level, residual stress, and FWHM. It was demonstrated that the developed methodology could distinguish new and fatigue specimens with an accuracy of 97.53%. Also, the prediction errors for residual stress and FWHM were as low as 4.73% and 1.62%, respectively. An interactive database was created to publicly share the data generated from the project. It is envisioned that the developed NDE technology will equip manufacturers with a responsive screening system for incoming used metallic components, and potentially lead to a significant increase in using used metallic components for remanufacturing.

42 ENGINEERING↗
DOE OSTI2024

Investigating explainable transfer learning for battery lifetime prediction under state transitions

Battery lifetime prediction at early cycles is crucial for researchers and manufacturers to examine product quality and promote technology development. Machine learning has been widely utilized to construct data-driven solutions for high-accuracy predictions. However, the internal mechanisms of batteries are sensitive to many factors, such as charging/discharging protocols, manufacturing/storage conditions, and usage patterns. These factors will induce state transitions, thereby decreasing the prediction accuracy of data-driven approaches. Transfer learning is a promising technique that overcomes this difficulty and achieves accurate predictions by jointly utilizing information from various sources. Hence, we develop two transfer learning methods, Bayesian Model Fusion and Weighted Orthogonal Matching Pursuit, to strategically combine prior knowledge with limited information from the target dataset to achieve superior prediction performance. From our results, our transfer learning methods reduce root-mean-squared error by 41% through adapting to the target domain. Furthermore, the transfer learning strategies identify the variations of impactful features across different sets of batteries and therefore disentangle the battery degradation mechanisms and the root cause of state transitions from the perspective of data mining. These findings suggest that the transfer learning strategies proposed in our work are capable of acquiring knowledge across multiple data sources for solving specialized issues.

25 ENERGY STORAGE↗
DOE OSTI2021

Early Battery Performance Prediction for Mixed Use Charging Profiles Using Hierarchal Machine Learning

A key step limiting how fast batteries can be deployed is the time necessary to provide evaluation and validation of performance. Using data analysis approaches, such as machine learning, the validation process can be accelerated. However, questions on the validity of projecting models trained on limited data or simple cycling profiles, such as constant current cycling, to real-world scenarios with complex loads remains. Here, we present the ability to predict performance with less than 1.2% mean absolute percent error when trained on cells aged using complex electric vehicle discharge profiles, and either AC Level 2 charge or DC Fast charge profiles, using only the first 45 cycles, namely 5% of the total testing time. While error is low across the projections, this study also highlights that battery lifetime analysis using only cycling data may not extrapolate safely to certain real-world conditions due to the impact of calendar degradation.

25 ENERGY STORAGE↗
DOE OSTI2020

EXPERIMENTAL INVESTIGATION OF IMPACT AND ABRASION EROSIONS AT LOW VELOCITIES AND COMPARISON TO CFD SIMULATIONS

Wear and erosion damage of materials due to interaction of the surface with solid particles is a major issue in various industries. This phenomenon is common in mining, and oil and gas production, causing damages worth millions of dollars annually. Erosion is becoming a critical issue in renewable technologies as well such as concentrated solar thermal power (CSP) systems. In some CSP systems, solid particles can be used to absorb solar energy and enhance the heat storage. However, these particles may cause significant amount of wear to system components while falling down the power tower at high temperatures. This damage can be costly, and therefore, investigating solid particle erosion in CSP systems is of utmost importance. In collaboration with Sandia National Laboratories, the erosion durability of particle-based Generation 3 (GEN3) CSP system are being investigated both experimentally and numerically. In order to develop models to predict the life time of such systems, erosion under low temperature and low particle impact velocity conditions are investigated. Impact erosion and abrasion erosion experiments are conducted for low velocity and low temperature conditions for various candidate particles and containment materials. The impact erosion testing is conducted for three different containment material including Stainless Steel 316, special refractory material, and Inconel 740H with CARBOBEAD HSP 40/70 ceramic particles and UNIWEST 430 silica quartz erodent particles. All this data will enable us to better model the erosion behavior of these materials and provides a data base to investigate erosion at high temperatures experienced in CSP systems. At low temperatures and low velocities the softer refractory material exhibited greater erosion by an order-of-magnitude when compared to the harder Inconel 740H and Stainless Steel 316 materials. The overall erosion ratio for all the candidate materials was of the order of 10 -7 kg/kg. We also investigated wear in containment materials from sliding of particles over the surfaces at very low angles, also referred to as abrasion. For the velocities expected in a typical 1MW CSP plant, visible surface wear was noted, but the overall mass loss per unit surface area was found to be dependent on the hardness of the containment material tested. In this manuscript, we also present Computational Fluid Dynamics (CFD) simulations and erosion prediction of low velocity impact erosion. These results are compared with the experimental data to evaluate the ability of available erosion models for predicting erosion under these conditions.

14 SOLAR ENERGY↗
DOE OSTI2020

Multiscale-Informed Modeling of High Temperature Component Response with Uncertainty Quantification

This report summarizes a joint effort between Argonne National Laboratory, Idaho National Laboratory, and Los Alamos National Laboratory to develop and deploy constitutive models targeted at predicting the life of Grade 91 alloy components subjected to high temperature environments typical of those that structural components in advanced nuclear reactors would experience. Two distinct, but complementary constitutive modeling approaches have been taken here. The first employs a phenomenological viscoplastic model for which parameters have been calibrated based on experimental data for a wide range of Grade 91 alloy that has undergone a variety of processing. A Bayesian approach was used to derive distributions of uncertain parameters for this model based on this data set. The second approach is a reduced order model suitable for engineering-scale analysis that is based on the results of a large set of mesoscale simulations. Mesoscale models allow for the microstructure and composition of a particular alloy to be directly taken into account in the computation of the viscoplastic response, but are computationally expensive, which makes it impractical to directly call those models for the material constitutive response in an engineering-scale simulation. The reduced-order representation of the response of the underlying model used here allows for an engineering-scale model to take into account the characteristics of the underlying microstructure, while only incurring a reasonable computational expense. Both of these approaches have different strengths, and are applicable for different parts of the design/analysis process. The phenomenological models can be readily parameterized based on a set of experimental data for a given class of materials and used for scoping calculations. Once a specific material is chosen and adequately characterized, the reduced order models can accurately predict the response of that specific alloy, and because the models are based on predictive models of the underlying microstructure, they can be used to more confidently predict the response under conditions in regions where there is limited experimental data. Both of these models have been integrated in the Grizzly code, which is used here to perform proof-of-concept uncertainty quantification analyses of a simple component under prototypical conditions. The built- in stochastic analysis capabilities in the MOOSE framework that Grizzly is built on are used here to run large sets of simulations for this uncertainty quantification analysis. As would be expected, because the reduced order models are developed for a much more tightly defined alloy, they predict tighter distributions of the time to failure than the phenomenological models, which are calibrated to a broader set of data. Also important is that these simulations demonstrate that a reduced order modeling approach can be successfully deployed to propagate uncertainties from the material scale to practical engineering-scale component simulations.

42 ENGINEERING↗
DOE OSTI2022

Stochastic Model for High Temperature Oxidation of Cr–Ni Austenitic Steels Assisted by Spallation

Abstract Cr–Ni austenitic steels offer significant high temperature corrosion protection by forming a surface oxide layer. However, above critical service conditions (temperature, atmosphere, thermal cycling), oxidized surface can experience intensive degradation because of scale spallation, which could be detrimental to the in-service life. To predict the effect of scale spallation on oxidation kinetics, a simulation was implemented using a stochastic model. The model considers topological parameters and intensity of spallation which can occur, while delivering a true oxidation constant. The experimental procedure identified the amount of formed spalled scale and topology of spallation based on the use of element mapping of the surface. This information was used to determine a true kinetic constant for a corresponding spallation intensity in oxidized Cr–Ni austenitic steel. To illustrate the capability of the stochastic model, a parametric analysis was performed. The model verified how the spallation parameters could change the oxidation processes from parabolic growth of an adhered oxide layer without spallation to a mixed linear-parabolic, or with a constant thickness of residual scale at high spallation intensity. The spallation model will be used in a separate article to characterize high temperature surface degradation of several Cr–Ni austenitic steels during harsh oxidation environments.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Fatigue Behavior and Mechanisms of High-Entropy Alloys

Fatigue failures of structural materials pose enormous risks to in-service structures, as well as human lives. The development of advanced durable structural materials with fatigue resistance has important social impact. The novel concept of high-entropy alloys (HEAs) has engendered considerable attention due to their exhibited unusual mechanical properties, and correspondingly opening a new road to design fatigue-resistant structural materials. Here, the present work discusses and reviews the current findings on fatigue behavior and mechanisms of HEAs. Based on the understanding of fatigue-resistant favorable deformation mechanisms in HEAs, the perspectives from the viewpoint of materials design are provided to advance the development of fatigue-resistant HEAs, and future works are also suggested.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Battery passports for promoting electric vehicle resale and repurposing

Starting in 2026, most batteries sold in the European Union will require a battery passport. This initiative is part of a broader legislative framework, led by the European Commission, to improve sustainable battery materials sourcing practices and enable a circular economy. All batteries having a capacity of greater than 2 kilowatt-hours will be covered under the legislation, effectively encompassing all electric vehicle (EV) batteries and stationary grid storage batteries. At its core, a battery passport defines a minimum, standard set of information that must be reported for every battery made and sold (see Figure 1). Legislative actions have so far focused on labeling standards enabling raw material traceability and recycling, which has received ongoing support from the European Council and Parliament. Furthermore, work remains to finalize the electrochemical performance and durability minimum reporting requirements by 2024, which has been challenging since performance and durability are subject to many different interpretations.

25 ENERGY STORAGE↗
DOE OSTI2025

Diagnostic-free onboard battery health assessment

Diverse usage patterns induce complex and variable aging behaviors in lithiumion batteries, complicating accurate health diagnosis and prognosis. Separate diagnostic cycles are often used to untangle the battery’s current state of health from prior complex aging patterns. However, these same diagnostic cycles alter the battery’s degradation trajectory, are time-intensive, and cannot be practically performed in onboard applications. Here, in this work, we leverage portions of operational measurements in combination with an interpretable machine learning model to enable rapid, onboard battery health diagnostics and prognostics without offline diagnostic testing and the requirement of historical data. We integrate mechanistic constraints within an encoder-decoder architecture to extract electrode states in a physically interpretable latent space and enable improved reconstruction of the degradation path. The health diagnosis model framework can be flexibly applied across diverse application interests with slight fine-tuning.

battery aging reconstruction↗
DOE OSTI2025

Final Results of the M AJORANA D EMONSTRATOR ’s Search for Double-Beta Decay of 76 Ge to Excited States of 76 Se

76 Ge can 𝛽⁢𝛽 decay into three possible excited states of 76 Se , with the emission of two or, if the neutrino is Majorana, zero neutrinos. None of these six transitions have yet been observed. The M AJORANA D EMONSTRATOR was designed to study 𝛽⁢𝛽 decay of 76 Ge using a low background array of high purity germanium detectors. With 98.2 kg-y of isotopic exposure, the demonstrator sets the strongest half-life limits to date for all six transition modes. For 2⁢𝜈⁢𝛽⁢𝛽 to the 0$^+_1$ state of 76 Se , this search has begun to probe for the first time half-life values predicted using modern many-body nuclear theory techniques, setting a limit of 𝑇 1/2 > 1.5 × 10 24 y (90% CL).

Majorana neutrinos↗
DOE OSTI2023

BLAST-Lite (Battery Lifetime Analysis and Simulation Tool - Lite) [SWR-22-69] Related to: BLAST aka: BLAST-Py

Battery Lifetime Analysis and Simulation Toolsuite (BLAST) provides a library of battery lifetime and degradation models for various commercial lithium-ion batteries from recent years. Degradation models are identified from publicly available lab-based aging data using NREL's battery life model identification toolkit. The battery life models predicted the expected lifetime of batteries used in mobile or stationary applications as functions of their temperature and use (state-of-charge, depth-of-discharge, and charge/discharge rates). Model implementation is in both Python and MATLAB programming languages. The MATLAB code also provides example applications (stationary storage and EV), climate data, and simple thermal management options. For more information on battery health diagnostics, prediction, and optimization, see NREL's Battery Lifespan webpage.

Smith, Kandler↗
DOE OSTI2021

Model-based Design Optimization to Achieve the Performance Goals (16.0 SEER/9.5 HSPF), Developing Heat Pump by Using Low-GWP Refrigerants and 5 mm Diameter Tubes

Usage of low-GWP refrigerants can reduce the Green House Gas (GHG) emission of HVAC systems. Our research in previous milestone report has shown that using heat exchangers with 5 mm diameter tubes instead of 9 mm diameter tubes is a promising solution to meet the performance goals of heat pump using low-GWP refrigerants. In addition, the 5mm tube heat exchangers can lead to lower system refrigerant charge and as a result, reduce environmental impact further. However, shifting to small tube diameters requires in-depth heat exchanger design optimization to adapt to the transition to low-GWP refrigerants. In the 2nd quarter of FY21, we conducted multi-objective optimizations using Particle Swarm Optimization algorithm on a residential 5-ton air source heat pump to investigate the potential system performance improvements and material savings. 4 low-GWP refrigerants, ARM20A, ARM20B, R454A and R454C are investigated in this study. The objectives of the optimization are to minimize the heat pump material cost and to maximize the system performance simultaneously. As a result, the HXs material cost is reduced by up to 77% according to the copper and aluminum material price in current market. Under heating mode operation, the smart 4-way valve guarantees that the optimal low-GWP systems maintain or outperform the heating performance of the R410A baseline system. The model-based design optimization yields 18.3-18.9 SEER and 10.6-11.9 HSPF for optimal systems using different low-GWP refrigerants. The initial performance goals (16.0 SEER/9.5 HSPF) are achieved. Furthermore, up to 50% system refrigerant charge reduction is possible in the optimized low-GWP heat pump system using ARM20B. And 91%-95% predicted life-time direct CO 2 emission reduction is achieved by using the optimal 5mm tube low-GWP heat pumps. The significant material saving, charge reduction and direct CO 2 emission reduction help in reducing the environmental impacts of heat pump systems. The optimal heat exchangers resulting from this research can fit into the original baseline indoor and outdoor fan-coil unit. This can reduce the retrofitting effort by minimizing the change in manufacturing and installation of the heat pumps and guarantee the compatibility with end-users’ house structure. Finally, the new products can be easily accepted by manufacturers and end-users.

42 ENGINEERING↗