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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 OSTI2026

Development of a Test-Bed for Testing and Refining EarthEn’s Supercritical CO 2 Based Energy Storage System

EarthEn’s energy storage concept leverages supercritical carbon dioxide (sCO 2 ) as a working fluid and relies on compact, high-performance components operating at elevated pressures and temperatures. To accelerate component development and reduce technical risk prior to larger-scale demonstrations, Oak Ridge National Laboratory (ORNL) developed a 100 kW-scale sCO 2 test-bed under a Cooperative Research and Development Agreement with EarthEn (CRADA NO. NFE-24-10050). The objective of the work was to design and construct a flexible experimental facility capable of reproducing key thermodynamic state points and heat-transfer conditions relevant to EarthEn’s thermal energy storage (TES) cycle, with particular emphasis on enabling development and evaluation of next-generation heat exchangers and TES concepts. The test-bed consists of a closed-loop sCO 2 circulation system housed within an open-topped enclosure. In its as-installed configuration, dense-phase sCO 2 is recirculated through a printed circuit recuperator, an electrically heated section, a throttling device used to simulate turbine expansion, and a water-cooled printed circuit heat exchanger that rejects heat to the building chilled-water system before returning to the pump. The pump is driven by a variable frequency drive, enabling controlled adjustment of flow and operating point. A comprehensive instrumentation suite was integrated to support both safe operation and high-quality data collection. Installed sensors include Coriolis flow meters for sCO 2 flow rate and density, resistance temperature detectors and thermocouples distributed throughout the loop (including the heated section and key heat exchanger ports), and pressure transducers for absolute and differential pressure measurements. The facility was designed to support high-pressure (19 MPa nominal) and high-temperature (575°C nominal) operation with credited overpressure protection provided by a rupture disk. Nominal operating conditions were selected to support 100 kW-class testing while maintaining flexibility for non-heated and heated shakedown, control development, and future integration of advanced TES test sections. In parallel with facility development, a system-level thermal-hydraulic model was created using Modelica-based tools to support component sizing, anticipate performance over targeted test conditions, and establish a framework for future model calibration against experimental data. At the conclusion of the project performance period, the facility was in final assembly, and the pressure boundary was nearly completed. However, several practical challenges associated with high-pressure/high-temperature systems and specialized component procurement impacted schedule and prevented initial pump-driven operation and full commissioning within the available resources. This report documents the as-built design, operating capabilities, and instrumentation, and it summarizes key lessons learned related to heater fabrication and testing, first-of-a-kind assembly factors, specialty flange supply constraints, and fill pump corrective actions. Finally, it outlines a phased plan for future commissioning and experimental campaigns, including control and instrumentation shakedown, heater characterization, model calibration, and testing at state points representative of EarthEn’s TES cycle.

25 ENERGY STORAGE↗
DOE OSTI2026

Absorber Clamp for Microcalorimeter Decay Energy Spectrometry

Microcalorimeter Decay Energy Spectrometry (DES) is of interest to nuclear safeguards due to its ability to provide high precision isotopic compositions of nanogram-to microgram-scale samples of Pu and U and related daughter products. The DES method is able to record decay energy of each alpha-decay event in a sample that is embedded in a metal matrix (absorber) and thermally linked to a microcalorimeter detector. This work optimizes the DES technique used to thermally link the absorber and microcalorimeter detector element to allow for more rapid assembly and to increase detector performance and operating life. Optimized attachment methods are crucial for enhancing the viability of DES in high-sample-throughput facilities, such as those that support international nuclear safeguards measurements. Here, in this study, we designed and implemented a pressure-based absorber clamp and evaluated the performance of this new attachment method relative to pressed indium bond attachment. Results using the absorber clamp demonstrate a streamlined detector assembly procedure that minimizes accidental damage to detectors, as well as increasing detector pulse speeds by 57%. Spectral comparison shows the clamp preserves detector performance relative to indium attachment.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2026

Demonstration of reconstruction-free static magnetic control of DIII-D plasma with deep reinforcement learning

This paper presents the development and experimental validation of a reinforcement learning (RL)-based magnetic controller on the DIII-D tokamak. The controller directly maps raw magnetic diagnostic signals to actuator commands, replacing the traditional isoflux control algorithm based on equilibrium reconstruction. Four RL controllers are trained using the Soft Actor–Critic algorithm with an asymmetric Actor–Critic architecture in the NSFsim simulator. All controllers are deployed in the DIII-D Plasma Control System and operated with a 4 kHz feedback loop. Two randomization strategies are evaluated during training: evolving kinetic profiles and fixed kinetic profiles within each episode. The latter approach is found to better capture experimental deviations in the current density profile and to provide overall improved control performance. Robust operation is demonstrated across heating power scans in both L- and H-mode plasmas, as well as during transient events such as L–H transitions and pellet injections. Control errors in plasma shape and radial position remained within 1.5–2.0 cm and 1 cm, respectively. A notable discrepancy was observed in the vertical X-point position, with errors of up to approximately 4 cm, attributed to the current density distribution mismatches between simulations and experiments.

DIII-D↗
DOE OSTI2024

Mechanical Response of Cr-Coated Zircaloy-4 Cladding to Pellet-Cladding Interactions

Chromium-coated zircaloy is a promising accident tolerant fuel (ATF) cladding design which can help mitigate high temperature oxidation. The mechanical response of the cladding during and after loading may be altered by the Cr coating throughout anticipated operational and accident occurrences such as a pellet-cladding interaction (PCI). In this work, the mechanical behavior of Cr-coated and uncoated cold worked stress-relieved (CWSR) Zircaloy-4 (Zry-4) cladding to PCI loading conditions are studied. Stress relaxation tests are performed on CWSR Zry-4 cladding using full-tube axial tension and internal pressurization to investigate mechanical anisotropy and rate-limiting deformation mechanisms of the uncoated Zry-4. These results are compared to internal pressure testing results of similar cladding with physical vapor deposition (PVD) Cr-coating to reveal how the Cr-coating affects the cladding mechanical response. Findings are discussed in the context of ATF cladding performance during operation and storage.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Sensor Data Analytics and Data Quality Assessment Software

The proposed framework derives a set of quality metrics to provide critical insights into and tracking of grid operations, sensor performance, sensor longevity, and event statistics. Power grid engineers can utilize this information to identify problems with existing sensor locations and problematic power grid assets including generators, transmission lines, load centers, and substations. This information can also be used to identify unexpected/abnormal behavior of power grid components, improve power grid observability, and operational monitoring, and thus enhance real-time decision-making support system. Power grid planners can utilize this information to augment existing sensing architecture with new sensors and improve the observability of the network.

Mahapatra, Kaveri↗
DOE OSTI2025

PowderJet: Spherical metal powder production via multi-orifice droplet-on-demand metal jetting

Leading metal additive manufacturing techniques, such as laser powder bed fusion and directed energy deposition, rely on high-quality spherical metal powders. However, traditional powder production methods like gas atomization face limitations, including low in-spec yield, asphericity, and internal porosity. We introduce PowderJet, a powder production platform that uses electromagnetic pulses to eject liquid metal droplets from a multi-orifice nozzle. Unlike stochastic methods, PowderJet tightly controls powder size, distribution, and purity through a droplet-on-demand approach. We detail the system’s design, operation, and performance using a combined experimental and computational fluid dynamics (CFD) framework. Initial results with Al4008 and Cu110 alloys demonstrate successful production, yielding unsieved aluminum powder batches with a mean diameter of 200 µm and a narrow size distribution (15 µm standard deviation). The produced powders are highly spherical, achieving a roundness > 0.95. PowderJet operates with a small melt volume (3 mL) and supports continuous refilling, enabling production rates between 30 and 140 cm³/hr depending on jetting frequency, number of orifices and particle size. CFD simulations show that future systems could achieve rates exceeding 1000 cm³/hr for particle sizes as small as 40 µm. PowderJet’s high yield of in-spec powder makes it ideal for producing precious or hazardous materials that are inefficient to manufacture using conventional methods. This platform offers a scalable, precise, and efficient solution for producing high-quality powders tailored for advanced manufacturing applications.

Atomization↗
DOE OSTI2026

From binary to quinary: The rationale and development of GaInAsSbBi for mid- and long-wave infrared sensing applications

Given the added complexity in flux calibration and composition evaluation inherent to quinary alloy growth, what motivates compounding the challenges of III–V-Bi growth with the goal of producing a quinary alloy of GaInAsSbBi for mid- and long-wave infrared sensing applications? Each elemental constituent provides some additional design freedom to achieve the ultimate goal of producing a lattice-matched, bulk random alloy mid-wave infrared III–V material with smooth surface morphology and high optoelectronic quality to enable high performance elevated operating temperatures. Here, this paper reviews the evolution of Bi-containing semiconductor research, focusing on mid- and long-wave infrared materials and highlighting key research findings that motivated the decisions to accept the added complexity in going from binaries like InAs or InSb, to InAsBi, to InAsSbBi, and, finally, to GaInAsSbBi to meet the performance demands of advanced infrared sensing applications.

Webster, Preston T. [Air Force Research Laboratory↗
DOE OSTI2026

Augmenting LLM-Based Agents for Improved Performance in Pentesting and Commissioning Operational Technology in Critical Infrastructure

Artificial intelligence (AI), and more specifically large language models (LLMs) have the potential for use in penetration testing (“pentesting”) against devices, networks, and computer systems in information technology (IT). We explore the possibility of extending pentesting from IT systems to operational technology (OT) systems, which are more obscure than IT systems in their protocols and design. A challenge therefore exists when applying pretrained LLMs to OT systems as corpora are likely to underrepresent OT systems in comparison to other more prevalent systems. We evaluate augmentations of LLMs with various methods, especially retrieval augmented generation (RAG), to improve performance of the LLMs in the OT domain. In addition to pentesting, some of the testing of these OT devices may include commissioning to ensure that the newly installed devices work correctly. Our framework may also be applied in such cases.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Disruption modelling for engineering and physics design of ST-E1 fusion power plant

Plasma disruptions represent a critical challenge for high-performance tokamak operations, as they can compromise machine integrity and reduce operational availability. Although future fusion devices essentially need to incorporate strategies to minimise disruption occurrence, complete avoidance remains unattainable. Consequently, assessing and characterising unmitigated disruption consequences is fundamental for the design and qualification of next-generation fusion power plants. This work supports the pre-conceptual design of ST-E1, a low aspect-ratio Tokamak Fusion Power Plant developed by Tokamak Energy Ltd., by presenting a comprehensive disruption modelling approach applied across different design stages. The methodology integrates both physics and engineering considerations to evaluate the impact of disruptions on machine performance and structural integrity. From an engineering perspective, several ST-E1 layout options were analysed to investigate the electromagnetic response of key components under disruption-induced loads, enabling comparison between alternative design solutions. On the physics side, a broad set of disruption scenarios was explored, scanning operational space parameters, plasma-material interactions, and associated thermal loads. Furthermore, the study examined variations in disruption behaviour arising from different reference equilibria, focusing on a range starting from Double Null to Single Null configurations, reflecting the increasing up-down asymmetry consequences. The results reveal significant contrasts in plasma dynamics and structures electromagnetic behaviour between configurations, highlighting the importance of disruption modelling in guiding design choices. These analyses have proven instrumental in shaping ST-E1 development, offering critical insights for mitigating risks and optimising future fusion power plant designs.

Borowiec, Katarzyna [ORNL] (ORCID:0000000335911739↗
DOE OSTI2026

Vapor-cavity-QED system for quantum computation and communication

In this work, we propose performing key operations in quantum computation and communication using room-temperature atoms moving across a grid of high-quality-factor, small-mode-volume cavities. These cavities enable high-cooperativity interactions with single atoms to be achieved with a characteristic timescale much shorter than the atomic transit time, allowing multiple coherent operations to take place. We study scenarios where we can drive a Raman transition to generate photons with specific temporal shapes and to absorb, and hence detect, single photons. The strong atom-cavity interaction can also be used to implement the atom-photon controlled-phase gate, which can then be used to construct photon-photon gates, create photonic cluster states, and perform nondemolition detection of single photons. We provide numerics validating our methods and discuss the implications of our results for several applications.

Austin, Sharoon [National Institute of Standards a↗
DOE OSTI2026

Risks to the DOW Mission From Global Advanced Energy Adoption

Advanced energy technologies have the potential to enhance energy security and resilience; however, they can introduce new vulnerabilities even as they mitigate existing ones. This dichotomy highlights that both action and inaction carry strategic risks in a contested and logistically complex operating environment. Regardless of U.S. civilian or military adoption of such technologies, key allies and adversaries are on adoption paths that will impact the U.S. military at the tactical, operational, and strategic level. The global adoption of advanced energy technologies presents the potential for both positive and negative consequences for U.S. Department of Defense (DOD) missions in the next 10-20 years. Three categories of risk drivers are presented in this analysis: infrastructure-related, adoption-related, and response-related. Each risk type can generate consequences for DOD, including power disruptions, suboptimal DOD mission performance and operational effectiveness, higher costs and shortages for both legacy and advanced energy technologies, and loss of U.S. influence and strategic deterrent value. Specific impacts could include tactical impacts, operational impacts, and strategic impacts. Mitigation strategies could include energy resource and technology planning, cybersecurity, supply chain resilience, workforce development, exercises and simulations, investments in commercialized technology, operational testing and pilot programs, research into emerging technologies, partnerships and working groups, common standards, budget planning, and repurposing infrastructure.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Testing- and Model- Based Optimization of Coal-fired Primary Heater Design for Indirect Supercritical CO 2 Power Cycles (Final Scientific and Technical Report)

The overall objective of this project was to perform the R&D necessary to mitigate the risk associated with the design of a primary heat exchanger for a solid-fired combustion system coupled with an indirect-fired closed-loop Brayton Cycle utilizing supercritical CO 2 . The key technological hurdle was the coupling of a solid-fuel firing system with the primary heater, which poses a singular challenge, which is the management of burner performance and operational conditions in a way to manage heat exchanger tube metal temperatures and temperature ramp rates in the absence of fluid phase change on the inside of the tubes. We designed and built the first ever pseudo power system employing a simple recuperated supercritical CO 2 closed-loop Brayton Cycle coupled to a solid-fuel fired system. Advanced coupled CFD and process modeling were used to design the primary heat exchanger (PHX), which consisted of both radiative and convective sections, to limit tube metal temperatures resulting from the heat release profile of the solid fuel flame near the radiative tubes. The heat exchanger was designed to produce finished CO 2 temperatures of 600 °C a pressure of 20.7 MPa and CO 2 flow of 5.5 kg/s. The constructed PHX was capable of 1.2 MWth heat uptake. During design of the PHX, the modeling showed that most variables influencing flame shape (burner stoichiometric ratio and register velocities and swirl) were not suitable to manage heat flux to the metal surfaces. This is because they substantially increased adiabatic flame temperature through the influence of localized stoichiometric ratio. Excess air and firing rate were the two most powerful variables that could be used to control tube surface temperatures. The coupled system was operated for a total of 407 hours, with the longest continuous run of 248 hours. For 62% of the operational time, the unit was unmanned and in automatic control. The fuels used for the testing included natural gas, two Utah Bituminous coals, woody biomass, and bagasse. During the testing we were able to verify the 1.2 MWth heat uptake and we operated at a finished CO 2 temperature of 607 °C and a pressure of 20.3 MPa simultaneously. The real-time corrosion rate of the Super 304H tube CO 2 surface in the region of the radiative section of the PHX were measured, at an approximate temperature of 550 °C. The two key variables related to corrosion rate are the pressure and flow rate of the CO 2 . A technoeconomic analysis was performed at a scale of 120 MWE. The updated analysis showed that the efficiency of an sCO 2 power producing plant will be related to the pressure drop of the PHX.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Modern deep neural networks for Direct Normal Irradiance forecasting: A classification approach

The escalating energy demand and the adverse environmental impacts of fossil-fuel use necessitate a shift towards cleaner and renewable alternatives. Concentrated Solar Power (CSP) technology emerges as a promising solution, offering a carbon-free alternative for power generation. The efficiency and profitability of CSP depend on the Direct Normal Irradiance (DNI) component of solar radiation; hence, accurate DNI forecasting can help optimize CSP plants’ operations and performance. The unpredictable nature of weather phenomena, particularly cloud cover, introduces uncertainty into DNI projections. Existing DNI forecasting models use meteorological factors, which are both challenging to estimate numerically over short prediction windows and expensive to model through data at a sufficiently high spatial and temporal resolution. This research addresses the challenge by presenting a novel approach that formulates DNI prediction as a multi-class classification problem, departing from conventional regression-based methods. The primary objective of this classification framework is to identify optimal periods aligning with specific operational thresholds for CSP plants, contributing to enhanced dispatch optimization strategies. We model the DNI classification problem using four advanced deep neural networks – rectified linear unit (ReLU) networks, 1D residual networks (ResNets), bidirectional long short-term memory (BiLSTM) networks, and transformers – achieving accuracies up to 93.5% without requiring meteorological parameters.

14 SOLAR ENERGY↗
DOE OSTI2024

Field-Emission Properties of Vertically Aligned Carbon Nanotube Cathodes of Varying Geometries

This work characterizes the bulk emission properties of carbon nanotube (CNT) forest cathodes fabricated with various geometries. Geometries explored include dense nanotube forests of varying height grown on 5×5 mm silicon (Si) substrates and discrete, patterned CNT pillars fabricated using UV photolithography. Dense forests heights ranged from 526 μ m to 1.41 mm, with packing fraction for dense forest calculated to be 4e10 nanotubes/cm2 based on an average nanotube separation distance of 100 nm for fixed growth dense forests. Patterned sample micro pillar heights ranged from 47 to 393 μ m with pillar widths on tested samples ranging from 250 to 270 μ m . Properties explored include emission current, turn-on field, and emission current performance over time. A parallel plate electron beam diode with a 100- μ m A-K gap and an automated test apparatus were developed to provide a configurable experiment that provides accurate and repeatable measurements for dc, dc sweep, and timed performance testing. Operating voltages for the voltage sweeps spanned from 0 to −350 V. Furthermore, testing has shown evidence of a hysteresis effect on the emission current tied to the applied field history as well as shifting of the turn-on field magnitude throughout the testing period, suggesting a conditioning effect during use. Three separate emission regions in the I–V curves during sweep testing have also been observed. In the geometric study, dense forests and patterned samples were sweep tested up to a peak applied voltage of −250 V, with the taller samples generally performing better. Currents produced in the geometric study from the dense forest emitters ranged from 36.8 to 572.34 μ A , with current densities ranging from 15 to 2.29 mA/cm2. Currents produced from the patterned micropillar emitters ranged from 39.4 to 317.51 μ A , with current densities ranging from 67 to 3 mA/cm2. DC time testing s...

36 MATERIALS SCIENCE↗
DOE OSTI2025

A Performance Portable, Fully Implicit Landau Collision Operator with Batched Linear Solvers

Modern accelerators use hierarchical parallel programming models that enable massive multithreading within a processing element (PE), with multiple PEs per device driven by traditional processes. Batching is a technique for exposing PE-level parallelism in algorithms that have traditionally run on MPI processes or multiple threads within a single process. Opportunities for batching arise in, for example, kinetic discretizations of magnetized plasmas where collisions are advanced in velocity space at each spatial point independently. This paper builds on previous work on a high-performance, fully nonlinear, Landau collision operator by batching the linear solver, as well as batching the spatial point problems and adding new support for multiple grids for multiscale, multispecies problems. An anisotropic relaxation verification test that agrees well with previously published results and analytical models is presented. The performance results from NVIDIA A100 and AMD MI250X nodes are presented with hardware utilization analysis for each architecture. Finally, the entire implicit Landau operator time advance is implemented in Kokkos for performance portability, running entirely on the device and is available in the PETSc numerical library.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Investigation of the Effect of Gate Oxide Screening with Adjustment Pulse on Commercial SiC Power MOSFETs

This paper presents a method to recover the negative threshold voltage shift during high field gate oxide screening of 1.2 kV 4H-SiC MOSFETs with an additional adjustment gate voltage pulse. To reduce field failure rates of the MOSFETs in operation, manufacturers perform a screening treatment to remove devices with extrinsic defects in the oxide. Current gate oxide screening procedures are limited to oxide fields at or below ~9 MV/cm for short durations (<1 s), which is not enough to remove all the devices with extrinsic defects. The results show that by implementing a lower field gate pulse, the threshold voltage shift can be partially recovered, and therefore the maximum screening field and time can be increased. However, both the initial screening pulse and the adjustment pulse require careful calibration to prevent significant degradation of the device threshold voltage, on-resistance, interface state density, or intrinsic lifetime. With a well calibrated set of pulses, higher screening fields can be utilized without significantly damaging the devices. This leads to an improvement in the overall screening efficiency of the process, reducing the number of devices with extrinsic oxide defects entering the field, and improving the reliability of the SiC MOSFETs in operation.

42 ENGINEERING↗
DOE OSTI2025

Rational Regulation of Layer‐by‐Layer Processed Active Layer via Trimer‐Induced Pre‐Swelling Strategy for Efficient and Robust Thick‐Film Organic Solar Cells

Thick-film (>300 nm) organic solar cells (OSCs) have garnered intensifying attention due to their compatibility with commercial roll-to-roll printing technology for the large-scale continuous fabrication process. However, due to the uncontrollable donor/acceptor (D/A) arrangement in thick-film condition, the restricted exciton splitting and severe carrier traps significantly impede the photovoltaic performance and operability. For this work, combined with layer-by-layer deposition technology, a twisted 3D star-shaped trimer (BTT-Out) is synthesized to develop a trimer-induced pre-swelling (TIP) strategy, where the BTT-Out is incorporated into the buried D18 donor layer to enable the fabrication of thick-film OSCs. The integrated approach characterizations reveal that the exceptional configuration and spontaneous self-organization behavior of BTT-Out trimer could pre-swell the D18 network to facilitate the acceptor's infiltration and accelerate the formation of D/A interfaces. This enhancement triggers the elevated polarons formation with amplified hole-transfer kinetics, which is essential for the augmented exciton splitting efficiency. Furthermore, the regulated swelling process can initiate the favorable self-assembly of L8-BO acceptors, which would ameliorate carrier transport channels and mitigate carrier traps. As a result, the TIP-modified thin-film OSC devices achieve the champion performance of 20.3% (thin-film) and 18.8% (thick-film) with upgraded stability, among one of the highest performances reported of thick-film OSCs.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Impact of toroidal magnetic field direction on integrated ELM-stable operation and divertor power exhaust via boron powder injection in EAST

We report the first in-depth comparison of the impact of toroidal magnetic field direction on solid boron injection used for Edge-Localized Mode (ELM) control, power exhaust, and core high-Z impurity control in the Experimental Advanced Superconducting Tokamak. With favorable ion ∇B drift towards the upper X-point in an upper-single-null configuration, boron injection effectively suppresses ELMs, produces a detachment of the inner divertor target, and leads to improved energy confinement. ELM suppression in this configuration is accompanied by the excitation of an Edge Harmonic Mode. In contrast, with unfavorable ion ∇B drift away from the upper X-point, boron injection also suppresses ELMs but leads to a more symmetric detachment state of both the inner and outer divertor targets, while plasma energy confinement is slightly degraded despite similar boron injection levels; a different low-frequency coherent mode without multiple harmonics is observed. Measurements from toroidally separated views show that the divertor response to boron injection is essentially toroidally symmetric, supporting the use of two-dimensional SOLPS-ITER modeling with a toroidally uniform impurity source. These experimental observations are qualitatively consistent with SOLPS-ITER simulations, which highlight the critical role of E × B drift effects in setting the Bt-dependent in–out asymmetry of detachment and in asymmetrically transporting particles and injected impurities within the scrape-off layer and private-flux region. These findings underscore the importance of drift physics and real-time wall conditioning in controlling low-Z impurity transport and optimizing edge solutions for integrated, ELM-stable, high-performance tokamak operation.

E × B drift↗