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DOE OSTI2025

Forecasting EV Charging Demand on the Distribution System

The U.S. transportation and electricity sectors have historically operated independently, but the growth of electric vehicles (EVs) is driving their convergence. After decades of stagnant demand, utilities must prepare for rising load growth, driven in part by transportation electrification. Utilities must anticipate when and where these new loads will materialize to effectively manage EV growth and maintain grid reliability. This presentation outlines NREL's approach to developing high-resolution EV load datasets for distribution planning, with insights from the Multi-State Transportation Electrification Impact Study on EV and load forecasting, infrastructure requirements, and managed charging strategies.

25 ENERGY STORAGE↗

NASA NTRS1993

An extended laser flash technique for thermal diffusivity measurement of high-temperature materials

Knowledge of thermal diffusivity data for high-temperature materials (solids and liquids) is very important in analyzing a number of processes, among them solidification, crystal growth, and welding. However, reliable thermal diffusivity versus temperature data, particularly those for high-temperature liquids, are still far from complete. The main measurement difficulties are due to the presence of convection and the requirement for a container. Fortunately, the availability of levitation techniques has made it possible to solve the containment problem. Based on the feasibility of the levitation technology, a new laser flash technique which is applicable to both levitated liquid and solid samples is being developed. At this point, the analysis for solid samples is near completion and highlights of the technique are presented here. The levitated solid sample which is assumed to be a sphere is subjected to a very short burst of high power radiant energy. The temperature of the irradiated surface area is elevated and a transient heat transfer process takes place within the sample. This containerless process is a two-dimensional unsteady heat conduction problem. Due to the nonlinearity of the radiative plus convective boundary condition, an analytic solution cannot be obtained. Two options are available at this point. Firstly, the radiation boundary condition can be linearized, which then accommodates a closed-form analytic solution. Comparison of the analytic curves for the temperature rise at different points to the experimentally-measured values will then provide the thermal diffusivity values. Secondly, one may set up an inverse conduction problem whereby experimentally obtained surface temperature history is used as the boundary conditions. The thermal diffusivity can then be elevated by minimizing the difference between the real heat flux boundary condition (radiation plus convection) and the measurements. Status of an experimental study directed at measuring the thermal diffusivity of high-temperature solid samples of pure Nickel and Inconel 718 superalloys are presented. Preliminary measurements showing surface temperature histories are discussed.

Shen, F.↗

NASA NTRSDate not supplied

Demonstration of in-Situ Resource Utilization of Lunar Regolith for Plant Growing Systems Through Scaled Capillary Models

The development of reliable and bioregenerative crop growth production systems is vital for human exploration into deep space. As the National Aeronautics and Space Administration (NASA) prepares for the Artemis missions, scientists need to find a way to provide consistent and sufficient water delivery for all stages of a plant’s life cycle. NASA has been able to successfully model passive flow through felt material, to mimic the water uptake and transport through a plant, in microgravity. However, more studies need to be conducted to adapt the model for a substrate-based system and incorporate how flow will change during each stage of plant growth. For future missions, payload requirements to support crop production systems will need to be limited, leading to the use of available resources, such as lunar regolith. Although numerous lunar regolith simulants are commercially available, few have been evaluated for their suitability in agricultural applications. First, a base regolith simulant will need to be identified based on its physical and chemical properties. Then, additional amendments to improve the properties of the simulants to support plant growth will be identified. The design and composition of the substrate will be based on water transport requirements for different stages of plant growth. Scaled capillary models can be utilized to study surface-tension driven flows through various designer substrates to modify the physical properties of the selected regolith simulant. These models can accurately represent how flow will act in a reduced gravity environment, which can be used to design a full-scale facility for surface missions. This project will aid space researchers in the design of future crop production systems for surface missions by creating a refined model that can be used at all stages of plant growth and utilize in situ resources.

Fluids↗

DOE OSTI2025

NREL is Delivering Integrated Solutions for an Affordable and Secure Energy Future

The National Renewable Energy Laboratory (NREL) is the U.S. Department of Energy's primary national laboratory for energy systems research and development. As the energy systems laboratory, NREL's unique strength lies in developing and integrating a broad array of energy technologies into robust, resilient systems - bridging foundational research with practical applications to lower energy costs, drive economic growth, bolster national security, and deliver abundant and reliable energy.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS2001

Silicon Carbide Electronic Devices

The status of emerging silicon carbide (SiC) widebandgap semiconductor electronics technology is briefly surveyed. SiC-based electronic devices and circuits are being developed for use in high-temperature, high-power, and/or high-radiation conditions under which conventional semiconductors cannot function. Projected performance benefits of SiC electronics are briefly illustrated for several applications. However, most of these operational benefits of SiC have yet to be realized in actual systems, primarily owing to the fact that the growth techniques of SiC crystals are relatively immature and device fabrication technologies are not yet sufficiently developed to the degree required for widespread, reliable commercial use. Key crystal growth and device fabrication issues that limit the performance and capability of high-temperature and/or high-power SiC electronics are identified. The electrical and material quality differences between emerging SiC and mature silicon electronics technology are highlighted.

Neudeck, P. G.↗

NASA NTRS2009

Use of Raman Spectroscopy and Delta Volume Growth from Void Collapse to Assess Overwrap Stress Gradients Compromising the Reliability of Large Kevlar/Epoxy COPVs

Composite Overwrapped Pressure Vessels (COPVs) are frequently used for storing pressurized gases aboard spacecraft and aircraft when weight saving is desirable compared to all-metal versions. Failure mechanisms in fibrous COPVs and variability in lifetime can be very different from their metallic counterparts; in the former, catastrophic stress-rupture can occur with virtually no warning, whereas in latter, a leak before burst design philosophy can be implemented. Qualification and certification typically requires only one burst test on a production sample (possibly after several pressure cycles) and the vessel need only meet a design burst strength (the maximum operating pressure divided by a knockdown factor). Typically there is no requirement to assess variability in burst strength or lifetime, much less determine production and materials processing parameters important to control of such variability. Characterizing such variability and its source is crucial to models for calculating required reliability over a given lifetime (e.g. R = 0.9999 for 15 years). In this paper we present a case study of how lack of control of certain process parameters in COPV manufacturing can result in variations among vessels and between production runs that can greatly increase uncertainty and reduce reliability. The vessels considered are 40-inch ( NASA Glenn Research center, Cleveland, OH, 44135 29,500 in3 ) spherical COPVs with a 0.74 in. thick Kevlar49/epoxy overwrap and with a titanium liner of which 34 were originally produced. Two burst tests were eventually performed that unexpectedly differed by almost 5%, and were 10% lower than anticipated from burst tests on 26-inch sister vessels similar in every detail. A major observation from measurements made during proof testing (autofrettage) of the 40-inch vessels was that permanent volume growth from liner yielding varied by a factor of more than two (150 in3 to 360 in3 ), which suggests large differences in the residual stress gradient through their overwraps. This resulted in large uncertainty in true fiber stress ratio (fiber stress at operating pressure divided by fiber stress at burst) which governs lifetime. The vessels were originally designed with tight safety margins, so it became crucial to develop a non-destructive evaluation (NDE) technique to directly measure the overwrap residual stress state of each vessel, and to identify those vessels at highest risk of having poor reliability. This paper describes a Raman Spectroscopy technique for measuring certain patterns of fluctuation in fiber elastic strains over the outside vessel surface (where all but one wrap is exposed at certain locations) that are shown to directly correlate to increased fiber stress ratios and reduced reliability.

Kezirian, Michael T.↗

NASA NTRS1994

Damage Mechanisms and Controlled Crack Propagation in a Hot Pressed Silicon Nitride Ceramic

The subcritical growth of cracks from pre-existing flaws in ceramics can severely affect the structural reliability of a material. The ability to directly observe subcritical crack growth and rigorously analyze its influence on fracture behavior is important for an accurate assessment of material performance. A Mode I fracture specimen and loading method has been developed which permits the observation of stable, subcritical crack extension in monolithic and toughened ceramics. The test specimen and procedure has demonstrated its ability to generate and stably propagate sharp, through-thickness cracks in brittle high modulus materials. Crack growth for an aluminum oxide ceramic was observed to be continuously stable throughout testing. Conversely, the fracture behavior of a silicon nitride ceramic exhibited crack growth as a series of subcritical extensions which are interrupted by dynamic propagation. Dynamic initiation and arrest fracture resistance measurements for the silicon nitride averaged 67 and 48 J/sq m, respectively. The dynamic initiation event was observed to be sudden and explosive. Increments of subcritical crack growth contributed to a 40 percent increase in fracture resistance before dynamic initiation. Subcritical crack growth visibly marked the fracture surface with an increase in surface roughness. Increments of subcritical crack growth loosen ceramic material near the fracture surface and the fracture debris is easily removed by a replication technique. Fracture debris is viewed as evidence that both crack bridging and subsurface microcracking may be some of the mechanisms contributing to the increase in fracture resistance. A Statistical Fracture Mechanics model specifically developed to address subcritical crack growth and fracture reliability is used together with a damaged zone of material at the crack tip to model experimental results. A Monte Carlo simulation of the actual experiments was used to establish a set of modeling input parameters. It was demonstrated that a single critical parameter does not characterize the conditions required for dynamic initiation. Experimental measurements for critical crack lengths, and the energy release rates exhibit significant scatter. The resulting output of the model produces good agreement with both the average values and scatter of experimental measurements.

Calomino, Anthony Martin↗

DOE OSTI2026

A Methodology to Evaluate the Grid Reliability Impact of Oscillations Induced by Large Loads

The rapid growth of hyperscale AI data centers is bringing renewed attention to the reliability risk that sustained forced oscillations pose to bulk power systems, with cyclic computational workloads emerging as a new forcing source. Unlike the broadband, stochastic disturbances from traditional industrial loads such as arc furnaces, AI training and inference facilities can inject large active power swings concentrated at specific frequencies over extended durations - characteristics that existing grid planning practices do not account for. While the North American Electric Reliability Corporation (NERC) has recognized this gap and called for system-level studies of large load interconnections, no standardized methodology exists to screen, simulate, and quantify these risks at the planning stage. This report presents the Risk Assessment Tool for Large Load-induced Events (RATLLE), a Python-based, publicly available script suite developed at the Pacific Northwest National Laboratory to evaluate bulk power system reliability risks from data center-induced oscillations. RATLLE implements a three-module workflow: a screening module that identifies vulnerable interconnection locations and excitable system modes; a simulation module that models cyclic data center load behavior using a commercial positive sequence simulation platform; and an analysis module that computes risk metrics and generates interactive visualization dashboards. The risk metrics, formulated around simulation observables, map oscillation impacts to a three-stage severity scale spanning latent equipment fatigue through imminent cascading failure. The methodology is demonstrated on two Western Electricity Coordinating Council (WECC) system models: a publicly available 240-bus reduced representation and a detailed 2031 Heavy Winter planning case. Case studies illustrate that even modest 50 MW forced oscillations at resonant frequencies can produce wide-area power swings, N-1 security constraint violations, and cascading generator trips through protection actions - outcomes that would not occur under normal operating conditions without oscillations present. The results underscore the need for standardized oscillation impact assessment in large load interconnection studies and provide a reproducible, extensible framework for utilities to adopt or customize within their existing planning workflows.

Biswas, Shuchismita↗

DOE OSTI2024

CONSTRAINT-INDEPENDENT CONSTANT CTOA DETERMINATION FOR DUCTILE STABLE CRACK GROWTH

Crack tip opening angle (CTOA) has been used as a reliable fracture toughness parameter for decades to characterize stable ductile crack growth for thin-walled aerospace structures in the low-constraint conditions. Recently, the CTOA parameter was also applied to the pipeline industry, and a CTOA test standard ASTM E3039 was thus developed for testing a critical constant CTOA. Research showed that the constant CTOA can reasonably describe fracture toughness required to arrest a dynamic crack propagation for a modern gas pipeline. However, the CTOA fracture criterion requires constraint-independent CTOA toughness against stable ductile crack growth. ASTM E3039 recommends a drop weight tearing test (DWTT) specimen for CTOA testing. Since a shallow crack is used, DWTT measured CTOA may depend on constraint level at the crack tip. To understand if it is the case, this paper evaluates the critical CTOA for a set of fracture toughness tests on single edge notched bend (SENB) specimens with shallow and deep cracks based on four CTOA estimation models. In which, the Ln(P)-LLD linear fit model is similar to that used by ASTM E3039 in the CTOA calculation. Fracture test data for X80 pipeline steel and HY80 structural steel are considered in the CTOA evaluation. The results show that the four CTOA models can determine a crack size-independent constant CTOA over stable ductile crack growth for the SENB specimens. As a result, CTOA determined by ASTM E3039 is constraintindependent and transferable to use for an actual crack propagating in a gas pipeline.

Zhu, Xian-Kui↗

NASA NTRS2002

Macromolecular Crystal Growth by Means of Microfluidics

We have performed a feasibility study in which we show that chip-based, microfluidic (LabChip(TM)) technology is suitable for protein crystal growth. This technology allows for accurate and reliable dispensing and mixing of very small volumes while minimizing bubble formation in the crystallization mixture. The amount of (protein) solution remaining after completion of an experiment is minimal, which makes this technique efficient and attractive for use with proteins, which are difficult or expensive to obtain. The nature of LabChip(TM) technology renders it highly amenable to automation. Protein crystals obtained in our initial feasibility studies were of excellent quality as determined by X-ray diffraction. Subsequent to the feasibility study, we designed and produced the first LabChip(TM) device specifically for protein crystallization in batch mode. It can reliably dispense and mix from a range of solution constituents into two independent growth wells. We are currently testing this design to prove its efficacy for protein crystallization optimization experiments. In the near future we will expand our design to incorporate up to 10 growth wells per LabChip(TM) device. Upon completion, additional crystallization techniques such as vapor diffusion and liquid-liquid diffusion will be accommodated. Macromolecular crystallization using microfluidic technology is envisioned as a fully automated system, which will use the 'tele-science' concept of remote operation and will be developed into a research facility for the International Space Station as well as on the ground.

vanderWoerd, Mark↗

NASA NTRS1979

Large Area Silicon Sheet by EFG

Influences on ribbon quality which might be caused by various materials of construction which are used in the growth furnace were assessed. At the present level of ribbon quality, which has produced 8.5% to 9.5% efficient solar cells, no particular influence of any furnace part was detected. The experiments led to the suspicion that the general environment and the somewhat unoptimized materials handling procedures might be responsible for the current variations in ribbon quality and that, therefore, continuous work with this furnace under rather more stringent environmental conditions and operating procedures could perhaps improve materials quality to some extent. The work on the multiple furnace was continued with two multiple growth runs being performed. In these runs, the melt replenishment system performed poorly and extensive modifications to it were designed to make reliable melt feeding for five ribbon growth possible. Additional characterization techniques for wide ribbons, stress measurements, and growth dynamics experiments are reported.

Source record↗

NASA NTRS1976

Alternative strategies for implementing silicon-ribbon technology for photovoltaic applications

Interactive computer models are being designed to support the development of technological and economic data required to define the potential of silicon sheet growth for large scale photovoltaic applications. Technology projection and sensitivity analysis suggest that single-ribbon growth systems offer the best potential for achieving low-cost silicon sheet material within the shortest period of time. Such systems must be highly reliable, be capable of near unattended growth, and feature automatic melt replenishment. Processing-technology improvement, such as the following, are the key elements for reducing the cost of silicon sheet material: (i) increasing ribbon width; (ii) speeding up the growth rate; and (iii) decreasing ribbon thickness. Such tasks should be pursued in that order to minimize sheet material cost. One interesting finding is that significant reductions in sheet material cost are achievable in the near future by increasing ribbon width to 5 cm.

Kran, A.↗

NASA NTRS2004

Flexible Microsensor Array for the Root Zone Monitoring of Porous Tube Plant Growth System

Control of oxygen and water in the root zone is vital to support plant growth in the microgravity environment. The ability to control these sometimes opposing parameters in the root zone is dependent upon the availability of sensors to detect these elements and provide feedback for control systems. In the present study we demonstrate the feasibility of using microsensor arrays on a flexible substrate for dissolved oxygen detection, and a 4-point impedance microprobe for surface wetness detection on the surface of a porous tube (PT) nutrient delivery system. The oxygen microsensor reported surface oxygen concentrations that correlated with the oxygen concentrations of the solution inside the PT when operated at positive pressures. At negative pressures the microsensor shows convergence to zero saturation (2.2 micro mol/L) values due to inadequate water film formation on porous tube surface. The 4-point microprobe is useful as a wetness detector as it provides a clear differentiation between dry and wet surfaces. The unique features of the dissolved oxygen microsensor array and 4-point microprobe include small and simple design, flexibility and multipoint sensing. The demonstrated technology is anticipated to provide low cost, and highly reliable sensor feedback monitoring plant growth nutrient delivery system in both terrestrial and microgravity environments.

Sathyan, Sandeep↗

NASA NTRS2017

Crack Growth Testing of an Aluminum Oxynitride (AlON) for International Space Station Kick Panes

The mechanical properties of an aluminum oxynitride supplied as ground beams and disks were measured using ASTM International (formerly American Society for Testing and Materials) standard test methods. The slow crack growth tests were complicated by a "short" finish that increased strength scatter. Refining of the finish by more material removal in the second stage of grinding or the use of uniaxial grinding as specified in ASTM C1499 might have avoided the issue. The structural design parameters are an elastic modulus of E = 319 GPa, Poisson's ratio of v = 0.26, a fracture toughness of KIvb(A) = 2.18 MPa/m, slow crack growth (SCG) parameter n = 36, and SCG parameter A = 1.96 x 10-11 m/s.(MPa/m)n. For a ground finish, the Weibull parameters are a mean modulus of m = 14.0 and characteristic strength of sigma theta = 250.2 MPa. The 2015 vintage material exhibits similar mechanical properties to a 2010 vintage billet. Indentation flaws were not sensitive to the inherent crack growth mechanisms of this material and produced misleading results.

strength↗

DOE OSTI2025

Mechanism of shape symmetry breaking in surfactant-mediated crystal growth

We present a dynamical model of crystal growth, in which it is possible to reliably achieve asymmetric products, beginning from symmetric initial conditions and growing within an isotropic environment. The asymmetric growth is the result of a positive feedback mechanism that amplifies the effect of thermal fluctuations in the coverage of surfactants on the growing crystalline facets. Within our simple model, we are able to understand the kinetic and thermodynamic factors involved in both the onset of symmetry breaking and the persistence of anisotropic growth. We demonstrate that the mechanism is general by studying models with increasing complexity. We argue that this mechanism of symmetry breaking underpins observations of colloidal, seed-mediated syntheses of single crystalline metal nanorods capped with strongly interacting surfactants. The parameters within our model are related to experimental observables such as the concentration, hydrophobicity, and binding strength of the surfactants, which suggests a potential route to optimize the yield of asymmetric products in colloidal nanoparticle syntheses.

Oaks-Leaf, Sam↗

NASA NTRS2012

Evaluation of Delamination Growth Characterization Methods Under Mode I Fatigue Loading

Reliable delamination characterization data for laminated composites are needed for input to analytical models of structures to predict delamination. The double-cantilevered beam (DCB) specimen is used with laminated composites to measure fracture toughness, G(sub Ic), delamination onset strain energy release rate, and growth rate data under cyclic loading. In the current study, DCB specimens of IM7/8552 graphite/epoxy supplied by two different manufacturers were tested in static and fatigue to compare the measured characterization data from the two sources, and to evaluate a proposed ASTM standard for generating Paris Law equations. Static results were used to generate compliance calibration constants for the fatigue data, and a delamination resistance curve, G(sub IR), which was used to determine the effects of fiber-bridging on delamination growth. Specimens were tested in fatigue at a cyclic G(sub Imax) level equal to 50, 40 or 30% of G(sub Ic), to determine a delamination onset curve and delamination growth rate. The delamination onset curve equations had similar exponents and the same trends. Delamination growth rate was calculated by fitting a Paris Law to the da/dN versus G(sub Imax) data. Both a 2-point and a 7-point data reduction method were used and the Paris Law equations were compared. To determine the effects of fiber-bridging, growth rate results were normalized by the delamination resistance curve for each material and compared to the non-normalized results. Paris Law exponents were found to decrease by 31% to 37% due to normalizing the growth data. Normalizing the data also greatly reduced the amount of scatter between the different specimens. Visual data records from the fatigue testing were used to calculate individual compliance calibration constants from the fatigue data for some of the specimens. The resulting da/dN versus G(sub Imax) plots showed much improved repeatability between specimens. Gretchen

Murri, Gretchen B.↗

NASA NTRS1981

Selection of a pump-fed propulsion system for planetary exploration missions

A study has been conducted to select the most desirable pump-fed propellant feed system approach for planetary spacecraft. Four systems, including two battery powered and two gas generator driven systems, were considered. Complete propulsion system schematics were developed, including preliminary detailed design of both the electric motor and the gas turbine pump drives. Utilizing a Figure-of-Merit system which included consideration for reliability, development risk, complexity and growth potential as well as weight, the advanced battery powered electric motor drive system was selected for continued development at JPL.

Auslander, T. W.↗

NASA NTRS1985

Thermal management system options for high power space platforms

Thermal Management System (TMS) design options for a high power (75kWe), low earth orbit, multimodule space platform were investigated. The approach taken was to establish a baseline TMS representative of current technology, and to make incremental improvements through successive subsystem trades that lead to a candidate TMS. The TMS trades included centralized and decentralized transport, single-phase and two-phase transport, alternate working fluids, liquid loop and heat pipe radiators, deployed fixed, body mounted and steerable radiators, and thermal storage. The subsystem options were evaluated against criteria such as weight, TMS power requirement, reliability, system isothermality penalty, and growth potential.

Sadunas, J. A.↗