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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

Linac to BAR/RCS transfer line design for EIC electron injection system

A transfer line has been designed for the Electron-Ion Collider (EIC) to transport electron bunches from the linac to the Rapid Cycling Synchrotron (RCS). In its initial operational stage, the line accommodates 1 nC electron bunches directly from the linac. To support a future upgrade involving a Beam Accumulator Ring (BAR), which will stack individual bunches to form high-charge 28 nC bunches, the design incorporates two switching dipoles enabling injection into and extraction from the BAR. Additionally, a beam dump has been included for operational flexibility and safety. The final segment of the line interfaces with the RCS through a modified Penner bend, preserving beam quality while satisfying geometric constraints. This layout ensures compatibility with both current and future operational modes of the EIC injection system.

Accelerator Physics↗
DOE OSTI2025

PDF Entity Annotation Tool (PEAT)

While different text mining approaches – including the use of Artificial Intelligence (AI) and other machine based methods - continue to expand at a rapid pace, the tools used by researchers to create the labeled datasets required for training, modeling, and evaluation remain rudimentary. Labeled datasets contain the target attributes the machine is going to learn; for example, training an algorithm to delineate between images of a car or truck would generally require a set of images with a quantitative description of the underlying features of each vehicle type. Development of labeled textual data that can be used to build natural language machine learning models for scientific literature is not currently integrated into existing manual workflows used by domain experts. Published literature is rich with important information, such as different types of embedded text, plots, and tables that can all be used as inputs to train ML/natural language processing (NLP) models, when extracted and prepared in machine readable formats. Currently, both normalized data extraction of use to domain experts and extraction to support development of ML/NLP models are labor intensive and cumbersome manual processes. Automatic extraction of data and information from formats such as PDFs that are optimized for layout and human readability, not machine readability. The PDF (Portable Document Format) Entity Annotation Tool (PEAT) was developed with the goal of allowing users to annotate publications within their current print format, while also allowing those annotations to be captured in a machine-readable format. One of the main issues with traditional annotation tools is that they require transforming the PDF into plain text to facilitate the annotation process. While doing so lessens the technical challenges of annotating data, the user loses all structure and provenance that was inherent in the underlying PDF. Also, textual data extraction from PDFs can be an error prone process. Challenges include identifying sequential blocks of text and a multitude of document formats (multiple columns, font encodings, etc.). As a result of these challenges, using existing tools for development of NLP/ML models directly from PDFs is difficult because the generated outputs are not interoperable. We created a system that allows annotations to be completed on the original PDF document structure, with no plain text extraction. The result is an application that allows for easier and more accurate annotations. In addition, by including a feature that grants the user the ability to easily create a schema, we have developed a system that can be used to annotate text for different domain-centric schemas of relevance to subject matter experts. Different knowledge domains require distinct schemas and annotation tags to support machine learning.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

STATUS OF THE SECOND INTERACTION REGION DESIGN FOR ELECTRON-ION COLLIDER

Provisions are being made in the Electron Ion Collider (EIC) design for future installation of a second Interaction Region (IR), in addition to the day-one primary IR. The envisioned location for the second IR is the existing experi- mental hall at RHIC IP8. It is designed to work with the same beam energy combinations as the first IR, covering a full range of the center-of-mass energy of ?20 GeV to ?140 GeV. The goal of the second IR is to complement the first IR, and to improve the detection of scattered particles with magnetic rigidities similar to those of the ion beam. To achieve this, the second IR hadron beamline features a secondary focus in the forward ion direction. The design of the second IR is still evolving. This paper reports the current status of its pa- rameters, magnet layout, and beam dynamics and discusses the ongoing improvements being made to ensure its optimal performance.

Gamage, B.↗
DOE OSTI2024

Retrofittable Advanced Combined Cycle Integration for Flexible Decarbonized Generation

This is the final scientific / technical report for Front End Engineering Design (FEED) study “Retrofittable Advanced Combined Cycle Integration for Flexible Decarbonized Generation” funded by the US Department of Energy (DOE), Office of Fossil Energy and Carbon Management (FECM), Carbon Capture R&D Program under award DE-FE0032131. The prime recipient is General Electric Company working through its Gas Power division (GEGP) with subrecipients Southern Company and Linde Engineering plus subcontractor Kiewit. Southern Company’s Plant Barry, a 2x1 7F.04 CCGT, is the host site. GEGP led the overall integration of the carbon capture system (CCS) with the existing natural gas combined cycle (NGCC) facility. Linde provided the detailed process engineering and equipment costing for the carbon capture island. Kiewit focused on plant layout, constructability, and installation. With the FEED study finished, the engineering is approximately 50% complete towards the detailed design package needed to proceed to procure, install, build, commission, and operate the integrated NGCC+CCS facility. This FEED study focuses on retrofitting a 95% CO 2 capture system with attention on plant integration. The study was particularly challenging due to unique and substantial cost impacts related to global sourcing challenges associated with COVID. Additional incentives, regulatory support, and dispatch certainty are needed to move forward with implementing CCS at this or other sites in the US. This FEED study highlights the value of integrating NGCC+CCS and is a template for future CCS retrofit studies.

42 ENGINEERING↗
DOE OSTI2024

The IEA Wind Task 49 Reference Floating Wind Array Design Basis

International Energy Agency Wind Technology Collaboration Programme (IEA Wind) Task 49 on Integrated Design of Floating Wind Arrays is an international collaboration aiming to advance the development of large-scale floating wind farms by providing open-access resources to the research and development and planning communities. The work of Task 49 focuses on array-level challenges related to the colocation of many floating wind turbines; their layouts, mooring systems, and cabling systems; failure risks; logistical considerations; marine spatial planning needs; and future research needs and innovation directions. This report provides a general design basis for the development of reference floating wind farm designs. These reference array designs will extend the scope of existing reference floating wind turbine designs to facilitate research on array-level floating wind technology challenges and innovations. The design basis promotes coordination and consistency in developing the reference array designs.

17 WIND ENERGY↗
DOE OSTI2024

Overview and Status of the Long-Baseline Neutrino Facility Far Detectors Cryogenics System

The Sanford Underground Research Facility (SURF) will host the Far Detectors of the Deep Underground Neutrino Experiment (DUNE), an international multi-kiloton Long-Baseline neutrino experiment that will be installed about a mile underground in Lead, SD. Detectors will be located inside four cryostats filled with almost 70,000 metric tons of ultrapure liquid argon, with a level of impurities lower than 100 parts per trillion of oxygen equivalent. The cryogenics infrastructure supporting this experiment is provided by the Long- Baseline Neutrino Facility (LBNF). This contribution presents modes of operation, layout and main features of the LBNF Far Detectors cryogenics system, which is composed of the following subsystems: argon receiving facilities, nitrogen system, argon distribution system, argon purification and regeneration systems, argon circulation system, argon condensers system, internal cryogenics, miscellaneous items, and process controls. An international engin eering tea m is designing these systems and will manufacture, install, test, commission, and qualify them. This contribution describes the main features, performance, functional requirements, and modes of operation of the LBNF Far Detectors cryogenics system. It also presents the status of the design, along with present and future needs to support the DUNE experiment.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Carbon Storage Planning Inquiry Tool (CS PlanIT)

The CS PlanIT provides stakeholders with easy access to geographically explore, query, and evaluate multiple data layers for a user-defined area of interest, with the goal to accelerate carbon storage resource, feasibility assessments, and planning efforts. The data within CS PlanIT are arranged and categorized to assess each stage of the Carbon Capture and Storage supply chain, from CO2 (Carbon Dioxide) emission sources, critical energy infrastructure (including transport), to CO2 geologic storage and sink locations. Furthermore, stakeholders can gain insights into community and environmental impacts, as CS PlanIT leverages Environmental Justice and Social Justice (EJSJ) and natural hazard datasets. Additionally, documentation in the form of an interactive ArcGIS story map and data catalog are included within the EDX publication to provide user’s information to better understand and explain CS PlanIT’s layout, functions, and associated data sets.

Justman, Devin M.↗
DOE OSTI2024

Technoeconomic Evaluation of Microreactor Using Detailed Bottom-up Estimate (Rev.1)

Microreactors are a novel class of nuclear reactors that are expected to be factory produced, transportable, and self-regulating. They are expected to be several orders of magnitude smaller in size than traditional reactors (with power outputs in the 1–20 MWe range typically). They are primarily envisaged to target niche, remote markets that are difficult to access and where energy costs are high. There has been a scarcity of technoeconomic assessment for these types of reactors due to the scarcity of designs without proprietary restraints (e.g., those that include balance of plants and building layouts) and cost estimates. The primary objective of this report was to develop a transparent, detailed, bottom-up cost estimate for a microreactor. While there is a high degree of uncertainty associated with the projected costs, this work provides a foundation that can built upon and improved to better model the economics of microreactors. The Microreactor Applications Research, Validation, and Evaluation (MARVEL) microreactor was selected for this analysis. This Department of Energy–sponsored demonstration was chosen because (1) its final design was recently completed and (2) a detailed class-3 cost-and-schedule estimation was conducted for it. This provided a strong technical basis for further analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Cyber-Physical System: Design for Sustainability and Resilience

When considering the design tools needed in the transition from numeric models to pilot plant, cyber-physical systems (CPS) come to the forefront as a method to model complex integrated energy systems. CPS approach has proven to be valuable to identify opportunities for economically viable early adoption of integrated energy technologies. This tutorial will introduce the concepts and the roles of CPS in co-design to minimize risks for pilot plant and technology deployment. This tutorial will also layout basic requirements for the CPS development, which requires a highly interdisciplinary effort with expertise in sensors, hardware testing, real-time modeling, controls, and system integration.

Harun, Nor Farida↗
DOE OSTI2024

Modeling Communication Infrastructures of Cyber Physical Systems

This effort explores modeling cyber infrastructure, including communication devices like switches, routers, sensors, and controllers, and physical media attributes like propagation of radio signals, in coordination with power distribution system model layouts. To do this, the project studies real-world configurations to define axioms of how different communication media is deployed with control equipment. These axioms will be used to develop tools to generate realistic cyber infrastructure models from starting power system models. This effort leverages and builds on the co-simulation platform developed by the other RD2C projects. The axioms and tools will be validated and demonstrated with the NS3 simulation tool as part of a co-simulation to show the behavior/impacts of cyber infrastructure on control operations.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Advancing Development of Emissions Detection (Final Report)

This document is the final report to the U.S. Department of Energy (DOE for contract DE-FE0031873) awarded to Colorado State University (CSU). CSU and partners at Harrisburg University of Science and Technology, University of Texas Arlington, and University of Texas at Austin organized several testing rounds to provide knowledge focused on advancing the detection capabilities of emissions monitoring devices. With this funding opportunity the research group began by establishing the Advancing the Development of Emission Detection (ADED) program, with the goal focused on enhancing the accuracy, reliability, and field applicability of methane detection technologies. This effort aimed to address the critical challenges of identifying and quantifying methane emissions while enabling industry stakeholders to meet regulatory compliance and environmental sustainability goals. The program engaged with industry, government, and technology stakeholders to promote adoption and consensus on testing techniques for methane detection solutions. Methane, a potent greenhouse gas, contributes significantly to global warming, and the oil and natural gas (O&G) sector is a primary source of methane emissions. Regulatory measures such as leak detection and repair (LDAR) programs have been implemented to address emissions. However, traditional LDAR approaches, reliant on handheld and component-level measurements, are resource-intensive. To address these limitations and move with evolving regulations, advanced methane technologies are emerging. These solutions include ground-based sensors, mobile systems (e.g., drones, vehicles, and aircraft), and satellite-based platforms. They offer innovative capabilities for autonomous monitoring, larger spatial coverage, and emission quantification using methods such as tracer gas techniques and inverse modeling with Gaussian plume analysis. The ADED program began with creating protocols for methane controlled release (CR) testing these continuous monitoring (CM) and survey technologies that detect and monitor methane emissions at O&G facilities. The protocols were then implemented throughout testing of CM and survey devices at CSU’s Methane Emissions Technology Evaluation Center (METEC) facility from 2021 through 2024. As apart of the protocol, solutions that tested under the ADED program installed their solutions at METEC, documented their system under test, and provided detection reports to the METEC team for analysis. The METEC team would provide the solutions with analyzed reports of their emissions and ground truth data of the releases conducted during their testing session. Under the ADED program, CMs were also tested at O&G facilities for a six week test run of challenge release (ChR) releases. The findings from the ADED program underscore the critical role of collaborative research and innovation in tackling methane emissions, offering a pathway for the oil and gas sector to achieve significant environmental and economic benefits. Results from METEC testing saw improvement of performance and accuracy across all solutions over the extent of the ADED experiments. The results also showed a variance in CM solution performance between CRs and ChRs. That variance pushed the team to further analyze the differences between CR testing environments and field conditions. With the drive from regulations and that variance in field conditions, the ADED team began designing a new CR testing protocol and additions to the METEC testing facility. The METEC team is furthering the progress made through the ADED program with awarded funding from DE-FE0032276. This funding pushes the development of METEC’s addition with new equipment, allowing for an updated facility layout. METEC still facilitates for traditional facilities, with a legacy pad, while expanding an new design based on how O&G infrastructure has Final Report - Contract Number: DE-FE0031873 been changed over the last decade. Throughout the ADED program the team has also been working with international partners to ensure staying in the trend globally. International partners have been essential in moving the new protocol forward to implement into CR testing at the METEC facility in Spring 2025.

42 ENGINEERING↗
DOE OSTI2025

Red Hills Storage Hub Feasibility Study - Summary of Milestone 2 - Conceptual Basis of Plants and Pipeline Infrastructure

This document provides the first conceptual-level design of plants and pipeline infrastructure, including maps showing the project location, the potential footprint of the carbon capture and storage plant, the potential site of the capture and compression unit, and the conceptual pipeline layout for transporting the CO2 product from the capture facility to the future potential injection sites.

Carbon Capture and Storage,CarbonSAFE↗
DOE OSTI2024

U.S. Domestic Molten Salt Reactor: Security-by-Design

U.S. nuclear power facilities face increasing challenges in meeting dynamic security requirements caused by evolving and expanding threats while keeping costs reasonable to make nuclear energy competitive. The past approach has often included implementing security features after a facility has been designed and without attention to optimization, which can lead to cost overruns. Incorporating security in the design process can provide robust, economical, and effective physical protection systems (PPS). The purpose of this work is both to develop a framework for the integration of security into the design phase of a molten salt reactor (MSR) and show how to effectively design a PPS with a reduced staffing headcount. Specifically, this work focuses on integrating PPS design features into a developed facility layout by making minor modifications to building structures. A suite of tools, including Scribe3D©, PathTrace©, and Blender©, were used to model a hypothetical, generic domestic MSR facility. Physical protection elements such as sensors, cameras, barriers, and responders were added into the model based on defending the hypothetical MSR facility against a hypothetical design basis threat (DBT). Multiple outsider sabotage scenarios were examined, with adversary team sizes ranging from 4–8 to determine security system effectiveness. The results of this work will influence PPS designs and facility designs for U.S. domestic MSRs. This work will also demonstrate how a series of experimental and modeling capabilities across the Department of Energy (DOE) complex can impact the design and completion of security-by-design (SeBD) for small modular reactors (SMRs). The conclusions and recommendations in this document may be applicable to all SMR designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Critical Component/Technology Gap in 21 st Century Power Plant Gasification Based Polygeneration: Advanced Ceramic Membranes/Modules for Ultra Efficient Hydrogen (H 2 ) Production/Carbon Dioxide (CO 2 ) Capture for Coal-Based Polygeneration

The 21 st Century Power Plant Gasification Based Polygeneration power plant layout is a relatively straightforward retrofit of well-established ammonia synthesis technology to the baseline IGCC process and envisions co-production of power and chemicals from coal in the context of carbon capture. A Dual Stage Membrane Process (DSMP) for pre-combustion CO 2 capture in a coal fired IGCC power plant has been demonstrated by Media and Process Technology Inc (MPT) (DE-FE0013064) in bench-scale live gas testing at the NCCC. This work, however, highlighted the importance of permeate purge capability to deliver deep H 2 recovery at moderate pressures and high carbon capture performance. Further, in the area of warm gas processing, a permeate purgeable membrane support for a wide range of inorganic high-performance membrane materials (CMS, Pd-alloy, zeolite, ZIF, graphene, etc.) was not available and hence had been a common and significant barrier to their commercialization. Hence, the Critical Technology Gap to implementing the DSMP in the Polygeneration power plant and more broadly in advanced warm gas separation applications was the inability to permeate purge the membranes coupled with the lack of the availability of a high packing density scalable package design. To overcome this Critical Technology Gap, in this project, the primary objective was the development of a permeate purgeable full ceramic support for these high-performance inorganic membranes and the complementary high packing density housing. Our goal and approach were to extend our “candle filter” design to a “dual end open” package to enable permeate purge and scalability. Microporous ceramic membranes have been proven to be a low cost, stable material for high temperature applications under harsh environment. They are the leading support choice of researchers in advanced inorganic membrane development in applications such as pre-combustion CO 2 capture. The new 2nd Generation “dual end open” bundle developed in this project is a universal support for these existing and emerging inorganic membrane technologies that up to now have lacked a pathway out of the laboratory. The full ceramic permeate purgeable support represents a transformational technology and opens the door to commercialization of these advanced membrane materials in a wide array of mega scale commercial applications in gas (and liquid) processing under aggressive conditions not suited to conventional polymeric membranes.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

SMART SiC Power ICs: Scalable, Manufacturable, and Robust Technology for SiC Power Integrated Circuits (Final Technical Report)

This collaborative project was initiated with the goal of developing Scalable, Manufacturable, and Robust Technology for SiC Power Integrated Circuits (SMART SiC Power ICs). In pursuit of this objective, innovative designs and fabrication processes were implemented, enabling the development of large-scale (>1 cm²) SiC Complementary Metal-Oxide-Semiconductor (CMOS) integrated circuits and high-voltage (400–600 V) lateral power MOSFETs (HV-LDMOS) on 150 mm 4H-SiC substrates. The resulting SMART SiC Power ICs are tailored to support a wide range of applications requiring diverse voltage and power levels, including automotive systems, industrial equipment, electronic data processing, energy harvesting, and power conditioning. To achieve the proposed ‘SMART’ technology for SiC ICs, the team focused on 1) the Development of highly scalable CMOS (with high channel mobilities for n-type and p-type MOSFETs), LDMOS (~600V, 10A rated), and IC technologies, 2) Establishment of a manufacturable process baseline in a production-grade-, 150mm, SiC fabrication facility, and 3) Demonstration of SMART SiC ICs. The project initially comprised of fabricating 5 lots. In lot 1 monolithic integration using a single process was achieved. Here, we were able to successfully accomplish Integrated HV NMOSFET with LV CMOS on N-epi/N+ Substrate. The HV NMOS demonstrated a Breakdown Voltage (BV) more than 600V. Circuit demonstration of CMOS was also another achievement from this lot. In lot 2, priority was in place for isolation and integration. Here we addressed the isolation concerns and integrated the HV NMOS and LV CMOS using the N-epi/P-epi/N+ substrate. Similar to the lot 1, we were able to achieve a BV of 600 V for HV NMOS. Optimized gate oxide process with high channel mobilities, better gate oxide reliability, development of SPICE models, successful ohmic process development, novel wafer area saving design layouts, P+ isolation schemes with channeling implantations and high temperature operational circuits demonstrations are some of the key highlights from lot 1 and lot2. In lot 3, discrete device performances of HV NMOS with a BV ~700V and reliable LV CMOS performances were achieved. Also, novel architectural solutions were successfully implemented to suppress the electric field crowding at the gate oxide for reliable operations. In lot 4, half bridge power driver ICs with a conversion efficiency of (target 90% to 95%) in the 1-5MHz switching frequency range for output power between 25 W to 3 kW have been included in. However, due to the unfortunate events of sudden foundry shutdown (SiCamore Semi) the processing of lot 4 wafers came to a complete stop (January 2024). Arrangements have recently been made to shift the fabrication to another foundry, General Electric Aerospace. The fabrication process now on course (as of December 2024). Characterizations are delayed due to this unfortunate circumstance. The proposed trench architectural-based devices and ICs (lot 5) underwent modifications from the original project proposal. This change was necessitated by limitations in the availability of trench-based processes at commercial production-grade fabrication facilities in the US. Apart from above achievements, a Process Development Kit (PDK) was successfully developed for planar type SiC CMOS/LDMOS.

42 ENGINEERING↗
DOE OSTI2025

Phase-Field Modeling of Damage Evolution in Ceramic Matrix Composite (CMC) and Environmental Barrier Coating (EBC)

Ceramic matrix composites (CMCs) protected by environmental barrier coatings (EBCs) present a promising materials solution for next generation gas turbines. Developments of more robust and efficient EBCs and mechanically tougher CMCs are thus of significant technological importance. Here we develop a phase-field modeling framework that incorporates the thermally grown oxide (TGO), recognized as a critical factor for degradation and failure of EBCs. We simulate crack growth in the TGO and the potential extension into the bond coat / CMC substrate. The model efficiently takes account of the large inelastic deformation induced by the severe volume expansion of TGO, thanks to our recently developed, so-called incremental realization of inelastic deformation (IRID) algorithm. A phase-field model is built for damage evolution in CMCs including crack growth and interfacial sliding. The effects of fiber layout and interfacial sliding on the macroscopic toughness of CMCs are revealed by large-scale simulations and compared to experiments.

advanced energy systems and materials↗
DOE OSTI2025

SESAME: ASCII2 File Format

A new ASCII format for SESAME data is explicitly defined and dubbed ASCII2. This format fixes some of the onerous limitations of the legacy ASCII-styled format in addition to relaxing the FORTRAN style fixed-format layout of data tables. With the exception of the multi-tiered indexes of the legacy binary format, the new ASCII2 is more compatible with the binary in that it does not restrict the extent of various integer data (e.g., SESAME material and table numbers) to six digits nor does it restrict the extent or precision of the various floating point data. There will be very limited support of the legacy ASCII-styled formats in the future.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Multi-physics Topology OPtimization and Additive Manufacturing for High-temperature Heat Exchangers

This research significantly advances the understanding of high-temperature heat exchanger design through an integrated approach that combines topology optimization (TO), triply periodic minimal surface (TPMS) structures, additive manufacturing (AM) and thermohydraulic testing. Each of these components contributes uniquely to a unified, high-performance design, fabrication and testing workflow. Topology optimization serves as the foundation of the design methodology by providing a systematic way to determine the most effective material layout for separating hot and cold fluids while maximizing thermal performance. The researchers introduced a novel three-material optimization framework using two density fields to represent hot fluid, cold fluid, and solid domains. This approach enables automated discovery of optimal shapes and flow paths that cannot be intuitively designed, especially under constraints imposed by manufacturing technologies. Furthermore, constraints such as minimal wall thickness and overhang angles were embedded into the optimization process, ensuring that resulting designs are not only thermally efficient but also manufacturable using modern additive techniques. In parallel, the study delves into the use of Gyroid-based TPMS geometries for constructing the core of the heat exchanger. TPMS structures are known for their high surface area, excellent fluid mixing capabilities, and minimal pressure drop characteristics. The researchers applied a data-driven modeling framework using Heteroscedastic Sparse Gaussian Process Regression (HSGPR) combined with genetic algorithms. This allowed for the rapid evaluation and optimization of key geometric parameters such as frequency, iso-value, and phase shift. The result was a set of Gyroid structures tailored for high heat transfer and low flow resistance, demonstrating clear improvements over conventional straight-channel designs. After the designing process, additive manufacturing played a critical role by turning these highly complex, optimized geometries into physical components. Utilizing Laser Powder Bed Fusion (LPBF) with Haynes 282, the study demonstrated the feasibility of fabricating these heat exchangers at high precision. Post-processing methods, including dilation-erosion operations, were applied to ensure local features adhered to self-supporting constraints. The fabricated structures were then subjected to thermohydraulic testing under conditions representative of supercritical CO 2 Brayton cycles, validating the predicted performance and confirming the viability of the full design-to-fabrication pipeline. Finally, thermohydraulic testing across the above studies served as a crucial experimental validation of advanced heat exchanger. Under consistent high-temperature and high-pressure conditions using supercritical CO 2 , the testing demonstrated that both TO and Gyroid-based TPMS designs significantly outperformed conventional straight-channel HXs. The TO design achieved a 115% increase in UA and NTU and a 27.6% boost in gravimetric power density, while the data-driven optimized Gyroid design delivered a 166% increase in UA and NTU and improved effectiveness from 68.7% to 86.1%. These results validate the simulation models, confirm the manufacturability of complex geometries under AM constraints, and provide key insights into design-performance trade-offs, thereby advancing the development of high-efficiency, compact heat exchangers for extreme environments.

36 MATERIALS SCIENCE↗