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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Data-driven Modeling for Grid Edge IBRs: A Digital Twin Perspective of User-Defined Models

Recent events in Odessa have brought attention to the challenges associated with the interaction between Inverter- Based Resources (IBRs) and the transmission and distribution system. The NERC event diagnosis report has highlighted sev- eral issues, emphasizing the need for continuous performance monitoring of these IBRs by system operators. Key areas of concern include the mismatch of control and protection perfor- mance of IBRs between the original equipment manufacturer (OEM)-provided models and field measurements. The inability to replicate the realistic response can result in incorrect reliability and resilience studies. In this paper, we developed an approach on how to emulate the behavior of an IBR using measurement data obtained for system operators to utilize in real-time and long- term planning. Two experiments are conducted in the phasor domain and electromagnetic transients (EMT) domain to emulate the behavior for grid forming and grid following inverters under various operating conditions and the effectiveness of the proposed model is demonstrated in terms of accuracy and ease of utilizing user-defined models (UDMs)

Mahapatra, Kaveri [BATTELLE (PACIFIC NW LAB)]↗
DOE OSTI2024

High-Power Polyphase PCB-Type Inductive Coupler for Wireless Electric Vehicle Charging

The cost and manufacturing difficulty of traditionally wound coils for wireless charging of electric vehicles has led to the exploration of alternative manufacturing for scalable deployment at a range of rated powers. A rotating-field polyphase wireless coupler is developed with balanced fully pitched coils which are not possible with conventional Litz wire. The usage of printed circuit board (PCB) technology is proposed for the innovative construction at large dimensions due to reduced cost, increased ease of manufacturability, and potential geometric customization compared to would coils. Design considerations specific to PCBs are detailed for wireless power transfer coils including advantages such as the potential for many turns and transposition with planar interconnections. A design procedure is developed which may be used to investigate the frequency to power to dimension correlation and limits associated with PCB coils. Designs are simulated in 3D electromagnetic finite element analysis (FEA) for the polyphase coil to evaluate the coupling between coils with varying geometric parameters at 100mm and 500mm outer diameters. A discussion is included on methods to increase PCB power ratings through a mixture of layer stacking, connections, and material selection.

Lewis, Donovin D.↗
DOE OSTI2024

Fast Iterative Multi-site Hosting Capacity Analysis for Distribution Systems With Search Space Pruning

Interconnection studies for distributed energy resources (DERs) is a time-intensive process, primarily due to the necessity of solving large number of power flow scenarios. Hosting capacity analysis (HCA) is a time-consuming aspect of interconnection studies that is divided into single-site HCA (SHCA) and multi-site HCA (MHCA). From a computational and understandable standpoint, the industry seeks iteration-based solutions for SHCA, although it doesn't maximize the total DER hosting capacity (DERHC) of the grid, as MHCA does. While non-iterative solutions are available for MHCA, they involve a trade-off between the modeling accuracy of the distribution system, solution quality, and ease of understanding. In this work, we present a fast iterative solution for MHCA, reducing computational complexity by eliminating the need to solve power flows for a large amount of search space, thus making iterative solutions feasible. This iterative approach guarantees both a global optimal solution with sufficient time and a fast, close-to-optimal solution through efficient search space pruning. It also easily integrates with existing utility HCA tools. The results are demonstrated on select locations in the IEEE-123 bus system for community-scale interconnection studies. We highlight the benefits of skipping the need to solve millions of power flows, all while maximizing the grid's total DERHC.

Guddanti, Kishan Prudhvi↗
DOE OSTI2024

A Microservices Architecture Toolkit for Interconnected Science Ecosystems

Microservices architecture is a promising approach for developing reusable scientific workflow capabilities for inte- grating diverse resources, such as experimental and observational instruments and advanced computational and data management systems, across many distributed organizations and facilities. In this paper, we describe how the INTERSECT Open Architec- ture leverages federated systems of microservices to construct interconnected science ecosystems, review how the INTERSECT software development kit eases microservice capability develop- ment, and demonstrate the use of such capabilities for deploying an example multi-facility INTERSECT ecosystem.

Brim, Michael↗
DOE OSTI2025

High-Performance Computing Based EMT Simulation: Power Grid with IBRs

Electromagnetic transient (EMT) simulation of power grids with high-fidelity models of inverter-based resources (IBRs) is time-consuming and difficult to scale. The necessity for high-fidelity models of IBRs that incorporate the dynamics of individual inverters within IBRs has been showcased in recent studies. These studies focused on events with partial power reduction in each IBR during a transmission line fault in the power grid. These types of events have been documented in multiple North American Electric Reliability Council (NERC) reports in the past decade. It is imperative then to find solutions to speed-up EMT simulations and scale the size of the region with IBRs studied in EMT simulations. In this paper, a combination of numerical simulation algorithms with high-performance computing techniques are employed in discretization and linear solvers employed in the proposed RE-INTEGRATE EMT simulation platform for power grid with IBRs. For ease of scalability, modular and object-oriented programming is used as these techniques are implemented. Additionally, automation software is developed to convert legacy software codes to the proposed RE-INTEGRATE EMT simulation platform. Thereafter, this platform is evaluated on multi-core central processing units (CPUs). Finally, scale-up tests are performed to showcase the scalability that is possible.

Marthi, Phani Ratna Vanamali [ORNL] (ORCID:0000000↗
DOE OSTI2026

Hoop Tensile Failure Stress of 500 µm-Diameter Ceramic Spheres

The tensile failure stress of a brittle-material sphere is important to the survival of the sphere itself but is particularly relevant to systems that employ such spheres for applications in which the sphere exterior is subjected to tension during system fabrication or operation. That maximum hoop or tangential stress can be measured by diametrally compressing a C-sphere specimen directly machined from such spheres. This combination of specimen geometry and test method was conceived at Oak Ridge National Laboratory around 20 years ago. Although the C-sphere geometry has been tested with larger spheres, the ease and efficacy of its testing are unknown for submillimeter sphere diameters. To consider this, C-sphere specimens were machined from yttria-stabilized zirconia (YSZ) spheres of ∼500 µm diameter. The maximum (hoop or tangential) tensile stress was determined as a function of compressive failure force and specimen dimensions using finite element analysis. Companion effective area and volume as a function of Weibull modulus were computed. Hoop tensile failure stresses were then measured and fractography conducted to examine flaw type and location and to estimate the mirror constant of this YSZ grade. This novel study demonstrates that hoop tensile failure stress can be determined with sub-millimeter brittle-material spheres.

Delia, Daniel [ORNL] (ORCID:0000000209023239)↗
DOE OSTI2025

S AP F LOWER : an automated tool for sap flow data preprocessing, gap-filling, and analysis using deep learning

Sap flow, a critical process in plant water use and ecosystem water cycles, is often measured using thermal dissipation probes (TDP) due to their ease of installation and continuous data collection. However, sap flow data frequently include noise, outliers, and gaps, creating challenges for analysis and requiring substantial manual processing. We developed S AP F LOWER , a tool that automates data preprocessing, model training, gap-filling, sapwood area scaling and modeling, and water use analysis. It integrates autocleaning, machine learning and deep learning models (e.g. random forest, Gaussian process regression, long short-term memory (LSTM), bidirectional LSTM (BiLSTM)), and efficient workflows to process sap flow data. S AP F LOWER can remove over 90% of noisy data while preserving legitimate variations and achieve high accuracy in gap-filling based on user-determined parameters. Random forest, LSTM, and BiLSTM models reduced root mean square error to 10% or less for long-term gaps. Model training and prediction can be performed efficiently within seconds. S AP F LOWER significantly enhances the efficiency and accessibility of TDP data analysis by automating complex tasks, enabling researchers without programming expertise to employ advanced techniques. Future improvements will focus on species-specific corrections for TDP and support for additional measurement methods. S AP F LOWER is openly available on GitHub (https://github.com/JiaxinWang123/SapFlower) and Zenodo (doi: 10.5281/zenodo.13665919).

ecosystem water balance↗
DOE OSTI2024

Cooled Spray Technology for Particulate Reduction in a Heavy-Duty Engine

Cooled spray (CS) technology passively reduces particulate matter (PM) emissions from diesel engines compared to non-CS-equipped diesel engines. CS inserts are mounted near the injector nozzle and control mixing so that the fuel and air can premix while limiting combustion near fuel-rich zones, thereby reducing the formation of particulate matter. CS components contain no moving parts and could be installed as a retrofit or built into new engines. However, CS technology is early in its development, and further investigations are needed to understand the overall performance implications and practicality of the technology. In this paper, we investigate several important aspects of CS, providing a clearer picture of some challenges and potential benefits of CS. Two alignment techniques are used to characterize measurement ease and bias, namely, an optical alignment and spray-plug impact alignment. While the optical technique facilitates alignment more easily, a bias was measured between the optical and spray-plug techniques, suggesting the optical technique may have insufficient accuracy without additional corrections. We also evaluate the engine performance of a well-aligned and poorly aligned CS insert, compared to the baseline configuration. The poorly aligned insert shows slower combustion than the baseline and mixed overall performance. However, the well-aligned insert shows faster combustion than the baseline and PM emission reduction at most operating conditions, with some conditions showing PM reduction up to 80%. Furthermore, the results of this paper highlight the alignment challenges of CS technology as well as the potential PM reduction benefit of the technology.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Fabrication, Modeling, and Testing of a Prototype Thermal Energy Storage Containment

Increasing penetration of variable renewable energy resources requires the deployment of energy storage at a range of durations. Long-duration energy storage (LDES) technologies will fulfill the need to firm variable renewable energy resource output year round; lithium-ion batteries are uneconomical at these durations. Thermal energy storage (TES) is one promising technology for LDES applications because of its siting flexibility and ease of scaling. Particle-based TES systems use low-cost solid particles that have higher temperature limits than the molten salts used in traditional concentrated solar power systems. A key component in particle-based TES systems is the containment silo for the high-temperature (>1100 degrees C) particles. This study combined experimental testing and computational modeling methods to design and characterize the performance of a particle containment silo for LDES applications. A laboratory-scale silo prototype was built and validated the congruent transient finite element analysis (FEA) model. The performance of a commercial-scale silo was then characterized using the validated model. The commercial-scale model predicted a storage efficiency above 95% after 5 days of storage with a design storage temperature of 1200 degrees C. Insulation material and concrete temperature limits were considered as well. The validation of the methodology means the FEA model can simulate a range of scenarios for future applications. This work supports the development of a promising LDES technology with implications for grid-scale electrical energy storage, but also for thermal energy storage for industrial process heating applications.

clean energy↗
DOE OSTI2025

Machining of Thin-Walled Structures From Stiffness-Driven Additively Manufactured Preform Geometry

Additive manufacturing provides the means to build component preforms with reduced excess material to create functional parts. In the case of aero-structural and aero-engine components, additive manufacturing technologies offer the possibility to substantially reduce the volume of material to be removed by machining operations. To achieve this objective, the preform must be built with the minimum material necessary to contain the final geometry and simultaneously provide enough stiffness to withstand the magnitude of the machining forces. This work describes a computationally efficient method to calculate the geometry required from the preform to reliably manufacture typical thin-walled structures via finish machining processes. This is achieved by defining the preform with near constant static stiffness across the width of the preform, in combination with a prescribed magnitude of stiffness at the top edge of the preform. The prescribed static stiffness is the function of the machining force magnitude, a direct consequence of the preselected cutting conditions. In conclusion, this article illustrates the application of the method to a straight single boundary thin-walled structure as an introduction case and for ease of description.

Additive manufacturing↗
DOE OSTI2024

Self-aligned fabrication of vertical, fin-based structures

Modern power devices rely on complex, three-dimensional, vertical designs to increase their power density, ease their thermal management, and improve their reliability. However, fabrication techniques have historically relied on 2D processes for patterning lateral features. This work presents a new technology that uses multiple steps of angled depositions to fabricate self-aligned vertical, fin-based devices that avoid fundamental lithography resolution and alignment limitations. The fabrication flows of two devices, the self-aligned vertical finFET and the high-κ dielectric fin diode, are presented to demonstrate how angled depositions can readily achieve transistors with submicrometer, vertical gates in a source-first process and also create high-aspect ratio GaN fins with a record 70:1 aspect ratio.

Perozek, Joshua (ORCID:0000000251519131)↗
DOE OSTI2026

Review of Ultrasonic Methods for Monitoring, Damage Detection, and Processing of Lithium-Ion Batteries Throughout Their Life Cycle

Lithium-ion batteries (LIBs) are the leading technology used in consumer electronics, electric vehicles, and grid-level electrochemical energy storage applications. The ever-increasing use of LIBs has highlighted a gap in understanding of their behavior throughout their life cycle. Current monitoring systems rely on electrical and sometimes temperature measurements to assess the internal state which limits information about complex electrochemical processes. In response, ultrasonic testing (UT) has shown promise for non-invasive assessment due to its ease of use and sensitivity to mechanical changes which are correlated with electrochemical changes within the battery. We summarize the research in UT methods applied to LIBs throughout their life cycle. We also discuss physics-based and data-driven modeling approaches used to interpret ultrasonic signals in the context of LIBs, with an emphasis on the existing challenge of establishing rigorous links between electrochemical behavior and elastic and poroelastic wave physics to gain insight regarding physical changes in the LIB that can be directly measured using UT. Finally, we discuss the challenges of implementing UT across the LIB life cycle and identify opportunities for further research. This review aims to provide helpful guidance to researchers and practitioners of UT in the growing field of UT for electrochemical battery systems.

25 ENERGY STORAGE↗
DOE OSTI2024

Photochemical phosphorus-enabled scaffold remodeling of carboxylic acids

The excitation of carbonyl compounds by light to generate radical intermediates has historically been restricted to ketones and aldehydes; carboxylic acids have been overlooked because of high energy requirements and low quantum efficiency. A successful activation strategy would necessitate a bathochromic shift in the absorbance profile, an increase in triplet diradical lifetime, and ease of further functionalization. We present a single-flask transformation of carboxylic acids to acyl phosphonates that can access synthetically useful triplet diradicals under visible light or near-ultraviolet irradiation. The use of phosphorus circumvents unproductive Norrish type I processes, promoting selectivity that enables hydrogen-atom transfer reactivity. Use of this strategy promotes the efficient scaffold remodeling of carboxylic acids through various annulation, contraction, and expansion manifolds.

Science & Technology - Other Topics↗
DOE OSTI2024

Implementation and (Inverse Modified) Error Analysis for Implicitly Templated ODE-Nets

We focus on learning unknown dynamics from data using ODE-nets templated on implicit numerical initial value problem solvers. First, we perform inverse modified error analysis of the ODE-nets using unrolled implicit schemes for ease of interpretation. It is shown that training an ODE-net using an unrolled implicit scheme returns a close approximation of an inverse modified differential equation (IMDE). In addition, we establish a theoretical basis for hyperparameter selection when training such ODE-nets, whereas current strategies usually treat numerical integration of ODE-nets as a black box. We thus formulate an adaptive algorithm which monitors the level of error and adapts the number of (unrolled) implicit solution iterations during the training process, so that the error of the unrolled approximation is less than the current learning loss. This helps accelerate training while maintaining accuracy. Several numerical experiments are performed to demonstrate the advantages of the proposed algorithm compared to nonadaptive unrollings and validate the theoretical analysis. Here, we also note that this approach naturally allows for incorporating partially known physical terms in the equations, giving rise to what is termed “gray box” identification.

ODE-nets↗
DOE OSTI2025

Enhancing Gaussian Process Surrogates for Optimization and Posterior Approximation via Random Exploration

This paper proposes novel noise-free Bayesian optimization strategies that rely on a random exploration step to enhance the accuracy of Gaussian process surrogate models. The new algorithms retain the ease of implementation of the classical GP-UCB algorithm, but the additional random exploration step accelerates their convergence, nearly achieving the optimal convergence rate. Furthermore, to facilitate Bayesian inference with intractable likelihoods, we propose to utilize optimization iterates for maximum a posteriori estimation to build a Gaussian process surrogate model for the unnormalized log-posterior density. We provide bounds for the Hellinger distance between the true and the approximate posterior distributions in terms of the number of design points. We demonstrate the effectiveness of our Bayesian optimization algorithms in nonconvex benchmark objective functions, in a machine learning hyperparameter tuning problem, and in a black-box engineering design problem. The effectiveness of our posterior approximation approach is demonstrated in two Bayesian inference problems for parameters of dynamical systems.

Bayesian inference↗
DOE OSTI2024

Cathodic Decomposition Electrodes as Standard Reference Electrodes for Molten Salts: Example of the Lithium Eutectic Electrode for the LiCl-KCl Eutectic

Alternatives to the widely-used standard anodic decomposition reference electrodes in molten salts are necessary to enable more easily reproduced thermochemical and electrochemical data in molten salt electrolytes. The class of standard reference electrodes called cathodic decomposition electrodes (CDEs) are easily constructed and can be used to make thermochemical measurements in molten salts more directly compared to anodic decomposition electrodes. The lithium eutectic electrode (LEE) was chosen as a sample test case for validation and was applied to thermochemical measurements of electroactive species in molten LiCl-KCl eutectic. Transient measurements were made to measure the Li + /Li reduction potential at zero current in pure LiCl-KCl eutectic relative to a Li-alloy reference electrode to validate the reference potential of the LEE. Literature-reported electromotive force measurements against Li-alloy reference electrodes were used to generate a relationship between the LEE and the standard chlorine electrode and this relationship was used to evaluate measured and reported formal potential measurements for the LiCl-KCl-GdCl 3 system. This work demonstrates the general framework for defining CDEs for any molten salt system and a method for calibrating external reference electrodes against a CDE standard reference electrode, improving the ease of obtaining thermochemical and electrochemical measurements in any molten salt system.

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

The Shape Factor for Pits and Its Impact on Pit Stability

This study employs the finite element method (FEM) to predict the impact of pit shape on pit stability via shape factors of various pit geometries relevant to localized corrosion. Lower values of the shape factor indicate an increased ease in maintaining pit stability. Analyzed geometries include undercut pits, bispherical pit-within-pit structures, and covered pits with perforated (lacy) covers. The effect of the water layer thickness, transport properties of the electrolyte inside and outside the pit, and cathode location on the pit shape factor were also explored. Results show that occluded pits exhibit lower shape factors than open ones, with disk-shaped pits decreasing further as c/r ratio and occlusion angle increase. The findings also suggest minimal influence from a secondary pit if the primary remains active. An equation is presented that quantifies the impact of lacy covers, revealing significant shape factor value reduction. Additionally, high salt concentrations inside pits have a limited stabilizing effect compared to geometry, while thin water layers and adjacent cathodic/sinks reduce pit stability.

Shehi, A. (ORCID:0009000271548041)↗
DOE OSTI2024

Chemically Amplified, Dry-Develop Poly(aldehyde) Photoresist

The catalytic decomposition of poly(phthalaldehyde) with a photoacid generator can be used as dry-develop photoresist, where the exposed film depolymerizes into small molecules to allow the development of features via controlled vaporization. Higher temperatures enabled shorter dry-development times, but also promoted faster photoacid diffusion that compromised pattern fidelity. Trihexylamine was used as a base quencher to counteract acid diffusion in a phthalaldehyde-propanal co-polymer photoresist. The propanal co-monomer in the polymer improves the vaporization rate because it has a higher vapor pressure than phthalaldehyde. Addition of the base quencher was found to improve the contrast, pattern fidelity, and ease-of-handling of the dry-develop resist in a direct-write UV lithography tool. The dry-development of 4 μ m features was achieved with no appreciable residue. For large area features, a spatially variable exposure method was used to direct the residue away from the exposed area. The gradient exposure method was used to produce 100 μ m features. Plasma etching after dry-development was also used to achieve residue-free dry-developed patterns. These results show the benefits of incorporating base additives into a dry-develop depolymerizable resist system and highlight the need for addressing residue formation.

Materials Science↗