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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 OSTI2025

High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP): Site Energy Management System Platform Development

A site energy management system is a critical component of future high-power EV charging hubs. It monitors and supervises all inter-hub operations, coordinates grid interactions, and implements energy management strategies and load-sharing controls at various levels and time scales. This report provides a comprehensive high-level overview and guidelines on the essential elements of such energy management systems. These elements primarily focus on the core functions, architecture, and monitoring aspects of site energy management. The core functions define the grid services and operational objectives that a charging hub is expected to provide and achieve. The architectural section investigates the coordination between hub assets, different control schemes, and their potential benefits and drawbacks. Lastly, the report discusses the needs, types, and functionalities of a monitoring and visualization system.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

The effect of high-power transient events on tungsten and tungsten coatings used for radio frequency launcher applications

High-temperature plasma-facing material coatings used for radio frequency (RF) launchers need to be robust enough to survive RF breakdown arcing or other transient events from the plasma (e.g., an edge localized mode) without causing a catastrophic failure of the coating. High-power transient effects are being explored by using an RF-induced vacuum arc to determine the robustness of tungsten coatings made by a variety of manufacturing methods. A 1/4-wavelength resonant section of vacuum transmission line terminated with an open circuit electrode structure with a well-defined electric field (30-60 kV/mm) produces repeatable arcing conditions. The initial focus is on tungsten as a plasma-facing material, including sintered tungsten, tungsten coatings on steel produced via physical vapor deposition (PVD), and functionally graded tungsten/steel coatings deposited by low-pressure plasma-spraying (LPPS). Thin PVD coatings (1-2 microns) fail catastrophically from an arc and result in severe delamination of the coating. The arc-induced damage of thicker coatings, such as those made via LPPS, tend to be restricted to the top few microns of the surface. Arcing often initiates on sharp surface microstructures and causes localized melting of tungsten at the surface of all the materials studied and results in resolidified melt pools with surface cracks. The resolidified surface results in a reduction in overall deuterium retention when exposed to typical RF plasma sheath conditions.

Caughman, John [ORNL] (ORCID:0000000206091164)↗
DOE OSTI2020

Experimental evaluation of direct current magnetron sputtered and high-power impulse magnetron sputtered Cr coatings on SiC for light water reactor applications

Two types of physical vapor deposition Cr coatings were deposited on chemical vapor deposited SiC coupons using conventional direct current magnetron sputtering (DCMS) and high-power impulse magnetron sputtering (HiPIMS) to mitigate the corrosion of SiC, an advanced fuel and structural material in light water nuclear reactor cores. Coating microstructure was characterized using scanning electron microscopy and scanning transmission election microscopy. X-ray diffraction analysis was conducted for phase identification and qualitative analysis of residual stresses. The mechanical integrity of the coatings was evaluated using scratch testing, micro-indentation, and nano-indentation tests. Additionally, the microstructure of the DCMS coating consisted of fine columnar grains with nanoscale intercolumnar channels, while the HiPIMS microstructure was denser and free of any columnar defects. The DCMS coating showed a small tensile residual stress, while the HiPIMS coating was under compressive stress. Both types of coatings showed good mechanical integrity in terms of ductility and adhesion to the substrate. Corrosion performance of the coatings was assessed with a 30-day high temperature water autoclave test. Both types of coatings formed a protective Cr 2 O 3 surface layer 20-30 nm thick during the autoclave test. In the DCMS coating, the columnar defects provided permeation pathways for water penetration resulting in oxide formation in the intercolumnar regions in the interior of the coating. Overall, both types of Cr coatings offer promise for the mitigation of hydrothermal corrosion of SiC in light water reactor operating environments.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Amorphous Metal Ribbon (AMR) and Metal Amorphous Nanocomposite (MANC) Materials Enabled High Power Density Vehicle Motor Applications (Final Technical Report)

A collaborative team from Carnegie Mellon Univ. (CMU), North Carolina State Univ. (NCSU) and Metglas, South Carolina have studied new high speed motors (HSMs) with high-power density for traction motor applications. These are enabled by hybrid designs, including Flux Switching with Permanent Magnets (FSWPM) motors, exploiting permanent magnets without heavy rare earths (RE-lean) and high induction/high resistivity soft magnetic materials that allow for high switching frequencies needed to increase power densities. Team members include Michael E. McHenry, Prof. Materials Science & Eng., CMU, with > 30 years experience in magnetic materials development; Subashish Bhattacharya, Prof. Electrical Eng. and Freedom Center Director at NCSU with > 30 years experience in development of power electronic components and systems and Eric Theisen, Director of Research at Metglas, the only US located supplier of AMR and MANC materials. The team offers novel axial motor architectures exploiting soft magnetic materials (SMMs) that switch with low loss at high frequencies and heavy rare earth free permanent magnets that address materials criticality issues, supply chain risks, and high costs for traction motors. Axial-flux permanent magnet motors (APFM), offer efficiency improvements reducing rotor losses and also significantly higher power density. Axial-flux construction requires less core material, high torque-to-weight ratio. Since AFPM machines have thin magnets, they are smaller than radial flux motors making them attractive in space-limited applications. Noise and vibration are less and planar air gaps are easily adjusted. Flexibility in air-gap direction allows many topologies.

36 MATERIALS SCIENCE↗
DOE OSTI2021

High power coupler development for EIC

The synchrotron radiation loss in EIC Electron Storage Ring is as high as up to 10 MW. This energy loss will be compensated by 17 2K 591 MHz single-cell SRF cavities with a combined total of 34 high power fundamental power couplers. Each power coupler will operate 92% of revolution time CW and ~8% of revolution time with 400 kW forward power due to the beam abort gap. To satisfy the EIC needs, we developed two 500 kW standing-wave FPC designs at BNL based on either a BeO and an Al 2 O 3 RF window. This paper will briefly summarize test results of the BeO window FPC , and describe the design development of the Al 2 O 3 window based FPC.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

Design of a high power 8 MeV electron beam injector for the LERF

We present the beamline design for a high power 8 MeV electron injector to be installed at the Low Energy Recirculator Facility (LERF). The injector is designed to provide beam power of up to 80 kW for testing positron source target candidates. We discuss the results of beam dynamics simulations conducted using the General Particle Tracer (GPT) software, where electromagnetic beamline elements were optimized using multi-objective genetic algorithm tools. Additionally, we present preliminary studies on secondary particle generation from both rotating solid and free surface liquid metal jet targets described elsewhere in this workshop.

Lizarraga-Rubio, Victor [Thomas Jefferson National↗
DOE OSTI2021

HIGH POWER COUPLER DEVELOPMENT FOR EIC

The synchrotron radiation loss in EIC Electron Storage Ring is as high as up to 10 MW. This energy loss will be compensated by 17 2K 591 MHz single-cell SRF cavities with a combined total of 34 high power fundamental power couplers. Each power coupler will operate 92% of revolution time CW and ~8% of revolution time with 400 kW forward power due to the beam abort gap. To satisfy the EIC needs, we developed two 500 kW standing-wave FPC designs at BNL based on either a BeO and an Al2O3 RF window. This paper will briefly summarize test results of the BeO window FPC, and describe the design development of the Al2O3 window based FPC.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

High-Power Impulse Magnetron Sputter Deposition of Boron Carbide with Full-Face Erosion Magnetron and Mixed Ar-Ne Plasma

Boron carbide (B 4 C) is an attractive inertial confinement fusion ablator material. The fabrication of B4C ablators by magnetron sputtering requires process optimization. To increase process flexibility, here we explore high-power impulse magnetron sputter (HiPIMS) deposition of B 4 C in pure Ar and mixed Ar-Ne plasmas. Here, the results show that higher plasma discharge currents can be reached with a mixed Ar-Ne plasma in the entire working pressure range studied (5 𝑡𝑜 50 mTorr). At 45 mTorr with 10% of Ne in the Ar-Ne mix, high peak target current densities of ~1 A cm −2 were demonstrated. Films deposited with such a mixed Ar-Ne plasma with a full-face erosion magnetron source on substrates biased at −25 V exhibited higher density and improved mechanical properties, albeit with higher compressive residual stresses compared to the case of HiPIMS deposition in a pure Ar plasma. This work demonstrates additional process flexibility of the HiPIMS discharge mode for the deposition of B 4 C coatings.

Ablator capsule↗
DOE OSTI2021

Improved Control Strategy of Grid Interface for EV High-Power Dynamic Wireless Charging

This paper proposes a control strategy for the grid interface converter in high-power dynamic wireless charging system (DWCS) to address two issues on distribution network integration. Due to the unique pulsating load profile of DWCS, load transient response capability is critical for the grid interface to maintain the dc-bus voltage stable. Besides, the inherent unbalanced situation of distribution network would lead to 2nd-order oscillations on the dc-bus voltage, which would further affect the stable operation of the entire system. In this paper, the DWCS model is developed, and the relationship between the dc-bus voltage and the input/output power is analyzed. Based on the developed model, a control strategy based on direct power control is presented. Both simulation results and hardware-in-the-loop (HIL) results demonstrate that the proposed control strategy not only improves load transient response capability, but also eliminates the 2nd-order oscillations on the dc-bus voltage under imbalanced distribution network conditions.

Zeng, Rong↗
DOE OSTI2026

Design of a high power 8 MeV electron beam injector for the LERF

Here, we present the beamline design for a high power 8 MeV electron injector to be installed at the Low Energy Recirculator Facility (LERF). The injector is designed to provide beam power of up to 80 kW for testing positron source target candidates. We discuss the results of beam dynamics simulations conducted using the General Particle Tracer (GPT) software, where electromagnetic beamline elements were optimized using multi-objective genetic algorithm tools. Additionally, we present preliminary studies on secondary particle generation from both rotating solid and free surface liquid metal jet targets described elsewhere in this workshop.

Lizarraga-Rubio, Victor Manuel [Thomas Jefferson N↗
DOE OSTI2022

High-Speed and High-Power Ferroelectric Switching Current Measurement Instrument for Materials with Large Coercive Voltage and Remanent Polarization

A high-speed and high-power current measurement instrument is described for measuring rapid switching of ferroelectric samples with large spontaneous polarization and coercive field. Instrument capabilities (±200 V, 200 mA, and 200 ns order response) are validated with a LiTaO 3 single crystal whose switching kinetics are well known. The new instrument described here enables measurements that are not possible using existing commercial measurement systems, including the observation of ferroelectric switching in large coercive field and large spontaneous polarization Al 0.7 Sc 0.3 N thin films.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2021

Study of the Effect of Reflections on High-Power, 110-GHz Pulsed Gyrotron Operation

The effect of reflection is studied experimentally and theoretically on a high-power 110-GHz gyrotron operating in the TE 22,6 mode in 3 μs pulses at 96 kV, 40 A. The experimental setup allows variation of the reflected power from 0 to 33% over a range of gyrotron operating conditions. The phase of the reflection is varied by translating the reflector along the axis. Operating at a higher efficiency point, at 4.40 T with 940kW of output power, reflected power exceeding 11% causes a switch from operation in the TE 22,6 to simultaneous operation in the TE 22,6 and TE 21,6 modes with a large decrease of the total gyrotron output power. This switching effect is in good agreement with simulations using the MAGY code. Operating at a more stable point, 4.44 T with 580kW of output power, when the reflection is increased, the output power remains in the TE 22,6 mode but it decreases monotonically with increasing reflection, dropping to 200kW at 33% reflection. Furthermore, at a reflection above 22%, a power modulation at 25 to 30MHz is observed, independent of the phase of the reflected wave. Such a modulated signal may be useful in spectroscopic and other applications.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Design of a broadband, high-power, off-axis spiral polarization reflector

Spirally polarized beams are known to produce a strong longitudinal field under high numerical aperture focusing. Here, we report on the design of a reflective optical element with an off-axis geometry that is capable of transforming a uniformly polarized beam into a predominantly spirally polarized beam. By utilizing the retardance present in Fresnel reflection, our device can operate over a broad range of wavelengths. The output polarization and intensity structure of a beam passing through the reflector are calculated using polarization and scalar ray tracing. Vector diffraction is used to calculate the polarization and intensity structure under $f/0.656$ focusing. The off-axis reflective design is well-suited for high-power laser applications and could enable current and future laser-based particle accelerators to achieve strong longitudinal fields at focus.

Black, A. Nicholas [Univ. of Rochester, NY (United↗
DOE OSTI2026

High-Power Amplifier Considerations for testing the LAMP RFQ and first DTL Cavity

As part of the LANSCE Accelerator Modernization Pro ject (LAMP), critical portions of the proposed accelerator will be tested as proof of concept and aid in planning the installation of LAMP at Los Alamos Neutron Science Cen ter. As part of this demonstration, the radio frequency quadrupole (RFQ) and the first drift-tube linac (DTL) cav ity will be tested with beam. For this purpose, high-power RF amplifiers are being designed to meet the testing de mands. This is a description of the requirements of these amplifiers and how the design is intended to meet them.

42 ENGINEERING↗
DOE OSTI2025

Hybrid Energy Management with Real-Time Control of a High-Power EV Charging Site

Decarbonization of transportation systems is driving higher capacity energy storage and faster charging power requirements in electric vehicles (EVs). Given the potential advantages - such as increased efficiency, reduced inverter capacity, and less total cable mass - there is a demand in the industry for more DC distribution for high-power charging (HPC) hubs. However, the cost-effective, adaptive, and robust operation of the DC-coupled HPC hub necessitates a robust site energy management system (SEMS). Validating SEMS operation using a digital twin of an HPC hub in a real-time simulator (RTS) platform is crucial before field deployment. In this study, we propose a hybrid energy management site controller designed to achieve high-level, long-term operational objectives while managing low-level power sharing control between hub assets. We develop a centralized model predictive controller (MPC) to optimize hub operating points and use these points to update the droop parameters of the site energy storage system (ESS). This approach ensures the hub follows an optimal operating point while maintaining the flexibility to respond to load surges. We tested and verified our proposed approach both offline and on a Controller Hardware-in-the-loop (C-HIL) simulation platform integrated with a SEMS framework, demonstrating real-time site operation and validating a cost-effective and robust site controller.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Optimal Litz Wire Design for High-Power Wireless Charging System

In this study, an optimized Litz wire and polyphase coil winding design is proposed for high-power wireless charging systems operating at 85 kHz frequency. Litz wire in a wireless charging system contributes to more than half of the losses of the system, making it a critical design component. Here, the Litz wire is optimized through Finite Element Analysis (FEA) considering electrical and mechanical design aspects and the design was validated through experimental tests on different Litz wires with various strand-diameters, twisting ratio, and number of strands. The proposed optimal Litz wire maximizes the system efficiency considering the tradeoff between coil resistance and mutual inductance. The optimal Litz wire shows that Litz wire constructed with the 63µm strands significantly outperform the traditionally used Litz wire with 100µm strand diameter. Additionally, the coil with optimal Litz wire design shows 60% reduction in the copper volume for the same loss, and at the same time increase the coil-to-coil efficiency by more than 2% by increasing the mutual inductance and reducing coil current. The optimized Litz wire was implemented in a 22-kW wireless charging system achieving 94.7% efficiency.

Aydin, Emrullah [ORNL]↗
DOE OSTI2025

Design of Transportation Frames for 650 MHz Cavities and High Power Couplers

This work presents the design of a transportation frame system for 650~MHz superconducting radio frequency cavities with high power couplers. Modal analysis identified the coupler antenna as the critical component with a 38~Hz natural frequency, leading to a dual-frame design with wire rope isolators that achieves 82\% vibration attenuation at the critical frequency. The system meets all transportation requirements, fits within standard shipping crates, and maintains structural integrity under 12g shock loads.

42 ENGINEERING↗
DOE OSTI2025

Design of Transportation Frames for 650 MHz Cavities and High Power Couplers

This work presents the design of a transportation frame system for 650~MHz superconducting radio frequency cavities with high power couplers. Modal analysis identified the coupler antenna as the critical component with a 38~Hz natural frequency, leading to a dual-frame design with wire rope isolators that achieves 82\% vibration attenuation at the critical frequency. The system meets all transportation requirements, fits within standard shipping crates, and maintains structural integrity under 12g shock loads.

Argento, Marco [Fermilab]↗