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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

Towards Polymer-Free, Femto-Second Laser-Welded Glass/Glass Solar Modules

This project explores the use of femto-second (fs) lasers to form glass-to-glass welds for hermetically sealed, polymer-free solar modules. Low iron solar glass coupons were welded together without the use of glass filler using a fs laser with dedicated optics to elongate the focal plane parallel to the incident beam. The resulting welds were then stress tested to failure to reveal the critical stress intensity factor, KIc. These values were used in a structural mechanics model of a 1 m by 2 m glass/glass module under a simulated static load test. The results show that the fs laser welds are strong enough for a suitably framed module to pass the IEC 61215 static load test with a load of 5400 Pa. Key to this finding is that the module must be framed and braced, and the glass must be ribbed to allow pockets for the cells and welds inside the border of the module. The result is a module design that is completely polymer-free, hermetically sealed, has improved thermal properties, and is easily recycled.

femto-second laser welded↗
DOE OSTI2026

Reducing the Cost of Fatigue Crack Growth Testing for Storage Vessel Steels in Hydrogen Gas

Hydrogen storage pressure vessels are designed against fatigue crack growth, and the ASME Boiler and Pressure Vessel Code requires the fatigue crack growth rate (da/dN) vs. stress-intensity factor range (ΔK) relationship of the construction steel to be measured directly in hydrogen gas. These measurements are notoriously slow and expensive: the cyclic loading frequencies prescribed by standards (often 0.1 Hz) are two or more orders of magnitude below those for conventional fatigue testing, individual tests run for days to weeks, and the high-pressure test-chamber set-up imposes a significant per-specimen labor cost. Due to these time and cost constraints, near-threshold data—the regime most valuable for extending design fatigue life—are rarely generated for ferritic storage vessel steels in hydrogen gas.

08 HYDROGEN↗
DOE OSTI2024

Anthropogenic effects on flood hazards in a hyper-arid watershed: The 2015 Atacama floods

An unprecedented precipitation event in the hyper-arid Atacama Desert of Northern Chile occurred in March 2015. Geomorphic alterations to the river channel and the coastal zone, coupled with the exceptional magnitude of the rainfall, caused catastrophic damage and loss of life. On the coast of the El Salado watershed, legacy mine tailings infilled the watershed-ocean connection, while the river channel was altered both by tailings and urbanization. The consequences of this event resulted from the coupling of anthropogenic geomorphic changes with an unusual climate event. Lack of field data, complex geomorphology and sediment loads influenced by human activity make analysing floods in these regions especially challenging. The objective of this work is to improve our understanding of the factors that control flood hazards by using numerical simulations to reconstruct the 2015 flood in El Salado. We carry out unsteady two-dimensional simulations fully coupled with the sediment concentration to identify the influence of tailing deposits, considering high-resolution data of the pre- and post-2015 flood topography. In conclusion, the results highlight the importance of specific event-based studies, using models that can help designing better strategies for climate change adaptation and risk mitigation, while providing information for risk reduction and channel restoration.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Predicting multi-nodal in-nozzle particle interactions in high-viscosity fluid mediums for acoustophoretic direct-ink writing of line-patterned composites

Patterned functional materials offer improved properties (electrical, thermal, etc.) over their bulk counterparts in many applications, including energy storage, flexible electronics, and sensors. However, manufacturing approaches for patterning materials over large areas with features on the order of hundreds of microns or less are limited. Acoustophoresis, which uses acoustic forces to control particle arrangement in a fluid medium, is a pathway to address this challenge. This process is dependent on particle and fluid properties and enables patterning of a broad range of materials. Herein, a model with experimental validation is presented to demonstrate that acoustophoresis can be combined with direct-ink writing (DIW) to fabricate line patterns over large cm-scale areas. An in-nozzle particle interaction model was developed to investigate the impact of processing conditions on multi-nodal acoustophoretic DIW. The model predicts patterned line widths within a factor of two relative to experimental results for a high viscosity case study. Here, the model was used to investigate the impact of frequency, particle loading, particle radius, and acoustic pressure on line width and patterning time, providing critical feedback regarding the processing conditions suitable for a target application. Model results illustrate that frequency has the greatest impact on line patterns: increasing from 1 to 3 MHz resulted in a greater than 65% reduction in line width and a greater than 85% reduction in patterning time. Additionally, experiments were conducted with an alumina-epoxy ink and a ~21 cm 2 area pattern was rastered in ~5.5 minutes, demonstrating a path towards large-area line-patterned composite fabrication.

25 ENERGY STORAGE↗
DOE OSTI2024

Long-term effects of cycle time and volume exchange ratio on poly(3-hydroxybutyrate-co-3-hydroxyvalerate) production from food waste digestate by Haloferax mediterranei cultivated in sequencing batch reactors for 450 days

Food waste digestate was fed into a sequencing batch reactor (SBR) for Haloferax mediterranei (HM) to produce poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV). This SBR was operated uninterruptedly for 450 days to test its stability, during which the cycle time and volume exchange ratio were varied to understand their impacts on the PHBV fermentation performance under ranged organic loading rates (OLR). Results showed that 1) PHBV productivity was proportional to OLR of food waste digestate; 2) substrate and product inhibitions were two limiting factors constraining substrate utilization and PHBV yields; 3) PHBV titer was dependent on the hydraulic retention time of the SBR while a volume exchange ratio lower than 0.5 is unfavorable due to the product inhibitor accumulation. Furthermore, this study for the first time demonstrated that the long-term stability of food waste-fed PHBV production by HM and revealed that inhibition effects could be barriers in SBR limiting the full-scale application of the technology.

09 BIOMASS FUELS↗
DOE OSTI2024

Influence of elevated temperature and oxygen on the capture of radioactive iodine by silver functionalized silica aerogel

Reprocessing is considered a competent strategy for spent nuclear fuel management, yet radioiodine ( 129 I) is emitted in reprocessing off-gas as a hazardous byproduct. Silver functionalized silica aerogel (Ag 0 -aerogel), a promising iodine capture material, experiences a reduction in its capacity after prolonged exposure to off-gas components at elevated temperatures, a phenomenon termed as aging. To fully understand this process, we isolated the contribution of each aging factor, exposing Ag 0 -aerogel samples to N 2 and dry air gas streams, respectively, at 150 °C for different time periods. Aged samples were loaded with I 2 to examine the capacity change and comprehensively characterized to investigate the evolution of their properties. Results show that temperature alone did not alter Ag 0 -aerogel's capacity but triggered Ag 0 nanoparticles sintering and generated organic sulfur species. The presence of O 2 reduced the capacity by ~20 %, causing (i) formation of silver sulfide (Ag 2 S) crystals and (ii) oxidation of Ag-thiolate (Ag-S-r) to Ag sulfonate (Ag-SO 3 -r). Given that Ag 2 S readily adsorbs I 2 , the formation of Ag-SO 3 -r is the major inhibitor for iodine adsorption. This hypothesis was supported by density functional theory (DFT) simulations. These findings unraveled key mechanisms of Ag 0 -aerogel aging, which are useful in the development of materials that withstand realistic spent-nuclear-fuel-reprocessing off-gas conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Evaluating SWAT + model uncertainties for human and natural outcomes: Application in a Great Lakes agricultural watershed

Nutrient exports from agricultural lands in the Great Lakes Region pose significant threats to water quality and ecological health through eutrophication, hypoxia, and harmful algal blooms. Climate change and agricultural adaptation practices complicate future nutrient loading due to intensified hydrologic cycles and land use decisions. Our research focuses on evaluating the Soil and Water Assessment Tool (SWAT) plus model parametric uncertainties for human and natural outcomes across different scales. These factors are integral to ensuring a balance between productive agricultural practices and maintaining the health of watershed hydrology. However, uncertainties in modeling such complex interactions pose significant challenges, limiting our ability to precisely determine critical factors that influence crop yield and soil moisture. Our analysis employs Sobol global sensitivity analysis to evaluate first-order, second order, and total-order indices for SWAT crop growth parameter, ensuring comprehensive assessment of individual and interactive effects on model outputs. The objective is to identify the parameters that significantly affect model outputs for crop yield and soil moisture and improve our understanding of their interactions at the basin and hydrological response unit (HRU) scale. Our case study, the Portage River Watershed, which drains into Lake Erie, is chosen to better capture finer scale interactions crucial for predicting nutrient loading under future climate scenarios. This foundational work is aimed at setting the stage for the future development of an agent-based model (ABM). The ABM model would incorporate SWAT outputs to dynamically simulate decision-making processes.

Bunyon, Enock↗
DOE OSTI2025

Design, Optimization, and Control of Floating Offshore Wind Farms for Optimal Energy Production (Final report)

The uncertainty and irregularity of ocean waves and the ocean environment is a major factor in the development of commercial scale floating wind turbines as the operation of floating structures in such an environment can lead to irregular and unpredictable loading, fatigue, and ultimately a reduction in the operational life of the turbine system which affects energy production over the lifetime of the turbine. Control solutions that can limit float motions and mitigate stressful events on the structure become essential for extending lifetime and limiting the operational uncertainty of a floating wind turbine. Digital twins are computational replicas of physical systems that operate in parallel with the operation of the physical system. Given advanced knowledge of a systems input, digital twins have the ability to predict the behavior of a system in advance, which can be valuable in the control of that system. In this project, we developed and assessed potential digital twin models developed in house and openly available (OpenFast) for use in the real time control of the six degree of freedom response motions of a floating wind turbine in ocean waves. Coupling these models with near-field real time irregular sea surface (wve) measurement/sensings and prediction models, we used the digital twin to predict how the floating turbine will respond to the incoming waves. Applying this information to a motion control system of the float, one can limit and control float motions to prevent undesirable loading events/large angular motions, thus increasing system life and ultimately contributing to optimizing energy production. Due to the computational intensity of operating a digital twin in real time, we investigated the use of artificial intelligence techniques to speed-up the processes of the digital twin, as well as the wave reconstruction/prediction models. Model tank testing at the University of Rhode Island and University of Maine both validated and demonstrated the developed techniques on simple float geometries and a scale model of the NREL 15 MW reference turbine.

17 WIND ENERGY↗
DOE OSTI2025

Towards an Introspective Dynamic Model of Globally Distributed Computing Infrastructures

Large-scale scientific collaborations like ATLAS, Belle II, CMS, DUNE, and others involve hundreds of research institutes and thousands of researchers spread across the globe. These experiments generate petabytes of data, with volumes soon expected to reach exabytes. Consequently, there is a growing need for computation, including structured data processing from raw data to consumer-ready derived data, extensive Monte Carlo simulation campaigns, and a wide range of end-user analysis. To manage these computational and storage demands, centralized workflow and data management systems are implemented. However, decisions regarding data placement and payload allocation are often made disjointly and via heuristic means. A significant obstacle in adopting more effective heuristic or AI-driven solutions is the absence of a quick and reliable introspective dynamic model to evaluate and refine alternative approaches. In this study, we aim to develop such an interactive system using real-world data. By examining job execution records from the PanDA workflow management system, we have pinpointed key performance indicators such as queuing time, error rate, and the extent of remote data access. The dataset includes five months of activity. Additionally, we are creating a generative AI model to simulate time series of payloads, which incorporate visible features like category, event count, and submitting group, as well as hidden features like the total computational load—derived from existing PanDA records and computing site capabilities. These hidden features, which are not visible to job allocators, whether heuristic or AI-driven, influence factors such as queuing times and data movement.

kilic, Ozgur Ozan [Brookhaven National Laboratory ↗
DOE OSTI2025

Subsurface hydrological controls on the short-term effects of hurricanes on nitrate–nitrogen runoff loading: a case study of Hurricane Ida using the Energy Exascale Earth System Model (E3SM) Land Model (v2.1)

When the nutrient level in the soil surpasses vegetation demand, nutrient losses due to surface runoff and subsurface leaching are the major reasons for the deterioration of water quality. The lower Mississippi River basin (LMRB) is one of the sub-basins that deliver the highest nitrogen loads to the Gulf of Mexico. Potential changes in episodic events induced by hurricanes may exacerbate water quality issue in the future. However, uncertainties in modeling the hydrologic response to hurricanes may limit the modeling of nutrient losses during such events. Using a machine learning approach, we calibrated the land component of the Energy Exascale Earth System Model (E3SM), or ELM, version 2.1, based on the water table depth (WTD) of a calibrated 3D subsurface hydrology model. While the overall performance of the calibrated ELM is satisfactory, some discrepancies in WTD remain in slope areas with low precipitation due to the missing lateral flow process in ELM. Simulations including biogeochemistry performed using ELM with and without model calibration showed important influences of soil hydrology, precipitation intensity, and runoff parameterization on the magnitude of nitrogen runoff loss and the leaching pathway. Despite such sensitivities, both ELM simulations produced reduced WTD and increased runoff and accelerated nitrate–nitrogen runoff loading during Hurricane Ida in August 2021, consistent with the observations. With observations suggesting more pronounced effects of Hurricane Ida on nitrogen runoff than the simulations, we identified factors for model improvement to provide a useful tool for studying hurricane-induced nutrient losses in the LMRB region.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Flaw Tolerance Assessment for DOE Standard SNF Dry Storage Canisters - 26550

The U.S. DOE has designed four spent nuclear fuel (SNF) dry storage canisters for storing DOE standardized SNFs. The DOE standard canisters are cylindrical shells with a diameter of 24 inches (610 m) or 18 inches (457 m), a wall thickness of 0.5 inches (12.7 m) or 0.375 inches (9.53 m), and a length of 15 feet (4.57 m) or 10 feet (3.05 m). These DOE canister geometries are completely different from commercial canisters. The latter may experience chloride-induced stress cracking corrosion (CI-SCC) because they are stored near coastal regions. The former may not experience CI-SCC but face different challenges because they are stored in the SNF storage facilities. Because of large residual stresses, mechanical flaws may occur in the DOE canisters during long-distance transportation or lifting handling. To date, only limited structural integrity analyses were carried out through drop tests on the DOE canisters, but a more general flaw tolerance assessment has not been performed. Therefore, the failure assessment diagram (FAD)-based fracture mechanics method, as codified by the latest API 579-1/ASME FFS-1-2021 Edition, is adopted in this work to assess surface flaw tolerance for DOE canisters under operation loading and welding residual stresses (WRS), where the new code-recommended WRS distributions are used. To more adequately consider the transverse distribution of WRS, an equivalent WRS distribution is proposed to account for the WRS reduction with distance from the weld centerline. Moreover, the closed-form solutions of stress intensity factor K, which serves as the crack driving force during subcritical crack growth, are developed from the tabular data of the K factors provided in API 579-1/ASME FFS-1 and used to determine more accurate flaw sizes at flaw instability. Subsequently, the Level 2 assessment procedures with 12 assessment steps, as codified and detailed in API 579-1 and ASME FFS-1, are followed to assess the flaw tolerance for the surface flaws in the DOE standard canisters with consideration of normal or accident operation loads combined with WRS. The assessment results show that the four designs of DOE standard canisters can tolerate all surface flaws that meet the code permitted maximum sizes of a flaw length of 8 inches (i.e., 200 mm) and a flaw depth of 80% wall thickness. This demonstrates that all designs of DOE standard canisters are robust and reliable.

DOE standard canister↗
DOE OSTI2025

Combined Effects of Electric Vehicle Charging and Rooftop Solar Integration on Voltage Imbalance in Residential Distribution Networks

Residential electric vehicle (EV) chargers, as single phase loads, contribute to unbalanced voltage drops across phases, while rooftop solar systems, as single phase generators, can exacerbate voltage imbalance by causing unbalanced voltage increases. This paper investigates combined effects of residential EV charging and rooftop solar generation on voltage imbalance in residential distribution grids. The study examines these simultaneous impacts using the IEEE 8500-node test system, enhanced with a secondary network to realistically model the EV chargers and rooftop solar integration. To account for the variability and uncertainty in the EV charging loads and solar generation, a Monte Carlo approach is employed to capture and quantify the simultaneous impact of the EV charging and rooftop solar integration. In this approach, multiple influencing factors are considered, including state-of-charge (SOC), maximum charging power levels, and geographic distribution of chargers. The results provide practical insights for utilities and stakeholders, offering expectations for planning and operating strategies that effectively manage the increasing adoption of EVs and solar power while maintaining grid reliability.

Choi, Jongchan [ORNL] (ORCID:000000025952455X)↗
DOE OSTI2024

Why is My Zero Energy Home Not a Zero Carbon Home?

For years, carbon calculations were done very simply. The method of calculation was to take annual totals of energy consumption and multiply by an average emission factor, either for the grid serving a project or for a larger region (e.g. an EPA eGRID sub region). The level of accuracy of this approximation was reasonably good, although the issue of accuracy was not, to our knowledge, tested. And the data required were minimal – just a year’s worth of bills for each fuel and one lookup factor. But this method assures that a net zero energy home is automatically a net zero carbon home because zero times any possible emission factor is still zero. Starting in the early 2010s, things changed – grids were starting to rely more and more heavily on renewables, and the difference was showing up on aggregate load curves. This was perhaps noticed first in California, where aggressive renewable policies led to significant renewable power generation large enough to affect the overall shape of the diurnal load curve for the Independent Systems Operator.

14 SOLAR ENERGY↗
DOE OSTI2024

Side-by-Side Comparison of Subhourly Clipping Models

Over the past several years there have been numerous attempts at quantifying the inherent power clipping of inverters due to subhourly irradiance variability that is not captured in hourly PV performance models. Different models have been proposed to correct for these clipping losses in PV performance estimates, including matrix lookup models, distribution modeling of the PV power performance within a given hour, and machine learning methods. To date, there have been few comprehensive quantitative comparisons of these inverter clipping correction modeling approaches to evaluate the effectiveness of these approaches in predicting the actual behavior of PV system inverter clipping. In this study, we perform such a comparison, evaluating the Allen and Walker correction loss modeling approaches recently implemented in the System Advisor Model (SAM) against clipping losses modeled with 1-minute climate data. These comparisons were performed across a variety of climate locations and inverter loading ratios to thoroughly analyze the effectiveness of these modeling approaches relative to each other. Results from this analysis reveal that both clipping correction approaches improve annual energy accuracy to within 2% of 1-minute modeled energy yield. The two models predict annual clipping loss more accurately than simple hourly power limit clipping, with the Allen method typically being slightly more accurate at typical ILR values and the Walker method often being slightly more accurate at high ILR values The models can improve accuracy over the status quo clipping approach up to 3 percentage points in systems with ILR of 2.0, showing the importance of this modeling factor in energy yield estimates.

accuracy↗
DOE OSTI2026

Modeling the Potential Impact of Storage on the US Power Sector in a Multisector Dynamic Context

The electric power sector is expected to grow in size, importance, and complexity around the world as economies expand and electric supply technologies and demand patterns evolve in significant ways. At the same time the electric power sector may see substantial increases in VRE generating technologies which can add variability and uncertainty to the diurnal and seasonal profile of electric supply. With these forces in play, the emergence of modular, flexible electricity storage technologies may have profound impacts on the operation of electric power systems. Here we reduce a storage modeling gap in MSD models by incorporating grid-based electricity storage into the electric sector dynamics of the Global Change Analysis Model-USA (GCAM-USA) with improved power sector representation. We find a potentially significant role for storage technologies in the future of the U.S. power system, with storage capacity ranging from 7.7 to 14.7 GW in 2050 and 13.9 to 31.6 GW in 2100 across several techno-economic scenarios. We also find that storage can help to smooth variability in residual load arising from evolving electricity demands and the introduction of high shares of VRE to the electric grid. This reduces reliance on high-cost peaking generators, improves system-wide capacity factors, and limits curtailment of VRE.

Patel, Pralit L.↗
DOE OSTI2026

Development of a Framework and Methodology for an Advanced Reactor Materials Environmental Effects Design Guide

Advanced non-light-water reactor components may operate at elevated temperature while experiencing cyclic loading, significant neutron irradiation, and exposure to reactor coolant. ASME Boiler and Pressure Vessel Code, Section III, Division 5, provides design rules for elevated-temperature service but does not include specific procedures to account for environmental effects on material properties. This report develops an initial framework and methodology for an Environmental Effects Design Guide (EEDG) focused on neutron irradiation; coolant-environment effects are reserved for future work. The proposed approach treats irradiation as a property-based overlay on the existing Division 5 design process, with two routes: a sparse-data route applying two reduction factors — FCR on creep-rupture strength and FF on fatigue life — for the creep-fatigue evaluations that typically control the design of advanced high-temperature reactor components, and a fuller framework developing the property-to-rule chain across the four Division 5 checks (primary load, strain limits and ratcheting, creep-fatigue, and buckling), together with swelling and weldments as scope items. Both routes are scoped by an in-pile qualification that restricts the use of post-irradiation-examination-derived properties in regimes where an in-pile mechanism could control the design outcome. Illustrative outputs derived on a compiled annealed Type 316 database — FCR ≈ 0.78–0.86 and FF ≈ 0.4 — demonstrate the calculation method within that specific dataset. The framework is an initial, testable design-rule concept; it identifies a practical path for preliminary design evaluations under sparse data and the material data and testing needed to develop the framework further.

Barua, Bipul (ORCID:0000000247184113)↗
DOE OSTI2025

Microstructure-sensitive mechanical behavior of an additively manufactured psuedoelastic shape memory alloy

The additive manufacturing of shape memory alloys into complex geometries enables fabrication of advanced functional systems across a variety of fields and domains. This work presents results focused on the mechanical behavior of additively manufactured shape memory pseudoelastic NiTi. The deformation induced solid state phase transformation from austenite to martensite allows this system to accommodate large recoverable strains. This deformation behavior is fundamentally driven by crystal-scale transformation physics. Laser powder bed fusion processing reveals that the resulting microstructure, both grain morphology and crystallographic texture, is strongly dependent on the manufacturing processing history. Exhaustive mechanical testing demonstrates that these microstructural factors strongly impact both tensile and cyclic stress–strain behavior. Cyclic dissipative behavior, however, is similar across all tested microstructures following an initial transient period. Remarkably, analysis of spatial strain fields during tensile loading reveals two distinctly different localization “modes”. The first is initiation of localized deformation bands which continuously propagate through the tensile bar during loading. In the second mode localization is observed but lacks propagation; instead additional localization cites nucleate during subsequent loading. The latter phenomena is suspected to be driven by grain-scale deformation physics as the localized band morphologies coincide with grain morphologies. These phenomena strongly impact the resulting aggregate stress–strain behavior. Hence, manufacturers and designers of psuedoelastic functional components must at the very least consider the potential variability in properties when considering additive manufacturing processing. More ideally the process–structure–property relations can be used to further tailor and optimize final functional performance.

Additive manufacturing↗