Search NASA⌕ Search

SEARCH · Search NASA

Results for “Micro”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Urban Air Quality Management at Low-Cost Using Micro Air Sensors: A Case Study From Accra, Ghana

Urban air quality management is dependent on the availability of local air pollution data. In many major urban centers of Africa, there is limited to non-existent information on air quality. This is gradually changing in part due to the increasing use of micro air sensors which have the potential to enable the generation of ground-based air quality data at fine scales for understanding local emission trends. Regional literature on the application of the high-resolution data for emission source identification in this region is limited. In this study a micro air sensor was co-located at the Physics Department, University of Ghana with a reference grade instrument to evaluate its performance for estimating PM2.5 pollution accurately at fine scales and the value of this data in identification of local sources and their behavior over time. For this study 15 weeks of data at hourly resolution with approximately 2500 data pairs are generated and analyzed (June 01, 2023, to September 15, 2023). For this time period a coefficient of determination (r 2 ) of 0.83 was generated with a mean absolute error (MAE) of 5.44 μgm -3 between the pre local calibration micro air sensor (i.e. out of box) and the reference-grade instrument. Following currently accepted best practice methods (see e.g., PAS4023) a domain specific (i.e. local) calibration factor was generated using a multi-linear regression model and when this factor is applied to the micro air sensor data, a reduction i.e., improvement in MAE to 1.43 μgm -3 was found. Daily variation was calculated, a receptor model was applied, and time series plots as a function of wind direction were generated, including PM2.5/PM10 ratio scatter and count plots to explore the utility of this observational approach for local source identification. The 3 data sets were compared (out of box, domain calibrated and reference-grade) and it was found that although there were variations in the data reported, source areas highlighted based on these data were similar, with input from local sources such as traffic emissions and biomass burning. As the temporal resolution of observational data associated with these micro air sensors is higher than for reference grade instruments (primarily due to costs and logistics limitations), they have the potential to provide insight into the complex, often hyper localized sources associated with urban areas, such as those found in major African cities.

Source apportionment↗
DOE OSTI2025

Understanding the limitations and potential of micro tensile testing of tungsten and needs for crystal plasticity modelling

Tungsten is the leading plasma facing material candidate due to its exceptional properties. Understanding the response to neutron irradiation is crucial for the lifetime evaluation of tungsten. The limited space in nuclear reactors and the high levels of radioactivity of the specimens after irradiation are significant barriers to accurately measuring the mechanical properties after neutron irradiation. Testing of micro tensile specimens is one approach to reduce the total amount of irradiated material needed for a set of mechanical testing experiments. However, micro samples are not necessarily measuring the bulk material properties, as size effects produce higher measured mechanical properties than is observed in engineering size counterparts. Determining the minimal sample size for reliable bulk property measurement, combined with modeling efforts, is essential. We conducted room temperature tensile tests on tungsten micro tensile specimens fabricated with focused ion beam, plasma focused ion beam and femto-second laser ablation system to dimension of 2×2×7?µm³, 7×7×18?µm³, and 80×100×233?µm³ (width×thickness×gauge-length), respectively. Elevated tensile testing was performed up to 475°C on 5×5×18?µm³ specimens fabricated with focused ion beam. The smallest specimens exhibited a high degree of ductility and strength, whereas the largest specimens demonstrated behavior akin to bulk tungsten. To investigate the effects introduced by the micro specimen fabrication processes and to obtain the necessary bulk dislocation density for the crystal plasticity model, we employed X-ray diffraction depth profiling. This measurement was performed using different X-ray sources with varying penetration depths. Finally, the potential and limitations of micro mechanical tests for tungsten will be discussed.

36 - MATERIALS SCIENCE↗
DOE OSTI2018

Wafer integrated micro‐scale concentrating photovoltaics

Abstract A novel micro‐scale photovoltaic concept, Wafer Integrated Micro‐scale Photovoltaics (WPV), is proposed, analyzed, and experimentally demonstrated. The WPV concept seamlessly integrates multijunction micro‐cells with a multi‐functional silicon platform that simultaneously provides optical concentration, hybrid PV/CPV architecture, and mechanical alignment features. Fabrication and optical performance characterization of the Si platform are described in this paper. Over 100% improvement in the concentration‐acceptance‐angle product ( CAP ) is demonstrated using the wafer‐embedded micro‐concentrating elements, leading to significantly reduced module material and fabrication costs, sufficient angular tolerance for low‐cost trackers, and an ultra‐compact optical architecture compatible with commercial flat panel infrastructures. The development of a prototypical module with a 400× concentration ratio is described. Outdoor optical characterization of the module shows acceptance angles of ±1.7° and ±2.5° for 90% of on‐axis power and full‐width‐half‐maximum, respectively. The projected performance of the PV/CPV hybrid architecture illustrates its potential for cost‐effective collection of both direct and diffuse sunlight, thereby extending the geographic and market domains for cost‐effective PV system deployment. Leveraging low‐cost micro‐fabrication and high‐level integration techniques, the WPV approach presents a promising route to combine the high performance of multijunction solar cells and the low costs of flat‐plate Si PV systems.

Li, Duanhui↗
DOE OSTI2023

Integrated Micro‐Scale Concentrating Photovoltaics: A Scalable Path Toward High‐Efficiency, Low‐Cost Solar Power

The global energy market is seeing increases in the electricity demand of a couple of percentage points annually. The photovoltaic (PV) industry is also growing rapidly every year. One of the PV technologies is concentrator photovoltaics (CPV). CPV uses high‐efficiency multijunction solar cells and optics to concentrate sunlight, thereby significantly reducing the amount of semiconductor material needed. Yet, due to the high upfont manufacturing cost of CPV, it currently does not offer a competitive price against silicon PV. With this a new branch is introduced to the industry, micro‐CPV, which can be broadly explained as the miniaturization of the solar cells and optical components. The motivation for micro‐CPV is lowering the cost by decreasing the material volume and enabling new system architectures and high‐throughput manufacturing methods, while still maintaining high electrical efficiencies, taking advantage of a lower thermal load, shorter optical paths, lower resistive losses, and lower material volumes. Herein, a comprehensive review of the technological advances is presented, key synergies between micro‐CPV and other industries sharing similar challenges are identified, exemplified by micro‐light emitting diodes display manufacturing. New assembly process development in these industries will facilitate commercial adoption of micro‐CPV with continued miniaturization while driving down the cost.

Jost, Norman↗
DOE OSTI2019

Predicting combustion characteristics in externally heated micro-tubes

Here this study employs a simplified analytical model to obtain qualitative predictions of transitions between non-adiabatic combustion regimes found in non-catalytic tubular micro-flow reactors, i.e. normal stable flames, flames with repetitive extinction and ignition (FREI), and weak flames that are stabilized by wall heat transfer. Assuming large activation energy for single-step kinetics, a comparison of exact solutions for constant and variable wall temperature profiles reveals that while a non-zero wall temperature gradient introduces a temperature lag, it has no impact on the structure of the flame solution itself. This result is significant as it establishes a link to quenching characteristics within heated micro-tubes, and further facilitates a simplified micro-flow reactor analysis. Predictions for sweeps of wall temperatures are combined to S-curves, which allow for a combustion regime classification for a given combination of micro-flow reactor geometry and mixture properties. A variation of parameters such as tube diameter or mixture stoichiometry yields predictions of shifts in regime transitions, thus providing insights on interactions between heat transfer and first order effects of chemical kinetics. A comparison to experimental data illustrates that the theoretical framework, - within inherent limitations, - captures qualitatively correct trends that reflect experimental observations, thus providing valuable insights for micro-flow reactor design and operation.

42 ENGINEERING↗
DOE OSTI2025

Automated vehicle microscopic energy consumption study (AV-Micro): Data collection and model development

While the Adaptive Cruise Control (ACC) system in automated vehicles (AVs) is expected to impact transportation energy significantly, existing AV energy consumption models only directly adopt those developed with Human-driven Vehicle (HV) data without even slight adaptation or calibration to accommodate unique AV energy consumption features. This study will investigate how accurately HV data-based models can predict the energy consumption of AVs. Empirical trajectory data and corresponding instantaneous energy consumption rates from both AVs and HVs were collected. We adopted two classical HV data-based models to fit these data. The calibration results indicated that these models yield around 20 30% prediction errors for AVs. To further improve the prediction accuracy, this study designed an AV-Micro model by incorporating components of multiple classic energy consumption models that better capture ACC energy consumption features, including piecewise driving behavior. With this, the AV-Micro model achieves lower than 10% prediction errors. The AV-Micro model’s high consistency across different test runs was verified with statistical significance tests, demonstrating its adaptability in different driving profiles. To confirm the discrepancies between the energy consumption features of AVs and HVs, more statistical significance tests were conducted to show that the AV-Micro model cannot be directly applied to HV data. The findings by calibrated AV-Micro models revealed that AVs consume approximately 80.5–146.4 J more energy than HVs for each meter traveled. Furthermore, the frequency analysis of energy consumption indicates that there is still some room for AVs to improve energy efficiency, particularly given their larger amplitude high-frequency fluctuations.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

Survey on the micro-pollutants presence in surface water system of northern Serbia and environmental and health risk assessment

Highlights: • First survey on the occurrence of 940 substances in the middle part of the Danube Basin. • Micro-pollutants from canals water had higher abundance of contaminants that from river. • High level of sterols indicated dominant effect of untreated domestic wastewater. • Correlations among the groups of micro-pollutants indicated their common origin. • Ecological risk suggesting a potential for adverse effects on fish. This study demonstrates the occurrence of 940 organic micro-pollutants in surface water of four rivers, one irrigation canal system, and two lakes in Vojvodina Province, the northern part of Serbia, summing in total eighteen samples. The number of detected chemicals ranged from 22 to 84, with 127 micro-pollutants detected at least once, representing 13% of the studied substances. The targeted compounds include n-alkanes, sterols, polycyclic aromatic hydrocarbons (PAHs), organochlorine pesticides polychlorinated biphenyls, pesticides, pharmaceutical active compounds, industrial chemicals, plasticizers, etc. Among the analysed compounds, sterols were the most dominant with maximum quantified concentrations. The substances which were quantified with frequency over 50% were two PAHs (2-methylnaphthalene, benzo(ghi)perylene), five sterols (cholesterol, cholestanol, stigmasterol, fucosterol, beta-sitosterol), three pharmaceuticals and personal care products (L-menthol, diethyltoluamide, caffeine), and ten household chemicals (4-tert-octylphenol, dimethyl phthalate, methyl palmitate, phenylethyl alcohol, 1-nonanol, alpha-terpineol, 2-phenoxy-ethanol, methyl myristate, acetophenone, and 2-ethyl-1-hexanol). The list of priority substances under the European Union Directive 2013/39/EU includes 49 priority substances (PSs) out of which 34 were analysed. Among these, eleven PSs were quantified, and only two compounds (fluoranthene and benzo (a) pyrene) exceeded EU Environmental Quality Standards targeted values. The obtained results were compared with the previously published data that dealt with the same targeted number of micro-pollutants in sediment samples. This revealed connections between the same sampling locations. Environmental risk assessment showed the existence of potential ecological risk as 72% of the obtained values for the ecological hazard index (HI) at investigated locations were higher that the targeted value (HI > 1). Estimated values for hazard quotient (HQ) and hazard index (HI) for non-carcinogenic risk were lower than the targeted value, indicating no non-carcinogenic risk through dermal contact and non-intentional ingestion of water. Estimated values for cancer risk were all below 1 × 10{sup −6}, which is not considered to pose significant human health risk.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Capillary-Enhanced Two-Phase Micro-Cooler Using Copper-Inverse-Opal Wick with Silicon Microchannel Manifold for High-Heat-Flux Cooling Application

In this work, we demonstrate a two-phase capillary-fed boiling micro-cooler that consists of a ~ 25-..mu..m-thick copper inverse opal (CIO) porous wicking structure for high-heat-flux boiling and a silicon 3D-manifold for distributed liquid delivery and vapor extraction across a 0.5 cm x 0.5 cm heated area. At low inlet water mass flow rates of 1.5 to 1.9 g(min)-1, the micro-cooler displays nearly two-phase boiling with exit vapor quality ~ 1 and a high critical heat flux (CHF) of 253 to 320 W cm-2 with low superheat of ~ 10 degrees C resulting in a thermal resistance of boiling ~ 0.025 cm2 degrees C W-1 or heat transfer coefficient of 0.4 MW m-2 degrees C-1. For higher flow rates of 5, 10, and 15 g(min)-1, the micro-cooler exhibits a hybrid single-phase and two-phase cooling regime where the contribution of the sensible heat (single-phase) cooling is linearly added to that of the two-phase cooling. For the highest flow rate of 15 g(min)-1, the CHF is increased to ~ 500 W cm-2 resulting in an overall thermal resistance of ~ 0.18 cm2 degrees C W-1. However, the two-phase heat transfer effectiveness, which estimates the utilization level of the inlet mass flow rate for two-phase boiling, is reduced to ~ 0.11. To achieve the best cooling system performances, the micro-cooler must operate entirely within the two-phase boiling regime (exit vapor quality or two-phase heat transfer effectiveness ~ 1). Ideally, the "coolant" should be delivered near its saturation temperature (~ 100 degrees C for water), which provides significant advantages for the energy-efficient operation of data centers and power electronics. We present detailed analysis with Infrared and high speed camera images at various inlet flow rates and heat fluxes to understand complex heat transfer in the micro-cooler. Furthermore, a conjugate thermofluidic simulation model, which incorporates the physics of capillary-fed boiling in a porous copper layer, agrees well with the experimental data.

capillary-enhanced boiling↗
DOE OSTI2021

Micro-cantilever beam experiments and modeling in porous polycrystalline UO 2

Understanding the impact of microstructure on the thermo-mechanical behavior of oxide nuclear fuels is vital to predicting their performance through multiscale models. Evaluating the mechanical properties at the sub-grain length scale is key to developing these multiscale models. In this work, 3D finite element (FE) models were constructed to simulate the micrometer-scale bending of micro-cantilever beams fabricated using porous polycrystalline uranium dioxide (UO 2 ) and tested at room temperature. Here, the results showed that the porosity and elastic anisotropy of individual grains can play a significant role in determining the effective mechanical properties of the material deduced from the tests. Specifically, the porosity had a non-negligible effect, given that the pore size was of the same order of magnitude as the dimensions of the micro-beams. Correlations between load-deflection data, pore location, and elastic properties (effective Young's modulus) were investigated using UO 2 micro-beam FE models, where pore clusters were included and placed at different locations along the length of the beam. Results indicated that the presence of pore clusters near the substrate, i.e., the clamp of the micro-cantilever beam, has the strongest effect on the load-deflection behavior, with the porosity leading to a reduction of stiffness that is the largest for any location of the pore clusters. Furthermore, it was also found that pore clusters located towards the middle of the span and close to the end of the beam have a comparatively small effect on the load-deflection behavior. Therefore, it is concluded that accurate estimates of Young's modulus can be obtained from micro-cantilever experiments after accounting for porosity on the one third of the beam length close to the clamp. This, in turn, provides an avenue to improve microscale experiments and their analysis in porous, anisotropic elastic materials.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Mechanical properties of neutron irradiated F82H using micro-tensile testing

Room temperature micro-tensile tests were successfully performed on F82H specimens neutron-irradiated at 573 K up to 5 dpa and unirradiated using a focused ion beam (FIB) device. Dimensions of the gauge section for micro-tensile specimens were about 10 µm (length) × 1 µm2 (area). These specimens were fabricated in a FIB device. The tensile properties obtained on specimens of micrometer size qualitatively agreed with results from millimeter size specimens. Using this micro-tensile testing technique is considered to become very useful data in combining the micro-tensile data on ion irradiated F82H with data on neutron irradiated material. This method overcomes the limitation on obtaining mechanical property on ion irradiated specimens to only micro-indentation testing.

Ando, Masami↗
DOE OSTI2022

Temperature-Dependent Constrained Diffusion of Micro-Confined Alkylimidazolium Chloride Ionic Liquids

Alkylimidazolium chloride ionic liquids (ILs) have many uses in a variety of separation systems, including micro-confined separation systems. To understand the separation mechanism in these systems, the diffusion properties of analytes in ILs under relevant operating conditions, including micro-confinement dimension and temperature, should be known. For example, separation efficiencies for various IL-based microextraction techniques are dependent on the sample volume and temperature. Temperature-dependent (20–100 °C) fluorescence recovery after photobleaching (FRAP) was utilized to determine the diffusion properties of a zwitterionic, hydrophilic dye, ATTO 647, in alkylimidazolium chloride ILs in micro-confined geometries. These micro-confined geometries were generated by sandwiching the IL between glass substrates that were separated by ~1 to 100 μm. From the measured temperature-dependent FRAP data, we note alkyl chain length-, thickness-, and temperature-dependent diffusion coefficients, with values ranging from 0.021 to 46 μm 2 /s. Deviations from Brownian diffusion are observed at lower temperatures and increasingly less so at elevated temperatures; the differences are attributed to alterations in intermolecular interactions that reduce temperature-dependent nanoscale structural heterogeneities. Furthermore, the temperature- and thickness-dependent data provide a useful foundation for efficient design of micro-confined IL separation systems.

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

Origin of reduced efficiency in GaN-based micro-LEDs studied by scanning near-field optical microscopy

The quantum efficiency of micro-light emitting diodes (micro-LEDs) is lower than that of large area LEDs. This efficiency reduction is typically attributed to the nonradiative Shockley–Read–Hall recombination at the surface defects and current leakage through the sidewall region without a clear distinction between these effects. In this work, we attempt to find out which of these phenomena is most critical for the reduced efficiency of micro-LEDs. This has been done by mapping electroluminescence (EL) and photoluminescence (PL) and measuring PL dynamics in blue GaN micro-LEDs fabricated by dry etching. It has been found that in the as-etched device, the EL intensity is much lower than in devices with KOH etching and atomic layer deposition of SiO 2 . This effect is especially pronounced close to the sidewalls. On the other hand, PL decay times are similar in as-etched and passivated devices, both in their center and at the sidewalls. This allows concluding that the main mechanism of the reduced efficiency of micro-LEDs fabricated by dry etching is the current leakage in the sidewall region and not the nonradiative recombination. The KOH etching has been found to be the most efficient means to eliminate the current leakage.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Micro-structuration effects on local magneto-transport in [Co/Pd]IrMn thin films

We measured the local magneto-transport (MT) signal with an out-of-plane magnetic field, including magneto-resistance (MR) and Extraordinary Hall effect (EHE), in exchange-biased [Co/Pd]IrMn thin multilayers that are micro-structured with a 100 μm window. We found that when measured locally around the window, the MT signal deviate from the expected behavior. We studied possible causes, including film micro-structuration, electrical contact geometry as well as magnetic field angular tilt. We found that tilting the magnetic field direction with respect to the normal direction does not significantly affect the MT signal, whereas the positioning and geometry of the contacts seem to highly affect the MT signal. For comparison purposes, we carried these MT measurements using the Van-der-Pauw method on a set of four microscopic contacts directly surrounding the window, and on another set of micro-contacts located outside the window, as well as a set of four contacts positioned several millimeters away of each other at the corners of the wafer. If the contacts are sufficiently far apart, the EHE and MR signals have the expected shape and are not significantly affected by the presence of the window. If, on the other hand, the contacts are micro-positioned, the shape of the EHE signal is drastically deformed, and may be modeled as a mix of the standard EHE and MR signals measured on the outer contacts. Furthermore, if the micro-contacts are located directly around the window, the deformation is amplified, and the weight of the MR signal in the mix is further increased by about 40 %. This suggests that the electron path in the Hall geometry is disturbed by both the proximity of the electrodes and by the presence of the window, which both contribute to the deformation for about two-third and one third, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Comparative Study of Techno-Economics of Lithium-Ion and Lead-Acid Batteries in Micro-Grids in Sub-Saharan Africa

Microgrids stand to play an important role in expanding electricity access in Sub-Saharan Africa. Batteries, which are often a core element of micro-grids, represent a substantial portion of the capital cost and are therefore an important component of developing sustainable business models for micro-grid deployment. As a result, understanding key considerations for selecting a battery type and operating it effectively are foundational for taking micro-grid growth to scale across the sub-continent. While batteries have been deployed in many systems worldwide over the past few decades, unanswered questions remain on how best to apply them to the context of off-grid micro-grids in Sub-Saharan Africa. Building on analytical work with developers in Sub-Saharan Africa and tools at NREL, this report investigates battery techno-economics and optimal operation in micro-grids, including evaluating criteria to decide between deploying lead acid or lithium-ion batteries, discussing key design considerations for the enclosures that house the batteries, and how to effectively condition the enclosure.

25 ENERGY STORAGE↗
DOE OSTI2019

Micro Reactor Simulation Using the PROTEUS Suite in FY19

Two micro reactor cores were simulated using the MOC solver of PROTEUS: MegaPower for a heat pipe micro reactor and Holos-Quad for a high-temperature gas-cooled micro reactor. Verification of PROTEUS standalone was performed by simulating 2D and 3D core benchmark problems developed based on MegaPower and Holos-Quad. Simulation results indicated that PROTEUS successfully modelled 2D and 3D cores of the MegaPower and Holos-Quad micro reactors and PROTEUS eigenvalues agreed well with the SERPENT Monte Carlo solutions. For a heat pipe cooled micro reactor, multiphysics simulations were performed using PROTEUS / FLUENT / ANLHTP. The coupling system of the three codes were developed using Python-based drivers, which exchange the data (power, temperature, and heat rate) required for the coupling and control the boundary conditions of FLUENT and ANLHTP. The coupled system was qualitatively verified using a 3D unit assembly problem composed of six fuel rods and seven heat pipes, which was developed based on the MegaPower compositions. The steady-state problem was solved using FLUENT / ANLHTP with given asymmetric fuel powers, demonstrating the reasonable convergence of temperatures of 7 heat pipes. Transient simulations were also performed by making one out of 7 heat pipes fail. For the transient, the coupled system of PROTEUS / FLUENT / ANLHTP demonstrated reasonable changes of total power and heat pipe temperatures with time, accounting for temperature feedback effects. In this simulation, no effect of structural change was accounted for, which will be performed using ANSYS-mechanical in future along with further verification with larger or whole-core 3D problems.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Key Regulatory Issues in Nuclear Micro-Reactor Transport and Siting

Inherent and passively safe nuclear micro reactors are being developed that feature mobility and autonomous operations much different than the current fleet. Numerous commercial, industrial, and military applications exist for this emerging technology. Challenges in licensing such flexible systems are foreseen, especially in areas related to siting and transport. New assessment approaches will be needed if micro reactors are to realize their full commercial potential while still preserving public safety. This report offers an initial examination of some key regulatory concerns related to micro reactor transport and siting in the continental U.S. Three deployment scenarios were developed to support a regulatory needs analysis concerning the appropriate regulatory structure for the technology, treatment of fueled and unfueled micro reactor modules during transport, and the means by which siting independence can be enhanced. With the exception of certain ultra mobile Department of Defense (DOD) applications, existing statutes suggest the Nuclear Regulatory Commission (NRC) is the appropriate regulatory agency to regulate a domestic commercial micro reactor fleet.

42 ENGINEERING↗
DOE OSTI2022

Pushing the Limits of Micro battery Capacity and Energy

Micro battery with higher energy density will extend the service life of the miniature sensors so that the scientists and engineers could be able to collect more data along with the time in ecological and environmental vectors, such as animal tracking. Within this project, a completely new cell design (Gen2) for micro batteries to further increase their cell capacity and energy is developed. The new cell design directly packages the active material in a hard aluminum case, decreasing the percentage of non-active components. The manufacturing process to improve wetting ability is studied and the trial run is finally given to evaluate the feasibility of the proposed technology. It’s found that both the capacity and energy with same battery size could be increased by 30% comparing with Gen1 micro battery technology previously developed by PNNL. The yield of Gen2 micro batteries is still lower due to the high degree of manual operation, especially for drilling process where more precise position control is needed. More effort is still required to improve the capability of automatic manufacturing processes. The new battery technology will support the development of smaller and lighter miniature sensors at PNNL and could potentially contribute to the large-scale manufacturing capabilities of micro batteries in US with reliable performances and long-term shelf life.

25 ENERGY STORAGE↗
DOE OSTI2026

Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology

Refrigerator technology has advanced significantly over the last couple of decades. Today’s refrigerators use only about 25% of the energy that was required to power models built in 1975. Even as they continually improve efficiency to meet standards, refrigerators have increased in size by almost 20%, added energy-consuming features such as through-the-door ice, and provide more benefits than ever before. However, a few challenges and technology gaps are preventing further improvement of the demand responsiveness and efficiency of the refrigerators. One of the major technology gaps in existing refrigerators is their outdated de-icing process. When the evaporator generates frost, an old-fashioned resistive heating element melts the ice. Most refrigerators have a timed defrost cycle, rather than an active system that could monitor the state of the frost. In these systems, not only is the precious electricity used at its least efficient form of conversion (direct conversion of electricity to heat), but also all the latent heat associated with the ice is wasted during the melting process. On top of that, the refrigerator needs to work harder to pull the temperature down after defrosting, and, last but not least, the food quality is severely impacted by the temperature swings during the defrost cycle. According to a study, the EU alone wastes 89 million tons of food in the supply chain every year. Any temperature swing during defrosting (about 6F according to Emerson for low-temperature cases) can negatively impact the shelf life of meat and other products for multiple days. All these issues can happen during the peak demand time of the electric grid. Unlike the conventional systems, the proposed novel advanced micro-vibrational deicing process uses no heat for defrosting. Instead, it uses the micro vibrations generated by a piezoelectric or vibration-generating module to mechanically break ice from the heat exchanger almost instantaneously. The project titled “Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology, performed by Ultrasonic Technology Solutions, LLC (UTS) of Knoxville, TN, in collaboration with Emerson (now Copeland), represents the final phase of a multi-year effort funded under the U.S. Department of Energy’s Building Technologies Office (BTO) BENEFIT FOA 2020. Initiated on October 1, 2021, and completed after a nine-month no-cost extension ending September 30, 2025, this project aimed to develop and validate a novel micro-vibrational mechanical defrosting system, achieving more than 25% improvement in defrosting energy efficiency over conventional baseline defrosting technologies. Over sixteen quarters, the project advanced from fundamental ice-mechanical characterization and prototype development to full-scale system integration and validation. Initial efforts established project management infrastructure and characterized ice adhesion properties, followed by the design and fabrication of early aluminum-based prototypes for resonance frequency testing. Subsequent quarters saw rapid technical progression, including the identification of optimal piezoelectric and motor-based vibration mechanisms, the demonstration of effective de-icing over 6x6-inch aluminum surfaces. The team achieved its Go/No-Go milestone by exceeding the 25% energy-efficiency improvement target—reaching up to 3,340% under optimized conditions—and later confirmed that motor-driven systems offered superior performance and energy efficiency compared to piezoelectric alternatives. Continued refinement led to the development of amplifier systems on printed circuit boards, improved control and instrumentation hardware, and integration into full-scale heat exchanger (HX) prototypes at both UTS and Copeland facilities. Multiple vibration-mounting studies and frost-growth experiments guided mechanical optimization and noise-mitigation strategies, achieving a 17.5 dB reduction in sound pressure level and verifying robust mechanical performance. Advanced analyses, including modal and harmonic simulations, established a quantitative understanding of vibrational behavior and de-icing efficiency across >1000 cm² systems. The final project phase successfully demonstrated scalable integration within reach-in and chest freezer prototypes, confirmed >25% efficiency improvements in large-area systems, and completed a comprehensive business model and scale-up strategy identifying electric defrost systems as the primary beachhead market. The culmination of this DOE-supported effort establishes micro-vibrational defrosting as a viable, high-efficiency, low-noise, and demand-flexible de-icing technology, paving the way for commercial deployment and broader application in next-generation refrigeration systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗