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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.

42 ENGINEERING↗
DOE OSTI2025

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.

42 ENGINEERING↗
DOE OSTI2024

TCO Analysis Approach and Regional Analysis of dWPT for Class 8 Tractors

Dynamic Wireless Power Transfer (dWPT) is a method by which battery electric vehicles (BEVs) can charge their battery while traveling on the road without the need for a physical conductive connection to the power source. dWPT has been proposed as a strategy to enable a reduction in vehicle battery capacity and associated mass and cost. In this slide deck presented at the EVs@Scale Consortium - Wireless Power Transfer Pillar Deep-Dive Meeting on November 11th, 2023, NREL provides results from an evaluation of dWPT using data from Class 8 tractors driving in the Atlanta Metro Area. NREL selected data for archetypal days representing local, regional, and long-haul trips, defined according to trip length, that included travel on primary roadways. EVI-InMotion (Electric Vehicle Infrastructure - InMotion), a systems planning and optimization tool developed at NREL, was used to evaluate dWPT performance assuming dWPT charging on 120 road segments for a total roadway lane distance of 2,365 miles. The EVI-InMotion results and representative day drive cycles were analyzed with NREL's T3CO (Transportation Technology Total Cost of Ownership) tool to estimate the total cost of ownership (TCO) for scenarios comprising two model years - 2030 and 2040 - and two technology progress cases. TCO was calculated for diesel, fuel cell electric, BEVs with batteries sized assuming no dWPT capabilities, and 200kWh BEVs with dWPT installed. This analysis finds that en-route stationary charging frequency and downtime when not on electrified roadways are the main contributors to TCO for the dWPT vehicles and that these vehicles can achieve cost parity with FCEVs at low electricity costs. Based on the scenario assumptions used here, low electricity costs would further help the cost parity with diesel vehicles in regional and long-haul cases due to stationary fueling downtime. This presentation also concludes that key factors affecting the parity potential of dWPT-capable vehicles include more extensive dWPT road coverage, higher en-route charging power, less expensive power batteries, and higher hydrogen or diesel fuel costs.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2020

Relating Geometric Nanoconfinement and Local Molecular Environment to Diffusion in Ionic Polymer Membranes

Understanding structure-diffusion relationships in ionic polymer membranes not only illuminates fundamental mechanisms for membrane transport, but also informs further membrane development. In this study, we employ NMR diffusometry and molecular dynamics (MD) simulations to investigate diffusion coefficients and activation energies of diffusion (Ea) for both a lithium-form perfluorosulfonic acid membrane and aqueous solutions of lithium triflate. NMR shows that, at high water/ion molar ratio (?), Ea for water diffusion is slightly lower in the membrane than in solution. Conversely, membrane transport exhibits much higher Ea at low hydration as compared to solutions. MD simulations of a model system consisting of carbon nanotubes with varying diameter reveal that Ea of diffusion clearly relates to both the geometric nanoconfinement of the hydrophilic pathways in the membrane as well as the local molecular environment. These results demonstrate that Ea of diffusion can serve as a revelatory tool for the study of molecular transport processes and the coupling of morphology with transport at the nanoscale. This study thus provides new insights and new experimental and computational models for understanding transport in a wide range of polymer membranes, such as those used in molecular separations applications.

Zhang, Rui↗
DOE OSTI2026

Fully generalized, turbulent trace impurity transport with Gkeyll and Flan in the DIII-D far-SOL

The Monte Carlo trace impurity turbulent transport code Flan is introduced for the first time. Flan follows impurities in a turbulent background plasma from Gkeyll using the Lorentz force to resolve the full particle gyro orbit. Collisions are handled using the Nanbu collision algorithm (Nanbu 1997 Phys. Rev. E 55 4642–52), and ionization/recombination is handled via ADAS coupling. The far-SOL of a generic DIII-D L-mode is simulated with and without the collision model to show how collisions affect radial tungsten transport. Anomalous diffusion coefficient (D r ) and pinch velocity (v p ) profiles are extracted from fits to the results. With collisions, D r and v p are between 0–1.0 m 2 s −1 and −100–100 m s −1 , respectively. Without collisions, D r and v p are between 0–0.3 m 2 s −1 and −50–50 m s −1 , respectively. Exponential fits to the radial W density profiles and experimental data from W deposition along a collector probe are in good agreement, demonstrating Flan as a useful interpretive modeling tool. Additional simulations show that impurity transport away from the wall increases with atomic number, though it is not clear why. Flan has the potential to better interpret existing data and improve reactor scale predictions of core contamination because the underlying physics model is very general and does not rely on arbitrary user-defined transport coefficients.

DIII-D↗
DOE OSTI2024

A Mobility Energy Productivity Evaluation of On-Demand Transit: A Case Study in Arlington, Texas

On-demand transit (ODT) systems are increasing in number and size. In order to evaluate and quantify outcomes, we use the Mobility Energy Productivity (MEP) metric, a holistic tool to analyze, quantify, and compare the mobility and accessibility of various transportation modes in a specific area. In this paper, we apply the MEP tool to the ODT system in Arlington, Texas, and compare the results among four existing transportation modes (drive, transportation network company, transit, and bike) and five additional ODT scenarios. We focus our analysis on the opportunities that an ODT system presents such as serving disadvantages communities. While the results in Arlington show the typical U.S. pattern of driving receiving the highest MEP score, the ODT system best serves those in disadvantaged communities, helping with an equity design goal. ODT improved the average MEP score across the service area by 100% when considering only non-private vehicle modes (bike, transit, and ODT). For the ODT scenarios, decreasing the wait time 50% compared to the baseline scenario led to a nearly 160% increase in MEP score, while increasing the ODT travel speed by 21% led to an 80% improvement in MEP score. The decreased wait time scenario had the highest MEP score out of the six ODT scenarios. This paper demonstrates how ODT can enhance mobility, particularly for disadvantaged communities. The results of a MEP analysis can be used by researchers and transit agencies to compare transportation modes and improve the effectiveness of transportation systems in subareas across a service area.

accessibility↗
DOE OSTI2026

Performance and transport in the ARC tokamak

The ARC TM tokamak, a high-field (𝐵 𝑇 = 11.4 T) fusion power plant, under development by Commonwealth Fusion Systems, is studied using a suite of integrated modelling tools to predict its fusion power generation (𝑃𝑓⁡𝑢⁢𝑠), transport and confinement properties. Analysis is based off an ARC operational point scoped first with zero-dimensional (0-D) plasma operational contour (POPCON) modelling to produce 1.13 GW of fusion power. A suite of integrated modelling tools (TRANSP, ASTRA and TORAX) were applied to predict the performance and kinetic profiles of the ARC design point, yielding a range of predicted performance spanning from ∼900 to 1300 MW in rough quantitative agreement with POPCON predictions. The sensitivity of these results to uncertain modelling inputs was probed using scans of pedestal boundary conditions around EPED-predicted values (total pressure and temperature ratios), tungsten concentration and seperatrix density around their nominal assumptions. Pedestal pressure and pedestal top (𝑇 𝑖 /𝑇 𝑒 ) play a large role in 1.5-dimensional performance predictions, able to modify the predicted 𝑃 𝑓⁡𝑢⁢𝑠 by a factor of 2 within reasonable assumptions. High-fidelity core nonlinear gyrokinetic profile predictions, performed using CGYRO (Candy et al. 2016 J. Comput. Phys., vol. 324, pp. 73–93) coupled with the PORTALS (Rodriguez-Fernandez et al. 2024 Nucl. Fusion, vol. 64, 076034; Phys. Plasmas, vol. 31, 2024, 062501) framework, yield substantially lower performance (𝑃 𝑓⁡𝑢⁢𝑠 =677 MW) compared with 0-D and medium-fidelity modelling for nominal assumptions, showing that there is non-negligible uncertainty between models and that future work on SPARC may help resolve discrepancies. Lower overall performance results from significantly reduced volume-averaged densities and temperatures, along with reduced levels of density and temperature peaking. Turbulence and transport are largely dominated by ion temperature gradient across the profile, confirmed by both linear stability and the response of the nonlinear fluxes to changes in gradients, with some impact of kinetic ballooning modes in the deep core. This work represents one of the most complete scoping of potential fusion power plant conditions performed to date. The extensive integrated modelling provides confidence in ARC performance approaching 1 GW, while nonlinear gyrokinetic modelling results in open questions into the physics of density and temperature peaking in fusion-power-plant-relevant operational space. A discussion of results and the role that the SPARC tokamak (Creely et al. 2020 J. Plasma Phys., vol. 86, 865860502) will play in informing ARC design, performance and operation is presented.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Progress in the Verification and Validation Efforts for START: A Spent Fuel Routing Tool

The U.S. Department of Energy’s (DOE) Office of Nuclear Energy (DOE-NE) is planning for an integrated waste management approach to transport, store, and dispose of spent nuclear fuel (SNF) and other high-level radioactive waste (HLW) as part of the Integrated Waste Management (IWM) program [1]. In support of this effort, the Stakeholder Tool for Assessing Radioactive Transportation (START) is being developed within the IWM program [2, 3]. This is a web-based decision support tool that can be used to analyze geospatial data related to the transportation of SNF and HLW. START is designed as a web-based application using an ArcGIS server through which the user can select the origin and destination of the route [4]. This is followed by selection of the mode of transportation of choice based on user preference. Some of the modes available to the user include rail, heavy haul truck, and barge. The option of utilizing more than one mode of transportation (intermodal transportation) is also implemented in START. A few examples of intermodal transportation include barge to rail, and heavy haul truck to rail. It must be noted that some routes might not have access to all modes of transportation, depending on the infrastructure availability at the origin and destination sites. Users can also select any stops or barriers they would like to introduce in the routes. This is followed by selection of the routing criteria of interest. Three primary routing options available to the user include minimum population, minimum distance, and minimum time. Apart from that, a few other options include accounting for a weighted average of the three aforementioned routing options. The next step involves the selection of the buffer distance of interest which includes the two choices available of 800 m and 2500 m, respectively. Finally, an option to select any prohibited rail carriers that the user does not wish to use is available. After making these selections, a route is ready to be created.

Gadey, Harish Reddy↗
DOE OSTI2024

Agent-based modeling for multimodal transportation of CO 2 for carbon capture, utilization, and storage: CCUS-agent

Here, to understand the system-level interactions between the entities in Carbon Capture, Utilization, and Storage (CCUS), an agent-based foundational modeling tool, CCUS-Agent, is developed for a large-scale study of transportation flows and infrastructure in the United States. Key features of the tool include (i) modular design, (ii) multiple transportation modes, (iii) capabilities for extension, and (iv) testing against various system components and networks of small and large sizes. Five matching algorithms for CO 2 supply agents (e.g., powerplants and industrial facilities) and demand agents (e.g., storage and utilization sites) are explored: Most Profitable First Year (MPFY), Most Profitable All Years (MPAY), Shortest Total Distance First Year (SDFY), Shortest Total Distance All Years (SDAY), and Shortest distance to long-haul transport All Years (ACAY). Before matching, the supply agent, demand agent, and route must be available, and the connection must be profitable. A profitable connection means the supply agent portion of revenue from the 45Q tax credit must cover the supply agent costs and all transportation costs, while the demand agent revenue portion must cover all demand agent costs. A case study employing over 5500 supply and demand agents and multimodal CCUS transportation infrastructure in the contiguous United States is conducted. The results suggest that it is possible to capture over 9 billion tonnes (GT) of CO 2 from 2025 to 2043, which will increase significantly to 22 GT if the capture costs are reduced by 40 %. The MPFY and SDFY algorithms capture more CO 2 earlier in the time horizon, while the MPAY and SDAY algorithms capture more later in the time horizon.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

A Novel Workflow for Coupled Simulation of Hydraulic Stimulation with Simultaneous Injection of Proppant

Enhanced Geothermal Systems (EGS) are located in impermeable host rock. Therefore, to achieve promising circulation, hydraulic stimulation is a key factor. Stimulation involves injecting a combination of fluids and proppant particles into existing fractures under high pressure. The effectiveness of stimulation depends on a variety of different factors, including the pressurization scheme and the optimal choice of carrying fluid and proppant particles to be used. For example, high-density particles can settle out of the injected slurry quickly, whereas lighter particles as well as a dense carrying fluid allow for a long transport into the reservoir. A numerical tool is therefore essential to take all these factors into account and to make robust predictions about the performance of the hydraulic stimulation. We present a novel computational application for coupled numerical simulation of hydraulic stimulation with concurrent injection of proppant in a fractured geothermal reservoir. This application is based on the open-source MOOSE framework that has been enriched with a set of equations to account for the circulation of proppant-laden slurries. It accounts for both the fluid and proppant components of the mixture, as well as particle-driven processes that include gravity settling, particle-particle interactions, and strong density and viscosity contrasts. A particular challenge is the mutual coupling with fracture mechanical processes in a propagating fracture using the FE code Defmod. Aperture and fluid pressure on one side and slurry density and viscosity changes on the other side interact and affect each other. Their basic understanding is therefore essential for the success of the stimulation. We compare our application to common numerical benchmark problems for both slurry flow and hydraulic stimulation.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Investigation of irradiation damage and heat deposition: a comparative analysis for HEU-to-LEU conversion in HFIR

The planned conversion of the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory from highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel requires detailed evaluation of experiment-relevant parameters to ensure continued performance for materials testing and isotope production. Here, this study presents the first comprehensive assessment of displacements per atom (dpa) and heat deposition rates in target materials within the HFIR flux trap with both HEU and candidate LEU core configurations. Seven analyses were conducted to evaluate key performance metrics, including fast neutron flux distribution, cross section response functions, cross section data, and local dpa and heat deposition rates using mesh- and cell-based tallies. Simulations employed Shift, Monte Carlo N-Particle (MCNP), and the HIFR Controller (HFIRCON) tool suite for high-fidelity transport and depletion modeling. The LEU designs—using U 3 Si 2 -Al dispersion fuel and operating at 95 MW—were compared to the current 85 MW HEU configuration. Results show that while the candidate LEU cores exhibit higher dpa rates due to a harder spectrum and extended cycle lengths, they also demonstrate reduced heat deposition rates in irradiation experiments, primarily due to increased gamma self-shielding from higher 238 U content in the core. These findings confirm that LEU conversion can maintain HFIR’s materials irradiation capabilities but may require redesigning existing experimental hardware.

HEU↗
DOE OSTI2023

Giant interfacial spin Hall angle from Rashba-Edelstein effect revealed by the spin Hall Hanle process

The Rashba-Edelstein effect (REE), which generates interfacial spin polarization and subsequent spin current, is a compelling spin-charge conversion mechanism for spintronic applications, since it’s not limited by the elemental spin-orbit couplings. In this work we demonstrate REE at Pt/ferroelectric interfaces by showing a positive correlation between polarization and effective spin Hall angle in the recently elucidated spin Hall Hanle effects (SHHE), in which a Larmor precession of spin polarization in a diffusion process from the interface manifest as magnetoresistance and Hall effect. We show that REE leads to a large enhancement of the effective spin Hall angle of ferroelectric interface Pt/h-LuFeO 3 compared with that of Pt/Al 2 O 3 , without obvious differences in the spin relaxation time. Modeling using SHHEs involving REE as an additional source of interfacial polarization suggests that REE can lead to an interfacial spin Hall angle (0.4 ± 0.1) in Pt/h-LuFeO 3 that is one order of magnitude larger than the bulk value of Pt. Our results demonstrate that a ferroelectric interface can produce large spin-charge conversion and that SHHEs are a sensitive tool for characterizing interfacial spin-transport properties.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Pricing Strategy of Electric Vehicle Aggregators Based on Locational Marginal Price to Minimize Photovoltaic (PV) Curtailment

The global climate crisis demands urgent action to mitigate global warming. Using renewable energy sources, such as solar and wind power, for electricity generation is crucial. This shift from centralized to distributed power systems, however, brings challenges, including voltage fluctuations and renewable energy curtailment. The rapid growth of the electric vehicle (EV) industry adds complexity, increasing overall electricity demand and straining the power supply during peak charging times. This paper proposes a scheduling strategy for EV aggregators to reduce renewable energy curtailment and stabilize grid operation by strategically scheduling EV charging. Using Multi -Agent Transport Simulation (MATSim), a traffic simulation tool, EV driving data in Denver, Colorado, USA, were modeled. The EV aggregator adjusts charging fees based on locational marginal prices, encouraging EVs to charge at different stations according to pricing. Simulations on an IEEE 33-bus system with distributed energy resources and EV charging stations validate the proposed algorithm, demonstrating its effectiveness in reducing curtailment by 12.55% and stabilizing grid operation.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

NMACFoam (Numerical-model for Membrane-spacer Assemblies and Configurations in OpenFOAM) [SWR-23-57]

NMACFoam is a computational fluid dynamics tool for simulating flow and solids transport in membrane-spacer channels pertaining to reverse osmosis or nanofiltration applications. It is developed on the OpenFOAM framework and allows for simulating spacers with complex geometries. It includes porous wall boundary conditions for membranes and can accurately capture concentration polarization effects. One can perform large calculations at module-scale domain sizes using high performance computing resources with NMACFoam, which scales to 1000s of processors for problems with 1-10 million cells.

Sitaraman, Hariswaran↗
DOE OSTI2021

Space to Air High-Altitude Region Adjoint Neutron Transport

Neutrons from an atmospheric nuclear explosion can be detected by sensors in orbit. Current tools for characterizing the neutron energy spectrum assume a known source and use forward transport to recreate the detector response. In realistic scenarios the true source is unknown, making this an inefficient, iterative approach. In contrast, the adjoint approach directly solves for the source spectrum, enabling source reconstruction. The time–energy fluence at the satellite and adjoint transport equation allow a Monte Carlo method to characterize the neutron source’s energy spectrum directly in a new model: the Space to High-Altitude Region Adjoint (SAHARA) model. A new adjoint source event estimator was developed in SAHARA to find feasible solutions to the neutron transport problem given the constraints of the adjoint environment. This work explores SAHARA’s development and performance for mono-energetic and continuous neutron energy sources. In general, the identified spectra were shifted towards energies approximately 5% lower than the true source spectra, but SAHARA was able to capture the correct spectral shapes. Continuous energy sources, including real-world sources Fat Man and Little Boy, resulted in identifiable spectra that could have been produced by the same distribution as the true sources as demonstrated by two-dimensional (2D) Kolmogorov–Smirnov tests.

LaMere, Zachary W.↗
DOE OSTI2022

Tracer Gas Model Development and Verification in PFLOTRAN

Tracer gases, whether they are chemical or isotopic in nature, are useful tools in examining the flow and transport of gaseous or volatile species in the underground. One application is using detection of short-lived argon and xenon radionuclides to monitor for underground nuclear explosions. However, even chemically inert species, such as the noble gases, have bene observed to exhibit non-conservative behavior when flowing through porous media containing certain materials, such as zeolites, due to gas adsorption processes. This report details the model developed, implemented, and tested in the open source and massively parallel subsurface flow and transport simulator PFLOTRAN for future use in modeling the transport of adsorbing tracer gases.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2024

Overview of Shielding Analyses at Oak Ridge National Laboratory’s Spallation Neutron Source Second Target Station

The Neutronics Group of the Second Target Station project at Oak Ridge National Laboratory is responsible for all neutronics analyses related to design and construction. This paper provides an overview of four neutronics analyses performed for the Second Target Station project, which is representative of all the ongoing work but especially tasks related to shielding. These analyses extend from the proton accelerator through the target monolith and bunker to the end of a neutron beamline. Each example highlights the tools and methods the Neutronics Group uses for analysis. The primary tool is the Monte Carlo radiation transport code MCNP 6.2, but this is augmented by other codes that supplement the input of MCNP. The other codes specifically highlighted in this paper include Attila4MC, ADVANTG, and AARE.

Miller, Thomas↗
DOE OSTI2022

Optimal Transport for Super Resolution Applied to Astronomy Imaging

Super resolution is an essential tool in optics, especially on interstellar scales, due to physical laws restricting possible imaging resolution. We propose using optimal transport and entropy for super resolution applications. We prove that the reconstruction is accurate when sparsity is known and noise or distortion is small enough. We prove that the optimizer is stable and robust to noise and perturbations. We compare this method to a state of the art convolutional neural network and get similar results for much less computational cost and greater methodological flexibility.

Rawson, Michael G.↗