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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Chapter 13: All-Electric Vertical Take-Off and Landing Aircraft (eVTOL) for Sustainable Urban Travel

Increasing urbanization, ground congestion, and greenhouse gas emissions have spurred aircraft pioneers to capitalize on advancements in battery technology, electric motors, software, and other advances to develop all-electric vertical take-off and landing (eVTOL) aircraft intended to save travelers time within densely populated urban regions. This study served as an example for conducting a life-cycle analysis (LCA) of an eVTOL aircraft, analyzing its manufacturing process, its in-life operation as a passenger transportation service between urban locations, and (in part) end-of-life treatment. This case study aims to provide guidance on how to accurately conduct eVTOL LCA, particularly on how to define the problem, how to obtain the right information from engineers inside and outside their own organizations, and what areas to focus on. As LCA results are only as accurate as the assumptions that were made, a more rigorous LCA that includes sensitivity analysis and uncertainty characterization can help further understand the limitations of those assumptions. New technologies such as blockchain may also play an important role in LCA, including the life-cycle inventory and improving confidence intervals. Completing a credible LCA is central to supporting the argument in favor of introducing the new technology. Completing such a study will allow companies to demonstrate to relevant stakeholders the likely impact of their aircraft on the environment by quantifying the operational climate footprint of the aircraft and the manufacturing process used to build it. To this end, this case study also provides examples of how to report and present LCA results, optimizing for communications to non-LCA experts. The LCA can also assist in identifying opportunities to improve the environmental performance at various life-cycle stages, informing decision makers as products and manufacturing processes evolve or are redesigned. Given the nascency of both eVTOL aircraft manufacturing and operations, it is strongly recommended that LCA analysts treat reports on eVTOL aircraft as works-in-progress. As new information is found, design changes are made, and the aircraft or operation gains maturity, it is inevitable that some amendments will need to be made to the LCA. It is suggested that a complete overhaul of the LCA be made every 18-24 months throughout the R&D, design, and operational scale-up phases of the project.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2022

DEVELOPMENT OF OIL FREE CENTRIFUGAL BLOWER AS ENABLING TECHNOLOGY FOR SOLID OXIDE FUEL CELL ANODE GAS RECYCLING

Broad commercialization of solid oxide fuel cells (SOFCs), requires anode offgas recycle blowers (AORB) that are specifically designed for handling the challenging operating conditions presented by the SOFC process gases. Otherwise, they can be susceptible to frequent maintenance, low reliability, and short life. This work presents details of the development and testing of an oil-free, low cost centrifugal AORB based on compliant foil bearing (CFB) technology for support of a 100 kW solid oxide fuel cell power plant. The advantages of this novel technology are discussed, particularly its long life and maintenance-free operation, which are derived from the use of CFBs. Also included are preliminary techno-economic analysis considerations for cost-effective deployment of the technology.

03 NATURAL GAS↗
DOE OSTI2026

TRIZ-Based Design Improvement for Facilitating Transmission Control Unit Remanufacturing

Design for Remanufacturing (DfRem) centers on enhancing product design and operations to facilitate remanufacturing while increasing both economic and environmental sustainability. DfRem requires a comprehensive understanding of product characteristics, production conditions, and operational constraints. Thus, DfRem requires a systematic methodology to identify and implement alternative designs. Among many critical steps in remanufacturing, disassembly is essential because it directly supports remanufacturing by separation of product components for cleaning, inspection, and other subsequent process steps. This study proposes a TRIZ-based framework to improve product design for disassembly in support of remanufacturing. The framework is applied to a transmission control unit (TCU) case study. The current TCU design prevents remanufacturing due to the sealant-based component joinery, which complicates disassembly and risks damaging the printed circuit board (PCB). After defining technical contradictions for the TCU product design and reviewing the suggested TRIZ principles to solve the conflicts, a cantilever snap-fit design alternative is developed. The economic feasibility of the snap-fit design is assessed by comparing the current and snap-fit design costs for three life cycles. The cost analysis demonstrates that the cost of the snap-fit design remains the same as the current design. Additionally, the snap-fit design offers substantial cost savings for three life cycles compared to the current design. We demonstrate how snap-fit design supports both environmental and economic sustainability.

42 ENGINEERING↗
DOE OSTI2026

Comparative Assessment of Battery Carbon Footprint Calculation Frameworks to Support U.S. Battery Manufacturing

A “battery passport” is a digital record that provides comprehensive information about an individual battery across its life cycle. This concept has been introduced by Battery Regulation (EU) 2023/1542 [1], which applies to batteries for electric vehicles (EVs), industrial batteries with a capacities greater than 2 kWh, and batteries for light means of transport (LMT) greater than 2kWh sold in the European Union (EU) market – impacting manufacturers and exporters across multiple jurisdictions globally. Among its reporting mandates, a key feature of battery passports is the requirement for a carbon footprint (CF) calculation methodology supported by enhanced data granularity to enable traceable and verifiable CF results. While no other jurisdictions have yet adopted formal battery passport requirements like the EU’s, some are developing CF calculation methods to comply with the EU Battery Regulation or are creating CF-related regulations that could evolve in a similar direction, reflecting the growing importance of battery CF guidelines for manufacturers seeking to remain competitive in global markets.

Zhang, Jingyi [Argonne National Laboratory (ANL), ↗
DOE OSTI2022

Role of Life Cycle Assessment in the Circular Economy

Industry leaders are increasingly turning to the circular economy to address a global need for reducing waste and reusing materials. Stakeholder pressure is mounting to establish better practices for more sustainable systems. Join your industry colleagues for an informative workshop to connect and accelerate standards development related to the circular economy of discarded manufacturing materials. The objective of the workshop is to develop a roadmap for ASTM technical standards to support the formation and engagement of manufacturers in a circular economy. Particular focus will be given to standards to support manufacturers in bringing their discarded materials into a mature materials marketplace as well as standards to measure and improve processing efficiencies resulting in reductions in discarded materials. The resulting roadmap will identify priorities for near-term standardization efforts. The roadmap will identify the necessary definitions for information flows supporting a sophisticate ecosystem for traceability and reuse of the materials. What is the role that life cycle assessment should have in setting manufacturing standards for applying circular economy strategies?

circular economy↗
DOE OSTI2021

Life Cycle Analysis of Renewable Natural Gas and Lactic Acid Production from Waste Feedstocks

Producing fuels and chemicals from waste is considered economically favorable, due to low feedstock cost, and environmentally favorable, due to avoided emissions from conventional waste management practices. In this study, we evaluate the life cycle greenhouse gas (GHG) emission reduction benefits of renewable natural gas (RNG) and lactic acid (LA) production from four types of wet waste feedstocks (wastewater sludge, food waste, swine manure, and fats, oil, and grease [FOG]) via anaerobic digestion (AD) and LA fermentation, respectively. RNG can be used as an alternative to fossil natural gas, while LA from waste feedstocks can displace conventional LA production pathways (mainly from corn via fermentation). Providing comprehensive life cycle GHG emissions of the combinations of waste feedstocks and products through different routes helps identify the GHG hotspots and show where emissions savings come from. The results show that the carbon intensities (CIs) of waste-derived RNG and LA are much lower than those of their counterparts. We estimated the life cycle GHG emissions for RNG to be between -146 and 27 g carbon dioxide equivalent (CO2e)/MJ, much lower than the CI of fossil fuels. Waste-derived LA pathways also show substantially lower CIs, ranging from -4.2 to -1.4 kgCO2e/kg LA, compared to the CIs of LA from corn and corn stover (1.2 and 0.3 kgCO2e/kg LA, respectively). We will also discuss that the low CIs of waste-derived products can come from low yields leading to high emission credits. Thus, life cycle analysis results presented per weight of treated waste can be used to support decisions about which waste feedstocks and products are to be used for sustainable waste valorization. In addition, we found that monetary emission reduction credits can play an important role in driving waste valorization.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Pitch Bearing Rating and Service Life Analysis

Pitch bearings are an essential component in wind turbines used to connect the blade root to the hub. They support the resulting simultaneous radial, axial, and overturning moment loads while allowing relative rotation of the blade to the hub. The most recent evidence indicates the replacement rate for pitch bearings on 3+ MW turbines can be several percent per year, reaching 10% by year 5. This is a far higher replacement rate than both older 1.5 to 2 MW turbines and 2 to 3 MW turbines, which only reach a 10% replacement rate by 14 to 24 years compared to the expected design life of at least 20 years. Typical pitch bearing replacements require the use of a large, expensive crane and removal of the blade(s) or rotor, with a significant amount of downtime. Given the most recent developments in pitch bearing reliability and the publication of the updated NREL and Fraunhofer IWES pitch bearing design guide, the purpose of this report is to update the performance and rating analysis of the example 1.9-meter diameter pitch bearing representative of that installed on a 1.5 MW wind turbine, compare the rating life to the observed service life of similar pitch bearings, and validate the service life modification factor with this large population of bearings. The report will also summarize the pitch bearing contact conditions, thereby serving as a guide for planned bench-level fretting wear tests at Argonne National Laboratory.

17 WIND ENERGY↗
DOE OSTI2022

Comparing Life Histories of the Shortest-Lived Turtle Known (Chicken Turtles, Deirochelys reticularia ) with Long-Lived Blanding's Turtles ( Emydoidea blandingii )

Evolutionary theories predict major differences in life-history trait values of long- and short-lived organisms. Such comparisons have not been possible for chelonians because no shortlived turtle was known until research revealed that chicken turtles (Deirochelys reticularia; DR) have a maximum longevity of 21 yrs. Life-history trait values of DR females are 1) age at maturity of females = 5–6 yrs; 2) clutches per season = 1.6; 3) annual fecundity = 6–8 female eggs per female; 4) average juvenile survivorship from age 1 to maturity = 0.60; and 5) low average annual adult survivorship = 0.66. We compared DR with the very long-lived Blanding’s turtles (Emydoidea blandingii; EB) in Michigan. Over 14 yrs with no mortality (the minimum age at maturity of EB), the maximum potential fecundity produced by a single female embryo and her mature female offspring was 5 female eggs for EB and 1040 eggs for DR. Comparisons of life table output for approximately stable populations of DR and EB resulted in cohort generation times of 7 and 37 yrs, respectively. The life-history prediction that short-lived organisms should produce smaller offspring was not supported. Average wet mass of eggs is 10 g (8.4–11.3 g) for DR and 12 g (10–14 g) for EB; and average wet mass of hatchlings is 7.3 g (6–9 g) for DR and 9.3 g (6–13 g) for EB. Both differences are smaller than expected based on the difference in longevity. Here, short-lived female DR have an unusual tactic of investing in high fecundity and making substantial body sizespecific investment in large eggs, which may reflect why juvenile survivorship had greater influence on population change rates than did adult survivorship. In contrast, adult survivorship had the greatest influence on population change rates of EB. Comparison of cohorts of 1000 female DR and EB hatchlings highlights the differences in life histories of short- and long-lived turtles: all DR would be dead by the time the last female EB had reached maturity at 21 yrs of age.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Wireless Sensor Modalities at a Nuclear Plant Site to Collect Vibration Data

One of the major contributors to the total operating costs of domestic nuclear fleet of reactors today is the operation and maintenance (O&M) costs. These include labor-intense preventive maintenance programs involving manually-performed inspection, calibration, testing, and maintenance of plant assets at periodic frequency and time-based replacement of assets at periodic frequency, irrespective of their conditions. This has resulted in a labor-centric business model to achieve high capacity factors. To build an optimal maintenance program, it’s time to transition from this labor-centric business model to a technology-centric business model. Fortunately, there are technologies (advanced sensor, data analytics, and risk assessment methodologies) that will support this transition. The technology-centric business model will result in significant plant life extension and reduction of time-based maintenance activities. This will drive down O&M costs as labor is a rising cost and technology is a declining cost. This approach will lay the foundation for real-time condition assessment of plant assets, allowing condition-based maintenance to enhance plant safety, reliability, and economics of operation. The goal of this project is to address challenges in the area of digital monitoring, i.e., the application of advanced sensor technologies (particularly wireless sensor technologies) and science-based data analytic capabilities to advance online monitoring and predictive maintenance in nuclear plants to improve plant performance (efficiency gain and economic competitiveness). To achieve the project goal, in partnership with Exelon Generating Company (Exelon), researchers from Idaho National Laboratory (INL) and Oak Ridge National Laboratory (ORNL) are performing research and development (R&D) to demonstrate application of wireless sensors using the distributed antenna system and advanced data analytics to achieve predictive maintenance. In the report, wireless vibration sensors, vibration data and its indicator are described. The wireless vibration sensors presented in this report support three types of wireless communication, namely, Wi-Fi, cellular, and 900 MHz. These wireless vibration sensors are considered by partner plant site for installation on plant asset to enable online vibration monitoring to replace periodic measurements. These vibration data along with other plant process data will be utilized to develop diagnostic and prognostic models.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Challenges and Opportunities in Deep Reinforcement Learning With Graph Neural Networks: A Comprehensive Review of Algorithms and Applications

Deep reinforcement learning (DRL) has empowered a variety of artificial intelligence fields, including pattern recognition, robotics, recommendation-systems, and gaming. Similarly, graph neural networks (GNN) have also demonstrated their superior performance in supervised learning for graph-structured data. In recent times, the fusion of GNN with DRL for graph-structured environments has attracted a lot of attention. Here, this paper provides a comprehensive review of these hybrid works. These works can be classified into two categories: (1) algorithmic enhancement, where DRL and GNN complement each other for better utility; (2) application-specific enhancement, where DRL and GNN support each other. This fusion effectively addresses various complex problems in engineering and life sciences. Based on the review, we further analyze the applicability and benefits of fusing these two domains, especially in terms of increasing generalizability and reducing computational complexity. Finally, the key challenges in integrating DRL and GNN, and potential future research directions are highlighted, which will be of interest to the broader machine learning community.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Reliability and Maintainability Changing the Culture

The Reliability and Maintainability team strives to ensure the reliability, availability, and maintainability of plant assets throughout their life cycle. This objective is accomplished by providing world-class maintenance engineering support and maintenance processes. University of Tennessee’s Reliability and Maintainability Center (UT RMC) Partnership – Provided subject matter expert (SME) analysis of current state of both sites integrated work control (IWC) and maintenance execution processes.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Task 12 PV Sustainability - Mineral Resource Use Footprints of Residential PV Systems

Resource use intensity is often mentioned as one of the main characteristics of PV systems and PV electricity. Recently, the International Energy Agency published a report on the role of critical minerals in clean energy transitions. The Product Environmental Footprint pilot study on PV electricity quantified (among other environmental impacts) its abiotic depletion potential. So far, a comprehensive assessment of resource use impacts highlighting the different facets of its impacts is however lacking. For the first time, the resource use impacts of PV electricity are quantified simultaneously with four impact category indicators recommended or suggested by the Life Cycle Initiative hosted at UN Environment. The indicators cover distinctly different aspects of resource use, namely resource depletion with the Abiotic Depletion Potential, ultimate reserves (ADP UR ), economic resource scarcity with the Abiotic Depletion Potential, economic reserves (ADP ER ), resource quality with the Surplus Ore Potential, Ultimate Recoverable Resources (SOP URR ) and re-source criticality with the ESSENZ method. The resource use impacts caused from the generation of 1 kWh electricity with a residential scale photovoltaic (PV) system installed in Central Europe using mono- and multi-crystalline silicon panels and CdTe panels, respectively are quantified. The product system includes manufacture, use and end of life treatment (take back and recycling) of the PV panels, cabling, inverter and supporting structure, the supply chains of the raw materials and energy used in PV panel and inverter manufacture as well as transport logistics.

14 SOLAR ENERGY↗
DOE OSTI2026

Battery Energy Storage System (BESS) End-of-Performance and Decommissioning Considerations [Slides]

This presentation provides a comprehensive overview of end-of-performance and decommissioning considerations for large-scale Battery Energy Storage Systems (BESS). It outlines expected system lifespans, midterm assessment needs, and pathways for extending operational life through augmentation or repowering. The presentation details regulatory requirements that govern decommissioning plans, cost estimates, financial assurance mechanisms, and performance obligations across multiple jurisdictions. It further examines end-of-life equipment management, including recycling, waste handling, transportation, and environmental compliance. Designed to support Malawi's electricity-sector institutions, the presentation highlights how planning for decommissioning and environmental stewardship can be integrated early in project development to ensure safe, financially accountable, and environmentally responsible BESS system retirement.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Machining of Alloy 709 Creep-fatigue Specimens from G. O. Carlson Heat

Alloy 709 has been selected as the next candidate material for Section III, Division 5 qualification in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC) for elevated-temperature nuclear construction. The qualification data package requires an assortment of information and material data including tensile, creep, and creep-fatigue performance at elevated temperatures from different material heats. The goal of the project is to generate a dataset to support qualification of Alloy 709 material for ASME BPVC design code. Working towards the project goal, Idaho National Laboratory needs to conduct a series of tests on three different heats to support the A709 code case development. At present, there is a gap in the data package for one of the heats: Heat number 58776 manufactured by G.O. Carlson. To address this data gap, Argonne National Laboratory transmitted five plates of A709 heat 58776 manufactured by G.O. Carlson to Idaho National Laboratory. These plates were solution annealed at 1150°C and heat treated at 775°C for 10 hours. The objective of this specification is to procure a series of creep-fatigue specimens to support the qualification data package. The creep-fatigue specimen design captures the cyclic material performance at elevated temperature. The material performance data generated from specimens machined herein will support the ASME BPVC code case development and establish design limits, and design life curves for Alloy 709 material.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Nanocellulose as an embedding matrix and applications thereof

A versatile drug delivery system comprised of plant-based nanocellulose can be used for providing high loading and extended release for virtually any drug. This system is made from nanocrystalline cellulose chemically cross-linked to form a hydrogel. This versatile hydrogel-based drug delivery system can be functionalized to support extended release of oral dosing, relieving patient burden and increasing quality of life.

Ray, Anamika↗
DOE OSTI2025

Hybrid data-driven cement-stabilized soil design: An integration of machine learning, multi-objective optimization, and life cycle assessment

Soil stabilization is crucial in geotechnical engineering, yet conventional methods are often time-consuming, resource-intensive, and environmentally unsustainable. Despite growing interest in Machine Learning (ML) and optimization tools for mix design, few studies integrate these methods with decision-making techniques and environmental assessment to support practical implementation. This study proposes a hybrid data-driven framework for predicting strength, optimizing mix compositions, and evaluating environmental impacts via life cycle assessment of cement-stabilized soft soils. Six ML models were evaluated, and the top-performing eXtreme Gradient Boosting (XGB) model was further improved using the Grey Wolf Optimizer (GWO). The optimized XGB-GWO model, integrated with a polynomial cost function, served as the objective function in a multi-objective optimization problem solved via the Non-Dominated Sorting Genetic Algorithm II (NSGA-II), with final mix selection guided by the entropy-weighted TOPSIS method. Validation through a case study produced mix designs offering superior strength-cost trade-offs, with the optimal mix achieving 2243.2 kPa unconfined compressive strength and a 16.07 % reduction in carbon emissions compared to the highest-cost design. In conclusion, this study offers a sustainable, scalable approach to soil stabilization and supports informed decision-making in construction.

Life cycle assessment↗
DOE OSTI2025

Designing Recyclable Biomass-Based Polyesters (Final Technical Report)

This project successfully demonstrated the production of sustainable polyesters from biomass-derived monomers, offering properties on par with or superior to fossil-based plastics such as LLDPE and PBAT. Using renewable chemical platforms like furfural and HMF, we synthesized over eight novel monomers and nearly 100 aliphatic-aromatic polyesters. Among these, PPeAT and PDDF emerged as highly promising candidates for flexible packaging applications, exhibiting excellent mechanical performance, tunable thermal properties, and enhanced barrier characteristics. Key advances included the development of ring-opening polymerization strategies using cyclic monomer intermediates to produce high molecular weight materials with excellent control. The resulting polymers achieved biobased content of at least 44 wt.%. We also implemented chemical recycling via catalytic methanolysis, recovering over 90% of monomers from PPeAT at semi-pilot scale. This supports a circular economy approach by enabling material reuse without performance loss. Techno-economic and life cycle assessments confirmed that these polyesters can reduce greenhouse gas emissions by up to 50% compared to petroleum-derived alternatives. Favorable mechanical properties may further reduce material demand, and cost competitiveness was demonstrated under specific market conditions. Feedstock cost and environmental footprint were identified as primary levers for future optimization. In summary, the project met or closely approached all technical targets, including biodegradability, strength, and processing compatibility. While minor issues such as color and melting point variation remain, the results strongly support continued development and scale-up of these sustainable materials.

09 BIOMASS FUELS↗
DOE OSTI2022

The development and use of decision support framework for informing selection of select agent toxins with modelling studies to inform permissible toxin amounts

Many countries have worked diligently to establish and implement policies and processes to regulate high consequence pathogens and toxins that could have a significant public health impact if misused. In the United States, the Antiterrorism and Effective Death Penalty Act of 1996 (Public Law 104-132, 1996), as amended by the Bioterrorism Preparedness and Response Act of 2002 (Public Law 107-188, 2002) requires that the Department of Health and Human Services (HHS) [through the Centers for Disease Control and Prevention (CDC)] establish a list of bacteria, viruses, and toxins that have the potential to pose a severe threat to public health and safety. Currently, this list is reviewed and updated on a biennial basis using input from subject matter experts (SMEs). We have developed decision support framework (DSF) approaches to facilitate selection of select toxins and, where toxicity data are known, conducted modelling studies to inform selection of toxin amounts that should be excluded from select agent regulations. Exclusion limits allow laboratories to possess toxins under an established limit to support their research or teaching activities without the requirement to register with the Federal Select Agent Program. Fact sheets capturing data from a previously vetted SME workshop convened by CDC, literature review and SME input were developed to assist in evaluating toxins using the DSF approach. The output of the DSF analysis agrees with the current select toxin designations, and no other toxins evaluated in this study were recommended for inclusion on the select agent and toxin list. To inform the selection of exclusion limits, attack scenarios were developed to estimate the amount of toxin needed to impact public health. Scenarios consisted of simulated aerosol releases of a toxin in high-population-density public facilities and the introduction of a toxin into a daily consumable product supply chain. Using published inhalation and ingestion median toxic dose (TD 50 ) and median lethal dose (LD 50 ) values, where available, a range of toxin amounts was examined to estimate the number of people exposed to these amounts in these scenarios. Based on data generated by these models, we proposed toxin exclusion values corresponding to levels below those that would trigger a significant public health response (i.e., amounts estimated to expose up to ten people by inhalation or one hundred people by ingestion to LD 50 or TD 50 levels of toxin in the modeled scenarios).

60 APPLIED LIFE SCIENCES↗