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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 OSTI2025

SAS4A/SASSYS-1 Validation with FFTF Tests

The FFTF liquid sodium cooled test reactor was built to assist the development and testing of advanced fuels and material for fast reactors. The goals of the FFTF Passive Safety Testing program included confirming the safety margins of FFTF as a liquid metal reactor, providing data for computer code validation, and demonstrating the inherent and passive safety benefits of its specific design features. The program included thirteen unprotected loss of flow without scram tests. In preparation for the Passive Safety Testing program, a series of individual reactivity feedback tests were performed which were designed to simulate and validate specific features and reactivity feedbacks of the FFTF core.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Grid Interactive Micro-Distributed Display Case

The goal of this project is to design, fabricate and validate the performance of an economically viable next-generation self-contained, refrigerated open vertical display case with integrated thermal storage that improves energy efficiency, enhances demand flexibility, uses an environmentally friendly refrigerant, improves human comfort

25 ENERGY STORAGE↗
DOE OSTI2025

Initial Characterization of the NREL Large-Amplitude Motion Platform

The Large Amplitude Motion Platform (LAMP) at NREL represents a significant advancement in the controlled testing of Wave Energy Converters (WECs) under laboratory conditions. Originally designed by E2M as a six-degree-of-freedom (DOF) Stewart platform for flight simulation, LAMP has been adapted by NREL to facilitate the mounting and evaluation of WECs. This adaptation enables dry testing of WECs using motion profiles similar to the ocean, facilitating the iterative design, testing, and validation of WEC performance prior to ocean deployments. This report presents the initial work completed to characterize LAMP, with particular emphasis on its stability and operational capabilities across various single and multi-degree-of-freedom (DOF) motion profiles. The report includes planned comparisons at three distinct mass payloads, aimed at assessing the platform's positional accuracy, frequency response, and endurance over extended runtime periods. These experimental tests are critical for establishing the platform's limitations and ensuring that the data generated during WEC validation is both accurate and reproducible. The outcomes of this study not only contribute to a deeper understanding of LAMP's capabilities but also lay the groundwork for future advancements in WEC testing methodologies. By providing robust and reliable performance data within a controlled laboratory setting, the findings are expected to significantly enhance the development and commercialization of marine energy technologies. This report presents the initial findings of the LAMP Characterization work and proposed steps to further understand and characterize LAMP. Data collected during this work can be found on MHKDR at: https://mhkdr.openei.org/submissions/602 Note that this report shares the measured/found instantaneous maximum operating range of LAMP. For most applications the maximum operating range cannot be used for system health and longevity. The operating range and capabilities of LAMP will be evaluated on a case-by-case basis, single-DOF position, velocity, and acceleration values presented in Table 4a-c, and Table 5 should be taken as instantaneous absolute maximum values. Future use of LAMP will likely be limited to smaller values.

16 TIDAL AND WAVE POWER↗
DOE OSTI2026

FAIR Data and Interpretable AI Framework for Architectured Metamaterials (Final Report)

This research program established a transformative framework for the discovery and design of mechanical metamaterials, which are architected structures engineered to control physical phenomena like sound and vibration in ways natural materials cannot. To overcome the traditional reliance on trial-and-error, the project developed an interpretable Artificial Intelligence (AI) framework that moves beyond "black box" models to reveal the specific geometric patterns—such as "unit-cell templates"—that govern a material’s performance. A major breakthrough was the development of a hierarchical design method, which allows a single material to block vibrations across multiple frequency ranges simultaneously by layering patterns at different scales without them interfering with one another. This was further expanded to include irregular, graph-based designs that use spanning tree algorithms to ensure structural connectivity while allowing for customized, direction-dependent properties like stiffness and acoustic impedance. Beyond design, the project addressed the practicalities of real-world production by developing uncertainty quantification techniques that account for manufacturing defects and material variability, reducing the need for expensive physical testing by orders of magnitude. To speed up the discovery process, the team implemented Gaussian Process Regression and other surrogate models that provide accurate performance predictions at a fraction of the traditional computational cost. The AI-generated designs were successfully validated through fabrication of physical samples and wave propagation experiments, confirming their ability to accurately guide or reflect waves as predicted. By contributing these tools and high-quality FAIR benchmark datasets to the wider scientific community, this work provides a scalable foundation for advancing technologies in aerospace vibration control, medical imaging, and noise reduction.

36 MATERIALS SCIENCE↗
DOE OSTI2026

A Perspective on Traditional and Data Driven Electrochemical Modeling and Analysis

To understand the behavior of electrochemical systems, we need to reduce the dimensionality of the measured current-voltage-time (I-V-t) data by fitting models, thus enabling us to analyze and compare the governing physics. Traditionally, the process for this is an 'expert first' approach: defining the model and its explicit assumptions based on inductive reasoning or empirical observation, fitting small portions of the I-V-t data where assumptions are most valid or carefully designing experiments to enforce key assumptions, and then interpreting the model parameters. However, modern data-driven methods enable a new paradigm: a 'data first' approach, where the latent behaviors governing the system's measured response are identified directly using machine-learning models that optimize both model structure and parameters from the I-V-t data, guaranteeing that the learned model explains as much of the observed system response as possible. After model identification, the model can then be interrogated by an expert to connect observed behaviors with underlying physics. This talk will review several different types of electrochemical analysis (electrochemical impedance, differential voltage-capacity, electrochemical kinetics) and compare the traditional and data-driven methods for analyzing the data.

42 ENGINEERING↗
DOE OSTI2026

Upgrading Biogas through in situ Conversion of Carbon Dioxide to Biomethane in Anaerobic Digesters

Organic waste streams generated by wastewater treatment plants, agricultural operations, and food processing industries represent an important yet underutilized opportunity for renewable energy production in the United States. Through anaerobic digestion, these waste streams can produce biogas, a mixture primarily composed of methane (CH4) and carbon dioxide (CO2), that can be upgraded to pipeline-quality natural gas. However, most existing upgrading technologies remove CO2 from biogas rather than utilizing it, leaving a significant portion of the potential energy unused. This project investigates a novel biological upgrading approach that converts CO2 into additional CH4 by supplying hydrogen (H2) to specialized microorganisms capable of performing hydrogenotrophic methanation. The main challenges associated with biological biogas upgrading are related to hydrogen supply, gas-liquid mass transfer, and process stability. First, due to the high cost of hydrogen gas, it is preferable that H2 be produced on-site using renewable energy sources such as wind or solar power. Second, hydrogen has low solubility in liquids, which limits its availability to microorganisms and requires strategies to improve gas dissolution and transfer within the reactor. Third, process inhibition may occur as a result of increased pH caused by CO2 consumption or elevated H2 partial pressure, both of which can negatively affect methanogenic activity. Although research in these areas has advanced during the course of this project, these challenges have not yet been fully resolved. To date, the biological systems that have achieved the highest methane concentrations are typically ex-situ reactors, where operational conditions can be more easily controlled. For this reason, the findings of the present project remain highly relevant. The project goal was to develop an innovative system that can accomplish biogas upgrading via biological conversion of CO2 to CH4, in a novel hybrid approach that combines the advantages of both in-situ and ex-situ systems. The proposed system employs a three-phase upflow anaerobic bioreactor with H2 delivery through a gas-permeable membrane, enabling efficient hydrogen transfer and microbial conversion. Under optimized operating conditions, the system achieved 99% H2 consumption and 90% CO2 conversion. A subsequent gas cleaning stage was implemented to further improve gas quality and meet target purity standards. The upgraded gas composition reached 97.7% CH4, 2.2% CO2, and 0.97% O2, while H2S concentrations remained below detection limits. In addition, a flue gas-driven inorganic thermoelectric generator (TEG) system was designed and experimentally validated as a potential source of electricity for H2 production. The system consisted of six TEG modules connected in series and achieved an open-circuit voltage of 4.5 V and a maximum power output of 224 mW at a temperature difference of approximately 53.5 °C, demonstrating effective conversion of waste heat into electrical power under simulated flue gas conditions. Finally, a comprehensive techno-economic analysis was completed to evaluate the capital and operating costs associated with the proposed system. The results provide important insights to guide future scale-up, optimization, and potential deployment of integrated biological biogas upgrading technologies.

09 BIOMASS FUELS↗
DOE OSTI2026

In Situ High-Temperature Ultrafast Electron Diffraction through Integrated Furnace and MEMS Platforms

Temperature fundamentally governs phase stability, defect evolution, and transport behavior in materials. Despite its central role, direct measurements of structural evolution at elevated temperatures on ultrafast timescales have remained limited. Here, we report the design, integration, and validation of 2 complementary in situ heating platforms that substantially extend the thermal operating range of ultrafast electron diffraction (UED). A compact furnace-type heating stage enables stable diffraction measurements from room temperature to 800 K with ±0.1 K stability under ultrahigh vacuum, achieved through multi-sensor feedback control, dual air-cooling channels, and a thermally isolated motion stage. In parallel, a microelectromechanical system (MEMS)-based heating platform provides rapid thermal response and access to extreme temperatures ≥1,373 K with ±0.1 K stability over hundreds-micrometer regions while supporting simultaneous electrical biasing for electrothermal coupling studies. Absolute temperature calibration is established using diffraction-based thermometry via aluminum lattice expansion and independently validated through in situ melting of bismuth thin films. UED measurements further reveal pronounced temperature-dependent nonequilibrium lattice dynamics in bismuth, including modifications to electron–phonon coupling and Debye–Waller behavior, as well as enhanced ultrafast diffuse scattering in aluminum at elevated temperatures. Together, these developments establish a practical framework for quantitative, time-resolved studies of temperature-driven kinetics and nonequilibrium structural dynamics under extreme thermal environments.

Bai, Qianqian [Chinese Academy of Sciences (CAS), ↗
DOE OSTI2024

Data Analytics and Visualization of Energy Systems for Critical Infrastructure Insights

Modernization of energy systems including transportation facilities provides opportunities for increased efficiency, expansion of commerce and meeting industry and federal goals. A significant increase in electrical demand is projected to meet these needs, which concentrates at facilities such as airports. For example, Xcel Energy working with two airports in their service area recently published information projecting an up to fivefold increase in electricity demand in the next 25 years [1]. Concurrently, the US Government Accountability Office (GAO) recently surveyed 30 commercial service airports identifying more than 300 outages of more than 5 minutes between 2015 and 2022 [2]. Power, reliability, and resilience planning becomes more important to safely maintain operations and the flow of commerce with fewer energy carriers providing necessary energy to safely move passengers and goods. NREL proposes to develop methodologies to allow owners, utilities, and federal agencies to dynamically analyze, forecast, and manage energy loads at airports, focused upon maintaining the flow of commerce in an efficient, sustainable, and resilient way. To address these energy challenges, a suite of technologies and methodologies can be leveraged to validate concepts, inform design, de-risk solutions and optimize energy management during deployment. These technologies include digitalization of energy systems, microgrid methodologies, and related energy technologies for building and vehicle loads. [1] Electrifying Airport Ecosystems - https://www.enterprisemobility.com/content/dam/enterpriseholdings/marketing/innovation-in-mobility/vehicle-innovation/airport-electrification-study-full-report-2024.pdf [2] Airport Infrastructure: Selected Airport's Efforts to Enhance Electrical Resilience https://www.gao.gov/products/gao-23-105203.

critcal infrastructure↗
DOE OSTI2025

NDMAS

Overview of Current ART-GCR Data: Fuel Fabrication, Irradiation Monitoring (Fuel & Graphite – near real-time for HDG-1), Post-Irradiation Examination (Fuel & Graphite), Graphite Characterization (Baseline and Irradiated), High Temperature Metals Mechanical Tests, Design, Methods, and Validation Data, Japan Atomic Energy Agency’s High Temperature Test Reactor (HTTR), Argonne National Laboratory’s Natural convection Shutdown heat removal Test Facility (NSTF), Oregon State University’s High Temperature Test Facility (HTTF), Generation IV International VHTR Materials Handbook, Additional related data, and Advanced Test Reactor operations (near real-time).

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Model-Based Investigation of Multi-Fault Interactions and Performance Degradation in Residential Heat Pump Systems

Faults in heat pump systems can significantly degrade performance, reduce efficiency, and accelerate component wear, leading to higher operating costs and maintenance demands. While numerous studies have investigated the impact of individual faults, the interactions between multiple concurrent faults remain insufficiently understood, despite their common occurrence in real-world operation. This study conducts a comprehensive simulation analysis of multiple simultaneous faults in a vapor compression heat pump using a validated heat pump design model (HPDM) tool. Detailed component-level modeling methods are implemented to examine performance sensitivity under combinations of refrigerant flow and heat exchanger faults. The results reveal complex fault interactions that can mask or amplify system deviations, challenging conventional diagnostic approaches. Findings from this work provide meaningful insights for the development of more robust fault detection and diagnosis algorithms, supporting improved reliability and energy efficiency in next-generation heat pump technologies.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗
DOE OSTI1995

Nuclear Safety [Vol. 36, No. 2, July-December 1995]

Nuclear Safety is a journal that covers significant issues in the field of nuclear safety. Its primary scope is safety in the design, construction, operation, and decommissioning of nuclear power reactors worldwide and the research and analysis activities that promote this goal, but it also encompasses the safety aspects of the entire nuclear fuel cycle, including fuel fabrication, spent-fuel processing and handling, and nuclear waste disposal, the handling of fissionable materials and radioisotopes, and the environmental effects of all these activities. Table of Contents for this issue follows. THE CHORNOBYL ACCIDENT: 195 The Chornobyl Accident Revisited, Part III: Chernobyl Source Term Release Dynamics and Reconstruction of Events During the Active Phase, A. R. Sich; GENERAL SAFETY CONSIDERATIONS: 218 Second ANS Workshop on the Safety of Soviet-Designed Nuclear Power Plants, R. A. Bari; 234 Elements of a Nuclear Criticality Safety Program, C. M. Hopper; 243 Rickover, Excellence, and Criticality Safety Programs, R. E. Wilson; ACCIDENT ANALYSIS: 249 Transient Analysis of the PIUS Advanced Reactor Design with the TRAC-PF1/MOD2 Code, B. E. Boyack, J. L Steiner, S. C. Harmony, H. J. Stumpf, and J. F. Lime; 278 The Hierarchy-By-Interval Approach to Identifying Important Models that Need Improvement in Severe-Accident Simulation Codes, T. J. Heames, M. Khatib-Rahbar, J. E. Kelly, R. P. Jenks-Johnson, and Y.-S. Chen; 290 RELAP5/MOD3 Code Coupling Model, R. P. Martin; 299 Missiles Caused by Severe Pressurized-Water Reactor Accidents, R. Krieg; DESIGN FEATURES: 310 Validation of COMMIX with Westinghouse AP-600 PCCS Test Data, J. G. Sun, T. H. Chien, J. Ding, and W T. Sha; ENVIRONMENTAL EFFECTS: 321 Spent Nuclear Fuel Characterization for a Bounding Reference Assembly for the Receiving Basin for Off-Site Fuel, S. D. Kahook, R. L. Garrett, L. R. Canas, and M J. Beckum; OPERATING EXPERIENCES: 332 Reactor Shutdown Experience, Compiled by J. W. Cletcher; U.S. NUCLEAR REGULATORY COMMISSION INFORMATION AND ANALYSES: 335 Reactor Coolant System Blowdown at Wolf Creek on September 17, 1994, J. V. Kauffman and S. L. Israel; RECENT DEVELOPMENTS: 344 Reports, Standards, and Safety Guides, D. S. Oueener; 349 Proposed Rule Changes as of June 30, 1995; ANNOUNCEMENTS: 320 Symposium on Acceptability of Risk From Radiation—Application to Manned Space Flight; 320 24th DOE/NRC Nuclear Air Cleaning and Treatment Conference; 361 Radiation Biology and Radiation Protection— Modern Developments and Tendencies in Radiation Biology; 362 1997 IEEE Sixth Conference on Human Factors and Power Plants; 354 The Authors; 360 Reviewers of Nuclear Safety, Vol. 36.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Organic Rankine Cycle Integration and Optimization for High Efficiency CHP Genset Systems (Final Technical Report)

This project successfully advanced the integration of Organic Rankine Cycle (ORC) technology with reciprocating engine–based combined heat and power (CHP) systems to improve electrical efficiency, total CHP efficiency, and grid-responsive operation. Over three budget periods, the work progressed from high-temperature ORC component development and thermodynamic model validation to next-generation system design, working fluid transition, and techno-economic analysis. Key technical accomplishments include development and validation of a thermodynamic model capable of accurately predicting ORC performance across an expanded temperature and pressure envelope; successful identification and validation of low-global-warming-potential (GWP) working fluids—most notably R1233zd(E)—as viable replacements for R245fa; and demonstration of scalable ORC architectures suitable for integration with 1–20 MW class reciprocating engines. These advances enable flexible CHP configurations that can increase electrical output while maintaining high overall utilization of available thermal energy. The project also produced a clean-sheet design for a next-generation ORC system targeting substantially higher power output per unit, supported by detailed component selection, heat exchanger evaluation, and system-level modeling. Techno-economic analyses indicate that ORC-enabled flexible CHP systems can meet or exceed Department of Energy (DOE) efficiency targets while providing value to both facility operators and the electric grid.. Late-stage testing of the largest next-generation ORC prototype identified limitations related to pump net positive suction head (NPSH) requirements and condenser flooding under certain operating conditions. Although these issues constrained full validation of that configuration within the project timeframe, they provided clear and actionable design guidance for future system refinements. Importantly, validated modeling, smaller-scale testing, and working fluid evaluations confirmed the technical viability of the overall approach. In aggregate, this project met its core objectives by establishing validated design tools, de-risking key ORC technologies for CHP applications, and defining a credible pathway toward commercialization of flexible, high-efficiency CHP systems. The results form a strong foundation for continued development and deployment beyond the conclusion of the DOE-funded effort.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Summary of FY2024 Experimental Results to Support Development of New Inelastic Material Models and Validation of Section III, Division 5, Class A Design Rules

To address the data gap crucial for updating existing viscoplastic constitutive material models for the Class A materials in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors (ASME, 2023) for inelastic design analysis, Oak Ridge National Laboratory (ORNL) conducted experimental studies on Alloy 800H and Alloy 617 across a range of temperatures up to their maximum temperature limits in Section III, Division 5. The studies aim to characterize the materials' deformation behavior under both strain-controlled mechanical cyclic loading and thermal cycling conditions. This report summarizes ORNL's FY 2024 experimental findings on Alloy 800H and Alloy 617, focusing on pure fatigue tests, cyclic stress-strain curves, thermomechanical fatigue experiments, and verification of the high temperature cyclic damage summation design rules.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Final Design for Thermal/Epithermal eXperiments (TEX) with Lithium Absorbers to Provide Validation Benchmarks for Y-12 Electrorefining Facility

One of the main goals of the Thermal/Epithermal eXperiments (TEX) project is to use existing Nuclear Criticality Safety Program (NCSP) assets to create critical experiment plutonium and uranium test beds for materials important to criticality safety that have insufficient benchmark evaluations. The plutonium test bed experiments were completed in 2018 and are published in the 2020 edition of the International Criticality Safety Benchmark Evaluation Project (ICSBEP) Handbook. The uranium test bed assemblies were completed in 2023 and accepted in the 2024 edition of the ICSBEP Handbook. The Nuclear Criticality Safety (NCS) group at Y-12 National Security Complex has identified programmatic need for validation cases for uranium electrorefining operations at Y-12. The electrorefining operation credits lithium enriched in 6 Li in addition to 35 Cl as absorbers in the design criticality safety evaluation for precluding criticality under upset conditions in the large and geometrically unfavorable electro-refiner. There is, however, inadequate experimental validation for the 6 Li absorbers. As an extension of the TEX uranium test bed, TEX-Cl critical experiments were performed with sodium chloride salt to address the 35 Cl thermal absorption as well as other validation needs at Los Alamos National Laboratory (LANL). These experiments were completed in 2024 and accepted into the 2025 ICSBEP Handbook. To continue the methodology used in TEX-Cl, TEX-Li aims to accomplish the same. The overall design of both experiments was to use commercially available, high purity, salts with polyethylene moderator and HEU plates to configure a critical assembly. Three experiments are planned for TEX-Li using encapsulated lithium carbonate (Li 2 CO 3 ), with natural 6 Li abundance. For all experiments, the highly enriched uranium (HEU) Jemima plates will be used as fissile material. Multiple layers will be stacked together with encapsulated Li 2 CO 3 alternated with polyethylene in standard configurations. Standard stacking was found to be optimal in matching the different sensitivity profiles provided by the Y-12 models. Three configurations are proposed with varying polyethylene moderation and a constant 1/4” absorber thickness. The first uses 11 layers of 5/4” polyethylene, the second uses 9 layers of 3/4” polyethylene, and the third uses 10 layers of 1/2” polyethylene. Calculations showed that some alternative forms of lithium-based materials provided slightly less-optimal sensitivity profiles when compared to lithium carbonate but come with other drawbacks. These alternatives included lithium aluminate (LiAlO 2 ), Aluminum-2050 alloy, Aluminum-8090, Aluminum-2095, lithium hydride (LiH), and lithium fluoride (LiF). Lithium aluminate and aluminum-2050 provided comparable sensitivity profiles when compared to lithium carbonate and can be used instead if lithium carbonate cannot be readily procured. After a broad material study, lithium carbonate outperformed any alternative material with a balance in affordability and workability. The assessment of experimental uncertainties of the non-absorber and absorber components was predicted to be 0.00089 and 0.00093 Δk eff , respectively. The largest uncertainties may be reduced with precision dimensional inspection of the components. Many of the parts and equipment for IER 575 have already been fabricated or procured for previous projects and therefore do not contribute significantly to the overall cost of this experiment. This includes the Jemima plates and Comet critical assembly machine, which are existing NCSP assets, as well as the aluminum platen and polyethylene reflector rings, which were fabricated and authorized for the TEX experiment involving HEU with polyethylene. Lithium carbonate containers will be procured by LANL and will be filled by LLNL. The total material costs for TEX-Li experiments are estimated to be on the order of $\$$47,400. Precision inspection, including dimensional, mass, density, and impurity, is recommended for all components for an estimated cost of $\$$12,000.

35Cl↗
DOE OSTI2026

Georgetown University – SYSM 5630 Systems Integration Verification and Validation : Todd Noste

At Lawrence Livermore National Laboratory in the National Ignition Facility Optics Group, we use the systems engineering approach for project management and as a design tool. Systems engineering is used in a graded approach to design and project management that is based on risk, informing how much rigor to apply. The tools and techniques from systems engineering offer a framework to organize projects with everyone speaking the same language to provide consistent and repeatable project success that satisfies the stakeholders’ needs and meets the mission. The classes have provided a framework with tools for communicating system design, requirements, verification and validation, and an operational context.

42 ENGINEERING↗
DOE OSTI2024

High Temperature Additive Architectures for 65% Efficiency (Final Technical Report)

This project aimed to develop advanced high-temperature additive components that contribute towards the DOE’s goal for advanced gas turbines that are capable of at least 65% efficiency in combined cycle application. The objective was to leverage state-of-the-art additive manufacturing to develop an innovative stage 1 turbine nozzle (S1N) that can provide cooling flow savings while maintaining the component durability expected in today’s gas turbines. The program had two phases. Phase I was a conceptual phase for novel advanced cooling designs enabled by additive manufacturing, as well as proposals for validation. Phase II included execution of the Phase I conceptual design, including manufacturing of prototype hardware and validation within an environment that is similar to engine operation. During Phase I of the program, the team devised a concept to reduce cooling air usage. The cooling air used in the side walls is filmed out along the side walls, while the cooling air used in the airfoil is eventually directed to near-wall channels and exits holes along the airfoil trailing end. During this program, the team performed additive trials to analyze the geometric limitations of additive manufacturing. This helped the team understand minimum wall thicknesses, hole sizes, and cooling channel dimensions among other limits. Phase II of this program pushed GE Vernova beyond its previous experience of designing and manufacturing an additively manufactured hot gas path component. Modern hot gas path components utilize material chemistries that are traditionally hard to weld, such as cast Renè 108, and exhibit solidification cracking when additively manufactured using Direct Metal Laser Melting (DMLM). Note that AM108 is a powder form of Renè 108. A S1N with advanced cooling is larger and more complex than parts previously built by additive manufacturing and required new learnings to resolve risks around solidification cracking. Finally, the team validated the design in a combustion rig that replicated operation in a gas turbine. In order to properly quantify the benefits of the new additive design, a baseline was also tested in the rig and operated under the same conditions. In addition, an uncertainty analysis was done to quantify any sources of error that could impact the results. At the end of the validation effort, it was determined that the additive nozzle exceeded the 15% reduction in cooling flow goal even with the worst-case assumptions for uncertainty.

03 NATURAL GAS↗
DOE OSTI2025

Design and Demonstration of a NH3-Fueled Two-Stroke Uniflow Engine for Greenhouse Gas Reduction

The maritime shipping industry is growing increasingly interested in both low and non-carbon-containing fuels to meet future greenhouse gas emission targets. Specifically of interest is ammonia, as it has a relatively high volumetric energy density compared to other future fuels, such as hydrogen, making it more economical to transport. The robust engine architecture of low-speed two-stroke marine engines makes them an ideal candidate for ammonia fuel, overcoming many of the issues surrounding its poor ignitability and low flame speed. If emissions and fueling system challenges can be addressed, retrofits of current low-speed two-stroke dual-fuel engines represent a viable pathway for bringing ammonia engines to market. This study explores these technical hurdles by describing the design, analysis, and experimental validation of a single cylinder research engine converted to operate on ammonia fuel. The engine is a reduced-scale uniflow two-stroke marine engine with two previous hardware configurations available – diesel and high-pressure CNG dual-fuel. A concept study was used to evaluate possible ammonia-fueled engine architectures and the associated tradeoffs and design considerations. With the chosen architecture, low-pressure dual fuel, 1D and 3D analysis tools were used to inform hardware selection and to determine hardware configurations which minimized ammonia-slip. In addition to these considerations the hardware and engine configuration were designed to provide a versatile and robust testing platform. This includes options to test both gaseous and liquid ammonia injection, as well as a wide range of performance parameters such as AFR, swirl, valve timing, SOI, and many others. Design constraints imposed by the existing engine hardware necessitated an iterative loop between design and analysis toolsets, ultimately converging on a final design for the ammonia-conversion hardware. The engine was rebuilt with the new hardware and evaluated in an engine test cell. A new control strategy developed and flashed onto a prototyping electronic control unit allowed for full control over all engine parameters. An initial calibration was developed, providing test data for validation of the engine 1D and 3D models. The impact of the design choices on engine operability and the ability to meet program targets is discussed as well as opportunities for further optimization of the ammonia-conversion hardware, informed by the validated models.

Kaul, Brian [ORNL] (ORCID:0000000184813620)↗