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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 OSTI2024

Direct microstability optimization of stellarator devices

Turbulent transport is regarded as one of the key issues in magnetic confinement nuclear fusion, both for tokamaks and stellarators. Here, in this work, we show that a significant decrease in a microstability-based proxy, as opposed to a geometric one, for the turbulent heat flux, namely the quasilinear heat flux, can be obtained in an efficient manner by coupling stellarator optimization with linear gyrokinetic simulations. This is accomplished by computing the quasilinear heat flux at each step of the optimization process, as well as the deviation from quasisymmetry, and minimizing their sum, leading to a balance between neoclassical and the turbulent transport proxy.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Quantum State Transfer between Heterogeneous 3D QPUs

We present detailed analyses and microwave simulations of a quantum interconnect architecture that couples two distinct three-dimensional quantum processing units (QPUs): (i) a two-cell superconducting radio-frequency (SRF) cavity coupled to multiple transmon qubits and (ii) a waveguide-based cavity hosting a planar circuit with transmons and resonators. The modules are linked via a low-loss superconducting coaxial cable, which serves as a quantum bus. Finite-element electromagnetic simulations are performed to optimize coupling strengths and mode frequencies for high-fidelity quantum state transfer between cavities. These simulation results provide a comprehensive blueprint for the experimental realization of a flexible quantum interconnect architecture, coupling heterogeneous QPUs.

Yaker, Joey [Fermilab]↗
DOE OSTI2025

Optimization-Based Data-Driven Approach for Detecting Fault Location in Power Systems

In grids with large penetration of converterinterfaced resources (CIRs), measurements of voltage, current, and line parameters can fluctuate significantly during fault conditions. These fluctuations, combined with complex network topologies and extensive system branching, make accurate fault location challenging. Faults, such as short circuits, can cause prolonged outages with serious socio-economic impacts, highlighting the need for rapid fault identification to minimize downtime. However, current fault detection methods—such as relays and digital fault recorders—often relay information too slowly, impeding swift corrective action. Given the limited availability of high-resolution phasor measurement units, this paper introduces an optimization-based observer to estimate fault locations, grid line parameters, and voltages using local CIR measurements. To preserve the confidentiality of CIRs and enhance estimation accuracy, this study uses a black-box model of CIRs. This bottom-up, event-driven approach can enhances protection and control systems through optimized and real-time fault detection. Simulation results show that the optimization-based data-driven observer can accurately detect fault locations and estimate grid states and parameters, providing valuable insights for utilities and operators in grid applications.

Subedi, Sunil [ORNL] (ORCID:000000034069090X)↗
DOE OSTI2025

Dynamic Modeling, Trajectory Optimization, and Linear Control of Cable-Driven Parallel Robots for Automated Panelized Building Retrofits

The construction industry faces a growing need for automation to reduce costs, improve accuracy and productivity, and address labor shortages. One area that stands to benefit significantly from automation is panelized prefabricated building envelope retrofits, which can improve a building’s energy efficiency in heating and cooling interior spaces. In this paper, we propose using cable-driven parallel robots (CDPRs), which can effectively lift and handle large objects, to install these panels. However, implementing CDPRs presents significant challenges because of their nonlinear dynamics, complex trajectory planning, and precise control requirements. To tackle these challenges, this work focuses on a new application of established control and trajectory optimization theories in a CDPR simulation of a building envelope retrofit under real-world conditions. We first model the dynamics of CDPRs, highlighting the critical role of damping in system behavior. Building on this dynamic model, we formulate a trajectory optimization problem to generate feasible and efficient motion plans for the robot under operational and environmental constraints. Given the high precision required in the construction industry, accurately tracking the optimized trajectory is essential. However, challenges such as partial observability and external vibrations complicate this task. To address these issues, a Linear Quadratic Gaussian control framework is applied, enabling the robot to track the optimized trajectories with precision. Simulation results show that the proposed controller enables precise end effector positioning with errors under 4 mm, even in the presence of external wind disturbances. Through comprehensive simulations, our approach allows for an in-depth exploration of the system’s nonlinear dynamics, trajectory optimization, and control strategies under controlled yet highly realistic conditions. The results demonstrate the feasibility of CDPRs for automating panel installation and provide insights into their practical deployment.

CDPR↗
DOE OSTI2024

Optimizing the Heisenberg Vortex Tube for Hydrogen Cooling (Final Technical Report)

Hydrogen utilization at Plug Power sites ranges between 70-93% with the remainder vented and lost to the atmosphere. The goal of this project was to improve hydrogen utilization at Plug Power fulfillment centers via the patented Heisenberg vortex tube (HVT). The HVT combines conventional counterflow vortex tubes with para-orthohydrogen conversion catalyst to allow the cooling of hydrogen flows with no moving parts or external energy inputs. In year 1 of this project the HVT was evaluated to improve hydrogen utilization via the following concepts: 1) increasing liquid hydrogen pump volumetric efficiency by 20% through vapor separation and subcooling of the liquid, 2) reducing liquid hydrogen storage tank boil-off losses by 20% through thermal vapor shielding (TVS), and 3) increase isentropic efficiency of supercritical hydrogen expansion at 40-50 K, from 31% to over 40%. The TVS concept was selected as the most favorable application for further development. While the conceptual analysis was underway, the cryocatalysis hydrogen experiment facility (CHEF) was retrofitted with a new cryocooler, higher pressure condenser tanks, and in-situ fiber-optic Raman probes for ortho-parahydrogen composition analysis at the inlets and outlets of the HVT. To our knowledge this is the first in-situ implementation of cryogenic Raman probes for ortho-parahydrogen analysis. Subsequent testing of catalyzed and non-catalyzed HVT identified a low flow rate, high-conversion efficacy regime well suited for TVS development. Computational fluid dynamics (CFD), Reduced order modeling (ROM), and quantum Monte Carlo atomistic simulations were applied to optimize the design of the HVT implemented for TVS. The simulations and analysis identified a ruthenium-based catalyst as the most optimal for high conversion with little pressure losses and was matched to experimental measurements. These results indicated the design could achieve the 20% boil-off reduction target. An HVT field-trial was designed and constructed by Plug Power and implemented at a customer site. However, budget limitations reduced the amount of catalyst that could be applied to the HVT. With the reduced amount of catalyst, CFD analysis estimated about 3% reduction in boil-off. A similar amount of boil-off reduction was observed during preliminary measurements during tank commissioning. However, the results have a large margin for error and were operated at relatively low tank temperatures when the HVT has the lowest potential for improvement. This project demonstrated the use of para-orthohydrogen catalysis for reducing liquid hydrogen tank boil-off losses. The field trial system is anticipated to provide long-term experimental measurements on tank operational performance that will allow Plug Power to instrument additional tanks in the future. Recommendations for future work include the development of higher activity, lower cost para-orthohydrogen conversion catalyst for use in the HVT. Tank process optimizations could maximize the efficacy of the HVT and further improve hydrogen utilization.

08 HYDROGEN↗
DOE OSTI2024

Development of typical solar years and typical wind years for efficient assessment of renewable energy systems across the U.S.

Weather data plays a critical role in renewable energy analysis. Compared to using multiple Actual Meteorological Years, simulations using a single typical year require significantly fewer computational resources. Previous efforts to create typical weather datasets for renewable energy analysis either lack justified or optimized strategies for selecting and weighting different weather parameters or are limited to a few specific locations. Here, in this study, we developed a dataset comprising Typical Solar Years (TSYs) and Typical Wind Years (TWYs) for over 2000 locations across the U.S., based on data from NASA's POWER project. The strategies for creating TSYs and TWYs were optimized based on the simulated outputs of various PV systems and wind turbines in 16 representative cities. This dataset provides an efficient means for the rapid evaluation and optimization of renewable energy systems throughout the entire U.S. Additionally, the optimal strategies identified in this study can be directly applied to create near-optimal TSYs and TWYs for most locations worldwide. However, readers can also employ the optimization approach presented in this work to develop optimal strategies tailored for particular regions.

NASA POWER↗
DOE OSTI2025

Active Learning Surrogates for Integrating Electron Microscopy and Computational Insights from Simulations in Autonomous Experiments

Artificial Intelligence (AI) combined with simulations and experiments has great potential to accelerate scientific discovery across technology and pharmaceuticals. However, the gap between simulations and experiments is challenging due to disparities in time and scale, making it difficult to estimate properties like energy and electronic states from experiments, and to provide feedback based on theoretical insights.Our research addresses the challenge by developing unique deep kernel based surrogate models that learns from microscopic images, mapping structural features to energy differences from defect formation. We start with full-training using simulated images to determine optimal settings, establishing a baseline for active learning. Using these settings from the baseline, active learning is trained, and predicts structures along simulation trajectories based on uncertainty and energetic stability, thus reducing data requirements, simulation time and computational costs. The results demonstrate that the model achieves a low average error margin of approximately 0.03 meV, indicating good performance. To enhance feature extraction and reconstruction capabilities, we developed an autoencoder-decoder as additional surrogate to create latent space to capture essential features, enabling precise comparisons between simulations and experiments. The results from this model achieved a reconstruction loss of around 0.2 and accurately reconstructed molecular structures.Overall, this work advances the steering of experiments through computational simulations by employing a surrogate models that actively predicts the trajectories of structural evolution, achieving time-to-solution comparable to experimental measurements.

Saranathan, Gayathri [Hewlett-Packard]↗
DOE OSTI2025

Optimization Through Multi-Fidelity Modeling

We present a novel method for optimizing parameter selection for simulations with an evaluation budget. We start with an existing method for building a multi-fidelity model out of many low-fidelity simulations and few high-fidelity simulations. We propose a novel method to simplify parameter selection without sacrificing performance. We verify these results and compare with existing literature. Next, we propose a novel algorithm which uses this difference model to suggest new points in the parameter design space to simulate. We add each point we simulate to the model to improve its quality for the next iteration. The algorithm trades off reducing the uncertainty of the existing model with optimization of the objective. The first is more useful when a large fraction of the computation budget remains. The second is more useful when a small fraction of the computation budget remains. Our method converges to the optimum by using a high-fidelity evaluation for just 16 of the 427 points. Our method is general enough to work if there is no low-fidelity model. Furthermore, it is agnostic to the underlying physics of the problem. Therefore, both the low-fidelity and high-fidelity models can be generated by any arbitrary function, including simulations and physical experiments.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Optimization of Ag Electrocatalyst Performance for CO2 to CO Conversion: Pairing Atomic Simulations with Experiments

Density-functional theory- based calculations that complement our series of experimental efforts on optimizing Ag electrocatalyst performance for CO2 to CO conversion were presented. Three key findings are drawn out from the combined UHV surface science, STM and electrochemical measurements: (1) Using a series of Ag nanoparticles with 2-6 nm average diameters, CO2 reduction reaction (CO2RR) activity increases, with particle between 2 nm and ∼4 nm demonstrating the highest combination of activity and selectivity; (2) Electronic metal−support interactions (EMSIs) between Ag and C dramatically improve CO2RR performance as evidenced by a scaling relationship between particle size and the relative Ag−C EMSIs strength, which improves the CO2-to-CO Faradaic efficiency of sub-2 nm Ag particles from 2 to ∼100% and increases the CO turnover frequency ∼15-fold compared with similarly sized bare Ag particles; (3) The performance Ag electrocatalysts is improved when supported on S-doped C materials. Computational modeling of 1−10 nm Ag particles predicts a nearly identical size-dependent trend with maximum CO2RR activity predicted for 3.7nm particles. The calculations support the promotional effect of C materials, showing a large charge transfer of 1.02 e from Ag clusters to defective C and a 0.41 eV less endergonic step of forming COOH intermediate on Ag/defective-C compared to the Ag/C system. Calculations indicate a more favorable energetic pathway of CO2-to-CO at the C-S-Ag interface, consistent with experiments.

CO2 utilization↗
DOE OSTI2026

Performance assessment of 3D printed multi-material energy absorber for automotive bumper: pedestrian lower extremity protection

Designing an energy absorber for automotive bumpers involves balancing low-speed and high-speed impacts to ensure safety, reduce repair costs, and meet regulatory standards. Here, this study explores a novel design using multi-material 3D printing and structural optimization to fabricate a lightweight and cost-efficient energy absorber. The design effectively dissipates energy in low-speed collisions and minimizes force transmission in high-speed pedestrain impacts, helping to meet both safety and performance requirements. The energy absorber design combines 20% carbon fiber-reinforced acrylonitrile butadiene styrene (CF-ABS) and thermoplastic polyurethane (TPU) for optimal stiffness and flexibility. It uses 3D-printed lattice structures optimized through finite element simulations to help meet both low-speed and high-speed impact requirements. Full-scale energy absorbers were 3D-printed using optimized CF-ABS/TPU blends and tested under high-speed impact using the Flexible Pedestrian Legform Impactor (Flex-PLI). For fair comparison, a baseline bumper with a traditional triangular lattice structure, also 3D-printed from the same CF-ABS/TPU materials, was similarly tested. Interestingly, both the optimized and baseline 3D-printed energy absorbers showed nearly identical performance, successfully meeting injury limits. Their performances were also benchmarked against an injection-molded energy absorber. While both 3D-printed and injection-molded designs met injury limits, the 3D-printed absorber exhibited a higher tibia bending moment, indicating an opportunity for further optimization. A Techno-Economic Analysis compared the costs of producing energy absorbers using traditional manufacturing and 3D printing. The analysis highlighted that 3D printing offers cost benefits for low to medium production volumes, with the total cost per energy absorber at ∼ $\$$74, compared to traditional methods that become economical beyond 2000 units.

Additive manufacturing↗
DOE OSTI2024

Stochastic Optimization to Find Optimum Beginning-of-Life Core Configuration of Stable Salt Reactor with Online Refueling

A stochastic optimization method has been developed to find an optimum equilibrium cycle core configuration of the waste-burning stable salt reactor, which is a fast-spectrum molten salt reactor with frequent online refueling. An optimum core configuration was determined with the goal of minimizing radial power peaking. Because of the vast number of potential candidate core configurations, stochastic optimization was applied based on simulated annealing and an additional acceleration method, which screened out unpromising core configurations. It has been demonstrated that the developed stochastic optimization method successfully finds the optimal core configuration regardless of the initial guess and outperforms the gradient descent approach. In addition, it has been observed that the use of a so-called out-in core configuration as the initial guess speeds up convergence of the iterative solution more than five times. Based on the searched optimum equilibrium cycle core configuration, new beginning-of-life (BOL) core configurations have been developed. In conclusion, the new BOL core configurations will be used in developing optimum refueling strategies.

Moltex static salt reactor↗
DOE OSTI2025

Incident beam optics optimization for the single crystal neutron diffractometer Pioneer with a polarized beam option

Pioneer, a next-generation single-crystal neutron diffractometer, is under development for Oak Ridge National Laboratory’s Second Target Station. Designed to address a wide range of scientific questions, Pioneer will deliver homogeneous neutron beams with customizable size and divergence and provide a polarized beam option. This article introduces its incident beam optics, highlighting the optimization methodology and the simulated performance. Pioneer will utilize a modified elliptical-straight guide for neutron transport and deploy slit packages and insertable apertures to control beam size and divergence. The optimized guide geometry matches the optimal-and-full-sample-illumination condition, and the beam control system effectively filters out unwanted neutrons while preserving the desired ones. In addition, we have found that polygon-approximated guides provide satisfactory transport efficiency and beam homogeneity, eliminating the need for truly curved guides. Further, to enhance neutronics performance and reduce cost, the coatings of supermirror elements are individually optimized to the lowest half-integer m-values that are sufficient to deliver the desired neutrons. After evaluating polarizing V-cavities and 3 He spin filters over the default polarized wavelength band of 1.2–5.5 Å, we selected a translatable multichannel polarizing V-cavity as the incident beam polarizer. Strategically placed at a location where the beam divergence is low and a large in-guide gap has negligible impact on transport efficiency, the optimized V-cavity achieves an average P 2 T of ~35%.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Optimization Studies of Radiation Shielding for PIP-II Project at Fermilab

The Proton Improvement Plan-II (PIP-II) at Fermilab represents a significant advancement in the quest to answer some of the most profound questions about our universe using the world's most intense high-energy neutrino beam. The project requires the construction of a new addition to the Fermilab accelerator complex – an 800-MeV high-intensity superconducting linear accelerator. Ensuring the safety and regulatory compliance of this ambitious project is paramount, necessitating thorough dose rate assessments under both normal operational and accidental scenarios to align with the Fermilab Radiological Control Manual (FRCM) standards. Our approach included a shielding optimization used for the simulations with the Monte Carlo code MARS [1,2,3] to incorporate new magnet and collimator designs, essential for reflecting the current state of PIP-II infrastructure. The implementation of high-resolution detector planes, despite their computational demands, enabled us to gather detailed radiation field data crucial for optimizing shielding configurations. To overcome the significant computational demands, we developed a branching code that drastically reduced simulation runtimes while maintaining statistical integrity. This was achieved through geometry splitting and the application of Russian Roulette techniques, tailored to prioritize regions of interest based on predefined importances and weight limits.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Optimization Studies of Radiation Shielding for PIP-II Project at Fermilab

The Proton Improvement Plan-II (PIP-II) at Fermilab represents a significant advancement in the quest to answer some of the most profound questions about our universe using the world's most intense high-energy neutrino beam. The project requires the construction of a new addition to the Fermilab accelerator complex – an 800-MeV high-intensity superconducting linear accelerator. Ensuring the safety and regulatory compliance of this ambitious project is paramount, necessitating thorough dose rate assessments under both normal operational and accidental scenarios to align with the Fermilab Radiological Control Manual (FRCM) standards. Our approach included a shielding optimization used for the simulations with the Monte Carlo code MARS [1,2,3] to incorporate new magnet and collimator designs, essential for reflecting the current state of PIP-II infrastructure. The implementation of high-resolution detector planes, despite their computational demands, enabled us to gather detailed radiation field data crucial for optimizing shielding configurations. To overcome the significant computational demands, we developed a branching code that drastically reduced simulation runtimes while maintaining statistical integrity. This was achieved through geometry splitting and the application of Russian Roulette techniques, tailored to prioritize regions of interest based on predefined importances and weight limits.

Makovec, Alajos↗
DOE OSTI2026

Consequential improvement acquisition function for efficient multi-fidelity Bayesian optimization

Abstract Surrogate-based Bayesian optimization has been widely applied in design optimization to increase sampling efficiency. However, the cost for each evaluation of the objective function can still be very high when physical experiments or large-scale simulations are involved. Multi-fidelity Bayesian optimization is the new approach to further improve the sampling efficiency by reducing the number of expensive samples at the highest fidelity level and supplementing them with less expensive ones at low-fidelity levels. In this paper, a new consequential improvement (CI) acquisition function is proposed to allow for the simultaneous selection of the solution and the fidelity level in problems with a known hierarchy of fidelity levels. The new CI acquisition function incorporates the consequential effectiveness of objective improvement with the considerations of cost, accuracy, and validity differences between high- and low-fidelity samples in engineering practice. The new method of multi-fidelity Bayesian optimization based on the CI is demonstrated with several analytical and simulation-based design examples. In the simulation-based design optimization example, the results show that the CI acquisition function has a decisive advantage in the sampling efficiency over the other methods of multi-fidelity Bayesian optimization with simultaneous selection. The results indicate that the proposed method is particularly advantageous in solving high-dimensional problems and when large cost ratios between high- and low-fidelity evaluations exist and high-fidelity validation is mandatory. Furthermore, the method robustly avoids the prevalent issue of over sampling at low-fidelity levels.

Aydogdu, Ibrahim [Georgia Institute of Technology,↗
DOE OSTI2025

Enabling Next Generation Reaction Injection Molding (RIM) for Lightweight Structures

Replacing metal components in trucks, trailers, and buses with lightweight polymer composites is challenging due to high temperatures and complex manufacturing. The Reaction Injection Molding (RIM) process using Dicyclopentadiene (DCPD) resin offers a solution by producing robust parts with excellent stiffness, impact strength, and resistance properties. Simulations are essential for optimizing this process, predicting defects, and improving quality. However, most commercial software is tailored for thermoplastics, requiring thermoset users to generate their own datasets. In this project, a material data card for DCPD was developed to perform RIM simulations. Design of Experiments (DOE) was used to identify key factors affecting filling, curing, and warpage, aiming to minimize cycle time and defects. The simulations explored varying injection gate parameters (size, location, number) and process conditions (mold/resin temperature, injection/curing pressure). Results showed that gate design significantly impacts filling behavior and defects. A single central gate provided balanced flow with fewer defects, while two corner gates led to more defects. Additionally, lower injection pressure increased filling time, while higher mold temperature accelerated curing but led to more warpage. This optimization framework aims to enhance DCPD part performance and promote sustainable manufacturing by reducing waste and energy consumption. This research has been performed in collaborations with McClarin Composites. The research outcome has been submitted to the Journal of Manufacturing Processes.

36 MATERIALS SCIENCE↗