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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 1,675 records · Page 93
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Map Matching and Real World Integrated Sensor Data Warehousing (Presentation)

The inclusion of interlinked temporal and spatial elements within integrated sensor data enables a tremendous degree of flexibility when analyzing multi-component datasets. The presentation illustrates how to warehouse, process, and analyze high-resolution integrated sensor datasets to support complex system analysis at the entity and system levels. The example cases presented utilizes in-vehicle sensor system data to assess vehicle performance, while integrating a map matching algorithm to link vehicle data to roads to demonstrate the enhanced analysis possible via interlinking data elements. Furthermore, in addition to the flexibility provided, the examples presented illustrate concepts of maintaining proprietary operational information (Fleet DNA) and privacy of study participants (Transportation Secure Data Center) while producing widely distributed data products. Should real-time operational data be logged at high resolution across multiple infrastructure types, map matched to their associated infrastructure, and distributed employing a similar approach; dependencies between urban environment infrastructures components could be better understood. This understanding is especially crucial for the cities of the future where transportation will rely more on grid infrastructure to support its energy demands.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

A 4 x 4 SiPM Sensor Array with Fast Preamplified Output Engineered for the PWO Detectors of the EIC EEEMCAL

The PbWO4 scintillation detectors for the Electron-Ion Collider Electron Endcap Electromagnetic Calorimeter (EEEMCAL) cannot use vacuum photomultipler tubes due to the high magnetic field environment. We are presenting a readout solution with a 4 x 4 SiPM array directly coupled to a preamplification and summing stage. A second amplification stage with variable gain and offset adjustments is also included in the compact electronics module. The integrated power supply feeds the signal processing chain and the adjustable bias control. The parameter settings are saved locally on a EEPROM and are adjustable via the integrated communication interface through USB or RS485. The design was optimized to maximize signal collection energy resolution, for fast timing and wide dynamic range while keeping a small footprint with low power consumption and heat dissipation. The output response is fast enough to meet the 100 ? 200 ns digitization gate requirements for the detector. The electronics assembly requires no active cooling and includes a temperature sensor and a gain compensation of thermal variations which are important features for stable operation in large scale detector structures. A detector prototype was constructed with 20 mm x 20 mm x 200 mm PWO crystals affixed with individual SiPM array readouts and arranged in a 3 x 3 array. This detector was tested at the Thomas Jefferson National Accelerator Facility with 5GeV positrons. We will present the results of these detector characterization measurements.

Philip, O.↗
DOE OSTI2026

Integrated Strategies for Overcoming Resolution Limits in Electron Beam Lithography of Chemically Amplified Resists

Electron beam lithography (EBL) of chemically amplified resists (CARs) faces fundamental challenges, including stochastic electron scattering and acid diffusion, that limit resolution and reproducibility. Using SU-8 as a model CAR, this study systematically investigated complementary strategies to address these challenges, combining multipass exposure, proximity effect correction (PEC) with midrange correction factors, base quencher incorporation, and post-exposure bake (PEB) suppression. Monte Carlo simulations and calibrated PEC modeling revealed that extending the point spread function to include a midrange scattering component significantly improved critical dimension (CD) control across varying pattern densities, correcting deviations that conventional two-term PEC failed to capture. Multipass exposure, particularly 4-pass writing with a 25% offset, redistributed the dose to average stochastic beam and scattering fluctuations, reducing line-width roughness by more than 50% and yielding more uniform nanoscale features. Photoacid confinement was investigated by adding urea as a base quencher, which successfully reduced acid diffusion but introduced substantial sensitivity penalties without improving ultimate resolution or Z-factor performance, underscoring the trade-offs of chemical versus physical confinement. Suppressing PEB most directly minimized acid diffusion, resulting in improved Z-factors and reproducible 30 nm half-pitch dense line/space patterns. Overall, these results demonstrated that PEC with midrange correction, multipass strategies, quencher additives, and PEB-free processing addresses different aspects of the EBL process window and that their integration provides a comprehensive framework for managing stochastic scattering, diffusion, and chemical amplification effects. This framework advances dense nanoscale patterning in CARs and establishes guiding principles for optimizing resist design and process strategies in high-resolution EBL and potentially other advanced lithographies, such as extreme ultraviolet (EUV) lithography.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Corrosion Evaluation for Tank 241-AP-106 Re-purposing

Tank AP-106 will be an integral part of the Direct Feed Low Activity Waste (DF-LAW) activity. This tank is an underground, carbon steel, double shell tank (DST). Before it can be utilized, the Cs-137 concentration levels in the waste must be reduced significantly. The AP-106 re-purposing process will manage normal waste tank additions procedures such that waste acceptance criteria objectives for Cs-137 removal are achieved. As this process was being developed, concerns regarding tank integrity during and after the process to Tank AP-106 and associated tanks (i.e., AP-102, AN-101, and AP-108) were addressed. The degradation mechanisms identified include: general and pitting corrosion, caustic stress corrosion cracking, galvanic corrosion, and microbiologically induced corrosion (MIC). Recommendations were provided to minimize the exposure of the tank to corrosive conditions (see Section 6.0). These recommendations included chemistry adjustments at defined steps in the process that will maintain the waste in compliance with the corrosion control program. Additionally, sampling and inspection (see Sections 6.0 and 7.0, respectively) recommendations that will assess the final condition of the tank environment and the tank were presented. The greatest risk for this process involves the handling of large quantities of Columbia River water (i.e., greater than 450,000 gallons) within the AP-106, associated tanks and supporting infrastructure (i.e., transfer line piping). As long as this water is blended into the supernate in a timely fashion, and the waste is adjusted appropriately with corrosion inhibitors, the final condition is expected to be within compliance. Recommendations were also made to address process interruptions that could result in exposure of the tank walls to aggressive conditions.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

Production Agency Quality Assurance Management Execution Strategy [Thesis]

There are multiple federal directives that Los Alamos National Laboratory (LANL) must follow for the proper implementation of quality assurance, strategic planning, and execution of manufacturing and surveillance operations. Recent assessments identified that manufacturing in all processing areas is dynamic due to influencing scope changes, design modifications, funding adjustments, and staff attrition. In response, this project was started to develop a comprehensive PAQ execution strategy to support the success of LANL’s manufacturing mission. This project’s method for developing an updated architecture was to create an integrated, flexible, reliable, and agile strategic process. The execution plan has five deliverables: 1) an integrated schedule view of PAQ work scope, 2) a resource management plan that aligns with the required scope, 3) a metrics monitoring dashboard, 4) a project management plan for sustaining NAP 401.1A implementation, and 5) a risk management plan. The research design is a mixed-method approach focused on data collection for each deliverable. The methodology entails qualitative and quantitative research, metrics monitoring, data analysis, and the creation of a dashboard. The qualitative methods used include literature reviews and interviews. The quantitative methods include resource, financial, schedule and survey data analysis. Preliminary and final results were peer reviewed by subject matter experts both within the ALDWP organization and deployed support.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Automation of Laser Plasma Focused Ion Beam Microscopy for Next-Gen Energy Materials

Automation can revolutionize the use of ultrafast laser ablation and plasma-focused ion beam (PFIB) techniques for high-throughput, reproducible cross-sectioning and various sample preparation in materials characterization. As these methods become essential for analyzing complex energy materials and next-generation devices, efficient, standardized workflows are needed to minimize variability and enhance precision. This work highlights our advancements in developing automated processes for sample preparation that integrates machine learning, workflow optimization, and large-scale data acquisition to improve efficiency and scalability in applications such as electrolyzers, photovoltaic cells, and microelectronics. To streamline cross-sectioning and lamella fabrication, we have implemented fully automated workflows that standardize laser ablation and PFIB milling sequences. These workflows incorporate pre-programmed protocols for material removal, alignment, and thinning, reducing user intervention and ensuring consistency across different sample types. Machine learning algorithms further enhance automation by predicting optimal milling strategies and adapting parameters based on material properties and sectioning requirements. This approach significantly improves throughput while maintaining the structural integrity of prepared samples for high-resolution imaging and analysis, including transmission electron microscopy. Beyond sample preparation, our automation platform enables the acquisition of large, high-resolution datasets through serial sectioning, image alignment, and 3D reconstruction. These automated routines facilitate multi-scale characterization, capturing structural and compositional details from the nanoscale to the device level. By reducing variability and increasing efficiency, our automated approach enhances defect analysis, failure diagnostics, and process optimization, accelerating advancements in materials research and device engineering.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Evaluation of AI-enabled Digital Documented Safety Analysis

The National Reactor Innovation Center (NRIC) is leading a transformative initiative to accelerate advanced reactor deployment by fundamentally reimagining how nuclear safety basis documentation is developed, reviewed, and maintained. Traditional Documented Safety Analysis (DSA) processes for DOE-authorized facilities rely on static, document-centric workflows that consume significant time and resources, exemplified by recent major licensing efforts requiring hundreds of thousands of staff hours and millions of pages of documentation review. These conventional approaches create barriers to the rapid, cost-effective deployment of advanced reactors that America's future energy needs demand. NRIC's DOE Authorization Digital Transformation Project addresses these challenges through an innovative framework that integrates artificial intelligence (AI), digital engineering, and systems-based data management into a cohesive digital ecosystem. This white paper presents NRIC's methodology for evaluating AI-enabled document generation capabilities within this broader digital infrastructure, using the Demonstration of Microreactor Experiments (DOME) facility as a pilot case study. The evaluation will assess an AI tool's ability to generate a Preliminary Documented Safety Analysis (PDSA) through progressive integration stages—from standalone document processing to full digital thread connectivity—while maintaining rigorous verification, validation, and regulatory acceptance standards. By establishing dynamic, traceable connections between design data and safety documentation, NRIC's approach has the potential to reduce both document development time and regulatory review cycles by as much as 50%, while simultaneously improving accuracy, consistency, and traceability. This initiative represents a critical step toward establishing reusable digital infrastructure that reactor developers can leverage to accelerate their path from concept to commercial operation, directly supporting NRIC's mission to demonstrate and deploy advanced nuclear energy technologies.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

Deformation behavior of sub-micron and micron sized alumina particles in compression

The ability to integrate ceramics with other materials has been limited due to high temperature (>800°C) ceramic processing. Recently, researchers demonstrated a novel process, aerosol deposition (AD), to fabricate ceramic films at room temperature (RT). In this process, sub-micron sized ceramic particles are accelerated by pressurized gas, impacted on the substrate, plastically deformed, and form a dense film under vacuum. This AD process eliminates high temperature processing thereby enabling new coatings and device integration, in which ceramics can be deposited on metals, plastics, and glass. However, knowledge in fundamental mechanisms for ceramic particles to deform and form a dense ceramic film is still needed and is essential in advancing this novel RT technology. In this work, a combination of experimentation and atomistic simulation was used to determine the deformation behavior of sub-micron sized ceramic particles; this is the first fundamental step needed to explain coating formation in the AD process. High purity, single crystal, alpha alumina particles with nominal sizes of 0.3 µm and 3.0 µm were examined. Particle characterization, using transmission electron microscopy (TEM), showed that the 0.3 µm particles were relatively defect-free single crystals whereas 3.0 µm particles were highly defective single crystals or particles contained low angle grain boundaries. Sub-micron sized Al 2 O 3 particles exhibited ductile failure in compression. In situ compression experiments showed 0.3µm particles deformed plastically, fractured, and became polycrystalline. Moreover, dislocation activity was observed within these particles during compression. These sub-micron sized Al 2 O 3 particles exhibited large accumulated strain (2-3 times those of micron-sized particles) before first fracture. In agreement with the findings from experimentation, atomistic simulations of nano-Al 2 O 3 particles showed dislocation slip and significant plastic deformation during compression. On the other hand, the micron sized Al 2 O 3 particles exhibited brittle fracture in compression. In situ compression experiments showed 3µm Al 2 O 3 particles fractured into pieces without observable plastic deformation in compression. Particle deformation behaviors will be used to inform Al 2 O 3 coating deposition parameters and particle-particle bonding in the consolidated Al 2 O 3 coatings.

Sarobol, Pylin↗
DOE OSTI2012

Upstream Measurements of Wind Profiles with Doppler Lidar for Improved Wind Energy Integration

New upstream measurements of wind profiles over the altitude range of wind turbines will be produced using a scanning Doppler lidar. These long range high quality measurements will provide improved wind power forecasts for wind energy integration into the power grid. The main goal of the project is to develop the optimal Doppler lidar operating parameters and data processing algorithms for improved wind energy integration by enhancing the wind power forecasts in the 30 to 60 minute time frame, especially for the large wind power ramps. Currently, there is very little upstream data at large wind farms, especially accurate wind profiles over the full height of the turbine blades. The potential of scanning Doppler lidar will be determined by rigorous computer modeling and evaluation of actual Doppler lidar data from the WindTracer system produced by Lockheed Martin Coherent Technologies, Inc. of Louisville, Colorado. Various data products will be investigated for input into numerical weather prediction models and statistically based nowcasting algorithms. Successful implementation of the proposed research will provide the required information for a full cost benefit analysis of the improved forecasts of wind power for energy integration as well as the added benefit of high quality wind and turbulence information for optimal control of the wind turbines at large wind farms.

17 WIND ENERGY↗
DOE OSTI2023

Biochemical Conversion of Lignocellulosic Biomass to Hydrocarbon Fuels and Products: 2022 State of Technology and Future Research

The annual State of Technology (SOT) assessment is a key activity for biochemical platform research. It allows the impact of research progress (both directly achieved in-house at the National Renewable Energy Laboratory [NREL] and indirectly extrapolated from available public data) to be quantified in terms of economic improvements in the overall cellulosic biofuel production process for a particular conversion pathway. As such, initial benchmarks can be established for currently demonstrated performance and progress can be tracked toward out-year goals to ultimately demonstrate cost-competitive biofuel technology. Building upon efforts to progress NREL's biochemical platform R&D work toward ultimate 2030 goals to demonstrate less than $2.50/gallon gasoline equivalent (GGE) fuel selling prices, experimental and techno-economic analysis (TEA) activities have primarily focused on "advanced" biochemical processing strategies to fuels and coproducts, guided by TEA modeling to highlight key barriers and priorities toward achieving this goal across a number of potential bioconversion pathways. The purpose of the present effort is to benchmark the latest experimental developments for these pathways as quantified by modeled minimum fuel selling prices (MFSPs), as a measure of current status relative to those final targets. For this SOT, TEA models were run for two separate biological conversion pathways to fuels, based on available data for integrated biomass deconstruction and hydrolysate processing; namely carboxylic acids (primarily butyric acid) and diols (2,3-butanediol [BDO]), reflecting NREL's recently published 2018 biochemical design report focused on those two pathways. The models were run across two scenarios for lignin utilization, namely combustion and conversion to value-added coproducts.

09 BIOMASS FUELS↗
DOE OSTI2022

A Multicomponent Reactive Transport Model for Integrated Surface‐Subsurface Hydrology Problems

Abstract Despite the widespread use of integrated hydrology models in a variety of applications, consideration of multicomponent reactive transport is still not common. The implementation of these processes requires coupling transport at the surface‐subsurface interface and efficient solution of the non‐linear geochemical model that is consistent with the integrated hydrology solution. The Advanced Terrestrial Simulator provides a flexible multiphysics framework that facilitated this process. In this work, the integrated reactive transport process kernel (PK) was weakly coupled to the integrated hydrology PK. In turn, integrated transport and reactions were coupled using an operator splitting approach. This splitting enabled an explicit solution of the integrated transport problem, including a novel algorithm to calculate exchange fluxes across the surface‐subsurface interface and a point‐by‐point solution of the geochemical problem. Geochemical capabilities were added using well‐established external codes, but rather than using a custom interface to each, a generic interface was used that clearly specifies the variables and operations used by the chemistry PK. The implementation is demonstrated with two example simulations: transport of a tracer in a soil column as it saturates over time and water ponds on the surface and reactive transport in a hillslope driven by successive wet‐dry cycles that result in infiltration, runoff and exfiltration processes.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2017

Hanford WTP LAW Melter Startup and Tuning Feed Material Development - 17065

The U.S. Department of Energy's (DOE) Hanford Site in southeast Washington state is home to 56 million gallons of chemical and radioactive waste stored in underground tanks, the result of more than four decades of plutonium production. To address this challenge, the U.S. Department of Energy contracted Bechtel National, Inc., to design and build the world's largest radioactive waste treatment plant. The Hanford Tank Waste Treatment and Immobilization Plant (WTP) will use vitrification to immobilize most of Hanford's waste. Vitrification involves blending the waste with glass-forming materials, and heating it to high temperature to form molten glass, then pouring it into stainless steel containers. In this glass form, its radioactivity will decay over hundreds to thousands of years. In advance of full operation of WTP, a sequential process of commissioning will be undertaken to ensure the plant operates safely and within design requirements. The first phase of WTP operations will focus on the Low-Activity Waste (LAW) Vitrification Facility and its supporting facilities and systems. Commissioning of the LAW Facility will employ a progressive approach to address the complexity of system operation and introduction of hazards. This approach starts with introduction of low hazard and simple testing configurations, and incrementally increasing the complexity and hazardous makeup of testing feed materials, culminating in fully integrated treatment of radioactive tank waste during hot commissioning. Testing with simulants that are chemically similar to radioactive tank waste introduces significant chemical hazards into treatment systems in the form of nitrogen oxides (NOx) and anhydrous ammonia. A method of testing to allow tuning and demonstration of equipment and to develop operator proficiency prior to introducing these chemical hazards was deemed necessary. To that end, the development and testing of a new 'tuning feed' material is in progress. The tuning feed is important because its use will enable the first-time integration of all LAW Facility process systems. The tuning feed must include key physical and chemical characteristics that correspond to the commissioning simulant and low activity tank waste, without the inherently hazardous materials or toxic off-gas constituents that result from tank waste treatment. Tuning feed is being developed to provide representative melter feed rheology, glass chemistry, cold cap formation, and off-gas generation rate in order to predict system response to actual tank waste to the extent practical. The tuning feed must also be compatible with process equipment and other process streams that will be encountered during the cold commissioning testing program. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Sci-Thur PM - Colourful Interactions: Highlights 04: A Fast Quantitative MRI Acquisition and Processing Pipeline for Radiation Treatment Planning and Simulation

MRI-only Radiation Treatment Planning (RTP) is becoming increasingly popular because of a simplified work-flow, and less inconvenience to the patient who avoids multiple scans. The advantages of MRI-based RTP over traditional CT-based RTP lie in its superior soft-tissue contrast, and absence of ionizing radiation dose. The lack of electron-density information in MRI can be addressed by automatic tissue classification. To distinguish bone from air, which both appear dark in MRI, an ultra-short echo time (UTE) pulse sequence may be used. Quantitative MRI parametric maps can provide improved tissue segmentation/classification and better sensitivity in monitoring disease progression and treatment outcome than standard weighted images. Superior tumor contrast can be achieved on pure T{sub 1} images compared to conventional T{sub 1}-weighted images acquired in the same scan duration and voxel resolution. In this study, we have developed a robust and fast quantitative MRI acquisition and post-processing work-flow that integrates these latest advances into the MRI-based RTP of brain lesions. Using 3D multi-echo FLASH images at two different optimized flip angles (both acquired in under 9 min, and 1mm isotropic resolution), parametric maps of T{sub 1}, proton-density (M{sub 0}), and T{sub 2}{sup *} are obtained with high contrast-to-noise ratio, and negligible geometrical distortions, water-fat shifts and susceptibility effects. An additional 3D UTE MRI dataset is acquired (in under 4 min) and post-processed to classify tissues for dose simulation. The pipeline was tested on four healthy volunteers and a clinical trial on brain cancer patients is underway.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Non-Destructive In-Process Assessment of Thermal Spray Repairs

This exploratory project, entitled “Non-Destructive In-process Assessment of Thermal Spray Repairs,” evaluated the capabilities and limitations of four non-destructive testing (NDE) technologies for detection of defects in as-sprayed thermal spray coatings: acousto-ultrasonics, vibro-thermography, thermal wave infrared (IR) imaging, and flash IR thermography. The project goal was to identify a single technology suitable for use as an in-process inspection for two common classes of defects in thermal spray coatings, porosity and disbonds. Two rounds of test coupons were fabricated with intentionally seeded defects in AISI 420 stainless steel coatings deposited by twin wire arc (TWA) spray onto gray cast iron substrates. These standardized test coupons allowed the sensitivity of the four NDE methods to be directly compared. The results indicated that the acousto-ultrasonic method will not meet requirements for accuracy, inspection time, and reproducibility, while the vibrothermography method will not meet requirements for integration within remanufacturing cells and process flows. The IR methods, thermal wave imaging and flash thermography, both exhibited acceptable accuracy and reproducibility; however, the former method does not meet the requirement for inspection time. Flash IR thermography met all requirements in the initial round of testing, and that result was confirmed in a second round of testing on samples with a larger, more complex geometry. A final recommendation for further development of flash IR thermography was therefore made based upon i) detection performance, and ii) feasibility of deployment into the target application of resurfacing CAT engine blocks and headers.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Iterative algorithms for processing experimental data

The need to solve linear and nonlinear integral equations arise, e.g., in recovering plasma parameters from the data of multichannel diagnostics. The paper presents an iterative method for solving integral equations with a singularity at the upper limit of integration. The method consists in constructing successive approximations and calculating the integral by quadrature formulas in each integration interval. An example of application of the iterative algorithm to numerically solve an integral equation similar to those arising in recovering the plasma density profile from reflectometry data is presented.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Random field optimization

Herein we present a new modeling paradigm for optimization that we call random field optimization. Random fields are a powerful modeling abstraction that aims to capture the behavior of random variables that live on infinite-dimensional spaces (e.g., space and time) such as stochastic processes (e.g., time series, Gaussian processes, and Markov processes), random matrices, and random spatial fields. This paradigm involves sophisticated mathematical objects (e.g., stochastic differential equations and space-time kernel functions) and has been widely used in neuroscience, geoscience, physics, civil engineering, and computer graphics. Despite of this, however, random fields have seen limited use in optimization; specifically, existing optimization paradigms that involve uncertainty (e.g., stochastic programming and robust optimization) mostly focus on the use of finite random variables. This trend is rapidly changing with the advent of statistical optimization (e.g., Bayesian optimization) and multi-scale optimization (e.g., integration of molecular sciences and process engineering). Our work extends a recently-proposed abstraction for infinite-dimensional optimization problems by capturing more general uncertainty representations. Moreover, we discuss solution paradigms for this new class of problems based on finite transformations and sampling, and identify open questions and challenges.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Metall: A persistent memory allocator for data-centric analytics

Data analytics applications transform raw input data into analytics-specific data structures before performing analytics. Unfortunately, such data ingestion steps are often more expensive than analytics. In addition, various types of NVRAM devices are already used in many HPC systems today. Such devices will be useful for storing and reusing data structures beyond a single process life cycle. We developed Metall, a persistent memory allocator built on top of the memory-mapped file mechanism. Metall enables applications to transparently allocate custom C++ data structures into various types of persistent memories. Metall incorporates a concise and high-performance memory management algorithm inspired by Supermalloc and the rich C++ interface developed by Boost.Interprocess library. On a dynamic graph construction workload, Metall achieved up to 11.7x and 48.3x performance improvements over Boost.Interprocess and memkind (PMEM kind), respectively. We also demonstrate Metall’s high adaptability by integrating Metall into a graph processing framework, GraphBLAS Template Library. Here this study’s outcomes indicate that Metall will be a strong tool for accelerating future large-scale data analytics by allowing applications to leverage persistent memory efficiently.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Thermally Insulating Transparent Barrier (THINNER) coatings on single pane windows

Conventional silica aerogel monoliths can provide remarkable thermal insulation but the presence of large pores (> 30 nm) tends to scatter visible light and render the material opaque or translucent instead of transparent. In addition, they are prone to cracking during synthesis and handling which makes them difficult to integrate in products and in particular in window solutions. This project developed two new solgel synthesis methods using silica precursors or preformed silica nanoparticles and ambient drying to produce mesoporous organo-silica monoliths. The monoliths were (i) thermally insulating, (ii) optically transparent, (iii) flexible, and (iv) hydrophobic. They feature porosity ranging from 50% to 90% with narrow pore size distribution with pore less than 20 nm resulting in excellent optical clarity (haze < 2%) and very low thermal conductivity (< 30 mW/mK). Interestingly, not only porosity but also pore size and mass fractal dimension were found to affect the thermal conductivity of the mesoporous silica. The superior transparency of the monoliths was shown to be attributed to dependent scattering among silica nanoparticles. Flexibility was achieved through trimethylchlorosilane surface modification. Furthermore, process scale-up and integration of the ambigel monoliths into window solutions using optically clear adhesives were also demonstrated in 6”x6” double-pane windows. The aerogel and the window solution were shown to be durable to accelerated aging under UV, moisture, and/or temperature gradient and thermal cycling. Overall, the window solution achieved the technical performance and the cost target of $10/sqft set for the SHIELD program. However, scaling to industry relevant scale (> 10’x10’) remains a challenge due to requirements on the drying process and fume hood size and to the propensity of large aerogel slab to crack during drying.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗