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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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DOE OSTI2025

X-ray thermal diffuse scattering as a texture-robust temperature diagnostic for dynamically compressed solids

We present a model of x-ray thermal diffuse scattering (TDS) from a cubic polycrystal with an arbitrary crystallographic texture, based on the classic approach of Warren [B. E. Warren, Acta Crystallogr. 6, 803 (1953)]. We compare the predictions of our model with femtosecond x-ray diffraction patterns gathered from ambient and dynamically compressed rolled copper foils obtained at the High Energy Density instrument of the European X-Ray Free-Electron Laser facility and find that the texture-aware TDS model yields more accurate results than does the conventional powder model owed to Warren. Nevertheless, we further show: with sufficient angular detector coverage, the TDS signal is largely unchanged by sample orientation and in all cases strongly resembles the signal from a perfectly random powder; shot-to-shot fluctuations in the TDS signal resulting from grain-sampling statistics are at the percent level, in stark contrast to the fluctuations in the Bragg-peak intensities (which are over an order of magnitude greater); and TDS is largely unchanged even following texture evolution caused by compression-induced plastic deformation. We conclude that TDS is robust against texture variation, making it a flexible temperature diagnostic applicable just as well to off-the-shelf commercial foils as to ideal powders.

Crystal lattices↗

DOE OSTI2025

Survey Report on Commercial Off-The-Shelf (COTS) Tracking Tools

Radioactive/nuclear (R/N) materials are integral parts of many business sectors such as medicine, industry, and research. In the United States alone, approximately 3 million packages containing R/N materials are shipped annually via highways, rail, air, and water. These materials are utilized in medical diagnostics and treatments, industrial radiography, and scientific research. The secure and efficient transportation of R/N materials is paramount to public safety and national security. Recent incidents involving the loss of R/N materials during transportation highlight significant security and safety concerns. For instance, in December 2024, a package containing four encapsulated Selenium-75 sources was reported lost in transit from the Czech Republic to Madrid, raising alarms about the security of such shipments. Similarly, a Germanium-68 pin source was reported lost in transit in New Jersey in December 2024, underscoring the risks associated with transporting radioactive materials.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

DOE OSTI2025

Computational Modeling of a 3D Printed Recuperator and Subsequent Experimental Loop for Supercritical Carbon Dioxide Cycles

Oak Ridge National Laboratory (ORNL), in collaboration with mechanical-thermal energy storage (mTES) provider EarthEn, a US Department of Energy (DOE) Lab-Embedded Entrepreneurship Program (LEEP) recipient at ORNL’s Innovation Crossroads 2023, is utilizing a state-of-the-art patented 3D printing technique to design an additively manufactured (AM) supercritical CO2 (sCO2) recuperator (REC) for EarthEn’s charge/discharge cycle. The AM REC will be printed at ORNL’s Manufacturing Demonstration Facility using Inconel Alloy 718 and tested on a closed-loop, ∼100 kW scale experimental facility that is under construction. The testing will compare the printed design against a commercial-off-the-shelf Printed Circuit Heat Exchanger (PCHE) REC. The design of the sCO2 facility is guided by a Modelica-based system model which is primarily dependent on the open-source TRANSFORM library developed at ORNL and uses the open-source CoolProp library for thermophysical properties of sCO2 via the External Media library. It is envisioned that an iterative process will be followed between the physical loop and the system model wherein the initial experimental data will be used to tune the model, which in turn will be used to guide future loop operation. Simultaneously, the AM REC is being designed using computer-aided design models, and it is also being analyzed for hydraulic and thermomechanical response using commercial computational fluid dynamics software, Simcenter STAR-CCM+, on highperformance computing resources.1

See, Nate [ORNL] (ORCID:0000000178581202)↗

DOE OSTI2025

ComStock Measure Scenario Documentation: Laboratory-Informed Modeling of Standard Performance Heat Pump Rooftop Units

This measure scenario replaces gas and electric resistance RTUs in the U.S. commercial building stock with standard efficiency commercial off the shelf heat pump rooftop units. This study uses performance data informed by NREL laboratory testing of a standard efficiency 7.5-ton heat pump RTU. This is the key distinction between this measure scenario and a similar ComStock measure scenario - Standard Performance Heat Pump Rooftop Units - that uses published manufacturer data tables to inform performance. These two scenarios are compared in this report.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

A Coincident CdTe Detector Array for Enhanced Nuclear Process Monitoring

Nuclear fuel cycle aqueous separation processes desire improved real-time material characterization and process monitoring techniques; gamma coincidence spectroscopy has the potential to meet this need in these high throughput and high radiation environments based on its ability to reduce background noise, thereby enhancing detection limits and improving isotopic identification accuracy. A detector array composed of three CdTe detectors was designed to surround a chemical processing pipe in a reprocessing facility and evaluate the feasibility of passively assaying the nuclear materials flowing though this measurement point. This array uses commercial off the shelf components that are radiation hard and highly efficiency at low energies relevant to actinide photon signatures. Detector efficiency characterizations, coincidence detection, and potential configuration improvements are presented here.

Good, Erin C.↗

DOE OSTI2026

TCAD-Machine Learning Enabled TID Compact Model Development for Commercial SiC MOSFET

We propose a TCAD (Technology Computer Aided Design)-machine learning coupled approach that combines a TCAD tool (Charon), optimization/uncertainty quantification tool (Dakota), surrogate models, and Bayesian learning capabilities. The coupling approach is used for accurate modeling and calibration of total ionizing dose (TID) induced threshold voltage (V th ) shifts in Commercial-Off-The-Shelf (COTS) semiconductor devices and to develop physics-informed TID compact models. This versatile approach is applied to model the TID effect in an exemplar COTS 3.3 kV SiC power MOSFET (Metal-Oxide-Semiconductor Field-Effect Transistor). With the Charon-Dakota coupling, we can determine key device geometry and doping values based on device physics, which are difficult to obtain or not available for COTS devices but important for TCAD simulation; additionally, we can efficiently generate thousands of simulation results in a large parameter space, which makes it possible to develop data-driven surrogate models and perform Bayesian calibration. Utilizing the full tool-coupling approach, we achieve calibrated TCAD simulation models that accurately capture the average TID-induced V th shifts behavior with total doses and V th shifts saturation at high doses as observed in experimental data. More importantly, the calibrated TCAD simulations are obtained with determined TID model parameters (e.g., hole trap density and capture cross section) values that contain well quantified uncertainties. Furthermore, we can isolate and quantify the noises that are not captured by the TCAD models but exist in the measured data due to measurements and devices variabilities. Lastly, the calibrated surrogate models are used to develop physics-informed TID compact models. The method is generalizable to other devices and/or radiation conditions with few modifications and can provide well-determined uncertainties.

COTS↗

DOE OSTI2025

Robust COTS objective for diffraction-limited, high-NA, long front working distance imaging

We present a robust objective lens optimized for applications requiring both high numerical aperture (NA) and long front working distance imaging, comprised of all commercial-off-the-shelf (COTS) spherical singlet lenses. Unlike traditional designs that require separate collimation and refocusing stages, our approach directly converges imaged light to the back focal plane using a single lens group. Our configuration corrects spherical aberrations and efficiently collects light to achieve diffraction-limited performance across a wide range of wavelengths while simplifying alignment and assembly. Using this approach, we design and construct an example objective lens that features a long front working distance of 61 mm and a clipped NA of 0.30 (limited by an aperture in our experimental setup). We experimentally verify that it achieves monochromatic diffraction-limited resolution at wavelengths from 375 nm to 866 nm without requiring replacement of the lenses or changing the inter-lens spacings, and its performance remains robust across a 46 mm range variation in total length (by adjusting mainly the back working distance). Additionally, we develop a quantitative method to measure the field of view (FOV) using an experimentally calibrated pinhole target. Under 397 nm illumination (i.e., from 40 Ca + ion fluorescence), the objective achieves a resolution of 0.87 μm with a 540 μm FOV. This robust, all-COTS, and versatile design is well-suited for a broad range of experiments, supporting high-precision measurements and exploring quantum phenomena.

Cui, Jiafeng [Oak Ridge National Laboratory (ORNL)↗

DOE OSTI2024

Cybersecurity for the Operational Technology Environment (CyOTE) (Final Technical Report)

Electric grids have historically been susceptible to both physical attacks and environmental hazards but the implementation of smart grids, remote management, and self-healing networks, has now made the grid vulnerable to cyber attacks. To address risks introduced by routable connectivity, utilities must establish dynamic solutions to identify, protect, detect, respond to, and recover from cyber security threats and vulnerabilities. In response to the evolving threat landscape U.S. Department of Energy-Office of Cybersecurity, Energy Security, and Emergency Response (DOE CESER) initiated the Cybersecurity for the OT Environment (CyOTE) pilot program, a U.S. Department of Energy (DOE) effort designed to leverage U.S. intelligence capabilities to prevent, detect, or mitigate a cyber attack on utility operational technology (OT) networks. As part of the CyOTE pilot, The Southern Company (Southern Company or Southern) researched, evaluated and deployed emerging Commercial off the Shelf (COTS) technologies and cyber security monitoring architectures to provide previously unrealized network visibility and situational awareness through deep packet inspection and data analytics. This Final Scientific/Technical Report documents the objectives, methodology, lessons learned, and results of Southern Company’s participation in the CyOTE pilot from December 2018 to September 2023.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Water-Resistant Container Testing: 48 oz Bruntmor Container Design

The purpose of this report is to detail the results of water ingress testing conducted on the 48 oz Bruntmor container design and discuss these results against the water-resistant container requirements of TA55-AP 522 and PA-RD-01009. The 48 oz Bruntmor is a proposed commercially off the shelf inner container option for material storage inside of a glovebox and/or as an approved non-hermetically sealed inner of an approved packaging configuration inside of an approved outer container as listed in PA-RD-01022. The 48 oz Bruntmor is shaped like a slip lid container, made of 18-8 stainless steel, and utilizes a smooth, threaded lid with a silicone gasket for closure and containment. This container both lid and body is hot rolled out of 18-8 stainless steel with one seam weld on the body.

42 ENGINEERING↗

DOE OSTI2026

Water-Resistant Container Testing: A426-7, A426-25, and A426-50 Container Designs

The purpose of this report is to detail the results of water ingress testing conducted on the A426-7, A426-25, and A426-50 Mini-Pot container designs and discuss these results against the water-resistant container requirements of TA55-AP-522 and PA-RD-01009. The A426 design series is a proposed commercially off the shelf inner container option for material storage inside of a glovebox and/or as an approved nonhermetically sealed inner of an approved packaging configuration inside of an approved outer container as listed in PA-RD-01022. The A426-25 and A426-50 are shaped similar to an ointment jar, made of 316L stainless steel, and utilize a threaded lid for closure and containment. The A426-7 container is shaped similar to a vial, made of 316L stainless steel, and utilizes a threaded lid for closure and containment. See Figure 1 and Table 1-3 for a summary of the container specifications. For more details on the container design, see Section 1.4.

42 ENGINEERING↗

DOE OSTI2024

Acoustic Particle Velocity Measurements around a Tidal Current Turbine

Quantifying the underwater sound produced by tidal turbines is essential both to understand their potential environmental impacts and to understand how that sound might interfere with the intended application of the turbine (e.g., powering acoustic monitoring systems). In this project, we measured the sound radiated by a small-scale crossflow tidal turbine. The turbine was deployed from October 2023 to March 2024 in the tidal channel at the entrance to Sequim Bay, WA. Acoustic measurements were made with three different sensor packages: a commercial-off-the-shelf vector sensor (operated by PNNL), a vector sensor array (operated by Integral Consulting), and drifting hydrophones (operated by UW). Acoustic recordings from the three sensors highlight changes in the turbine acoustic signature over the course of a tidal cycle and throughout the 6-month turbine deployment. Our results also highlight the utility of acoustic vector sensors for localizing sound attributable to marine energy devices in acoustically complex environments.

16 TIDAL AND WAVE POWER↗

DOE OSTI2026

Reference Hardware and Software Architecture for a Solenoid Pulser for Scientific Instrumentation at the National Ignition Facility

High current, high voltage solenoid pulser power systems for the generation of magnetic fields in a solenoid is not a radical or new concept. Despite being a cornerstone of scientific and weapons research for over 100 years, a commercial off the shelf unit easily configurable for a broad set of applications has yet to appear on the open market. Pulser systems are instead designed for specific target requirements. For gigawatt to terawatt systems, this is unavoidable. For megawatt systems however, many hundreds of thousands of dollars are wasted designing pulser systems from the ground up for clients, when it is possible to simply architect a modular system once that can have its capacitors swapped for many possible target applications. The National Ignition Facility (NIF) at the Lawrence Livermore National Laboratory (LLNL) is one such institution that would benefit from such a system, having bought such pulsers for several imaging systems. Ideally, all such a system would require is only a bachelors-level circuit analysis to find the correct capacitor values, as well as a written procedure to calibrate the software to correctly deliver the voltages required by the application. In this work, systems architecture and software engineering techniques are used to design and analyze such a system. Such a design, it is the hope of this author, will be used in scientific and engineering purposes in the future to build solenoid pulsers at the National Ignition Facility and other institutions to drastically cut development costs of scientific instrumentation.

42 ENGINEERING↗

DOE OSTI2023

ER4047 Filler Wire Development - Initial Studies

This report describes the results of bead on pipe welding trials for the purpose of evaluating commercial off the shelf (COTS) 0.047” ER4047 filler material vendors for down selection of the of best candidate filler material for future Gas-metal Arc Welding (GMAW) development efforts. Four candidate COTS ER4047 filler wires were evaluated during this work - Astrolite, Alcotec, Hobart, and Lincoln. The storage condition of each of these filler wires was documented and visual inspection was performed.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Powering the Woods Hole X-Spar Buoy with Ocean Wave Energy—A Control Co-Design Feasibility Study

Despite its success in measuring air–sea exchange, the Woods Hole Oceanographic Institution’s (WHOI) X-Spar Buoy faces operational limitations due to energy constraints, motivating the integration of an energy harvesting apparatus to improve its deployment duration and capabilities. This work explores the feasibility of an augmented, self-powered system in two parts. Part 1 presents the collaborative design between X-Spar developers and wave energy researchers translating user needs into specific functional requirements. Based on requirements like desired power levels, deployability, survivability, and minimal interference with environmental data collection, unsuitable concepts are pre-eliminated from further feasibility study consideration. In part 2, we focus on one of the promising concepts: an internal rigid body wave energy converter. We apply control co-design methods to consider commercial of the shelf hardware components in the dynamic models and investigate the concept’s power conversion capabilities using linear 2-port wave-to-wire models with concurrently optimized control algorithms that are distinct for every considered hardware configuration. During this feasibility study we utilize two different control algorithms, the numerically optimal (but acausal) benchmark and the optimized damping feedback. We assess the sensitivity of average power to variations in drive-train friction, a parameter with high uncertainty, and analyze stroke limitations to ensure operational constraints are met. Our results indicate that a well-designed power take-off (PTO) system could significantly extend the WEC-Spar’s mission by providing additional electrical power without compromising data quality.

autonomous systems↗

DOE OSTI2024

Electrothermal vaporization as a new method for pre-inspection check samples

The use of electrothermal vaporization (ETV) has not been readily applied to nuclear safeguards or pre inspection check (PIC) sample analysis, even though the technique is ideally suited for low level (pg) isotopic quantification due to its high analyte transport efficiency. Here demonstrate the ETV method for PIC safeguard analysis. The ETV system is an automated, commercial of the shelf (COTS) technology, with the capability to introduce solid samples to a mass spectrometer platform. The system has been shown to simultaneously determine uranium assay, and the major isotopic ratios for uranium and plutonium. The ETV unit has demonstrated analysis up to 50 samples a day autonomously. The utilization of this ETV methodology provide a secondary option to the current PIC analysis and offers high throughput, enhanced sensitivity, and broader isotopic detection platform.

Hexel, Cole↗

DOE OSTI2024

Microgrid Integration with High Performance Computing Systems for Microreactor Operation

Multiple nuclear microreactor concepts are currently being developed across several sizes and fuel types with high performance computing (HPC) systems anticipated to be end-users of the power. Nuclear microreactors are small in size, portable, produce less than 10 MW electric, operate autonomously, and have a refueling interval of as many as 10 years. However, their load-follow is also generally limited to 10%/minute or worse whereas the power variance in HPC systems easily exceeds this constraint under normal operations. This study explores an approach that requires no load-follow from the microreactor but integrates the HPC system with a microgrid built from commercial-off-the-shelf components. Three typical HPC architectures are explored in the context of microgrid operation in this study. Components of power quality and transient response are empirically measured for five different HPC load-follow response levels using a self-contained mobile datacenter connected to the microgrid capable of integration with a nuclear microreactor.

microgrids↗

DOE OSTI2026

Catalytic monoterpenes conversion over Pd and zeolite to sustainable aviation fuel

Waste terpenes from wood drying are typically processed using a Regenerative Thermal Oxidizer (RTO) and converted to CO2 which is then released to the atmosphere. A novel alternative to this approach is to capture these terpenes using Fluidized Bed Concentrator (FBC) technology developed by CaptisAire which provides a useful waste carbon feedstock for subsequent upgrading. We have developed a catalytic approach where these waste terpenes (comprised of pinenes, limonene, and camphene), are converted to aromatic, and cycloalkane hydrocarbons suitable for use as a Sustainable Aviation Fuel (SAF) blendstock without the need for additional hydrogen. This provides a renewable source for aviation fuel aromatics and increases the potential blend content of renewably sourced alkanes from Hydroprocessed Esters and Fatty Acids (HEFA) and Alcohol to Jet (ATJ) processes. Terpenes were converted in a batch reactor at 260 °C and 120 psi N2 using a combination of Pd/C and H-BEA zeolite. Experimental results infer the role of the zeolite Brønsted acid to facilitate isomerization of pinenes and camphene to limonene, which then undergoes subsequent dehydro-aromatization to p-cymene using Pd/C. Hydrogen release from the dehydro-aromatization process, enables inert conversion of monoterpenes to cycloalkanes without additional hydrogen. Monoterpenes conversion to C10 aromatics (60%) and C10 cycloalkanes (40%) in an inert environment, provides a viable route for SAF blendstock sourced directly from captured waste terpenes. Transition to commercial off-the-shelf catalysts, facilitates scale-up of the terpene conversion process and improves commercial viability. We subsequently created hydrocarbon blends using HEFA or ATJ and converted terpenes, providing a 100% SAF blend with potential to replace traditional Jet-A.

Lawal, Ajibola [ORNL] (ORCID:0000000187266570)↗

DOE OSTI2025

Advances in supervisory control strategies for a heat pump centric HVAC system − a comprehensive review on applications

There is an increase in research investigating the development and deployment of supervisory controllers that enable high efficiency electrically driven vapor compression heat pumps operating within grid interactive efficient buildings to provide demand side management. This paper reviews over sixty relevant case studies within this domain that focus on commercial off-the-shelf heat pumps whose primary task is providing space conditioning. The concept of a heat pump-centric heating, ventilation, and air-conditioning system is introduced, accompanied by a detailed overview of various kinds of electric heat pumps and building-level thermal energy storage configurations. Additionally, the different types of supervisory controller designs, including rule-based control and model predictive control, are discussed, along with the various methods for communication between a supervisory controller and a downstream heat pump’s local controller. A comparative analysis is conducted in order to categorize the reviewed case studies based on their system design, supervisory control algorithm, and validation methodology. This detailed analysis allows the review to establish current research trends, identify potential gaps, and suggest future directions for the development of this technology. Overall, the authors recommend that more future research be devoted to low-cost practical retrofits that allow for easy integration of active thermal energy storage within heat pump-centric heating, ventilation, and air-conditioning system systems that utilize direct expansion heat pumps. We also suggest more research into the development and deployment of supervisory controllers that can properly communicate with commercial off-the-shelf heat pump local controller available control inputs, e.g., zone temperature setpoint. Lastly, more rigorous experimental demonstrations of advanced supervisory control within real and or closed-loop, transient/ quasi-steady state environments are necessary to reduce industry wide skepticism of this technology.

Demand side management↗