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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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14 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2026

Fatigue Life of Flow-Formed Aluminum 2195 and 6061 Alloys

The successful design and fabrication of metallic cryotanks for commercial aviation applications require lightweight, durable materials capable of withstanding high pressures and cryogenic temperatures through tens of thousands of thermomechanical refueling cycles. Flow forming is an advanced manufacturing technique that offers high-rate production and scalability for fabricating integrally stiffened cylinders suitable for cryotank applications. This work establishes the durability of flow-formed aluminum alloys by characterizing their fatigue life performance under conditions that mimic cryotank refueling cycles. Residual stresses in flow-formed aluminum-lithium (Al-Li) 2195-T6 cylinders were assessed using the contour method and found to be minimal. Fatigue life testing was conducted on flow-formed Al-Li 2195-T6 at room temperature and cryogenic temperatures (-321°F [-196°C]), with wrought Al-Li 2195-T6 serving as a baseline for comparison. Results showed that flow-formed materials exhibited fatigue performance comparable to or better than wrought materials, with no statistically significant differences observed between different specimen orientations relative to processing directions. Fractography revealed reduced delaminations in the flow-formed Al-Li 2195 samples as compared to wrought, indicating potential improvement to the microstructure that could result in improved service properties. Texture analysis using electron backscattered diffraction (EBSD) indicated recrystallization during heat treatment, potentially contributing to reduced delamination susceptibility. These findings demonstrating flow-formed material durability coupled with the high manufacturing efficiency of flow forming, makes flow forming an attractive process to produce aircraft cryotanks.

EBF3↗
DOE OSTI2025

Design and Production for Maximum Structural Efficiency With Respect to Fiber Orientation With Increased Understanding of Hybrid Fiber Flow Behavior

Discontinuous fiber-reinforced thermoplastic composites have gained considerable attention in automotive, aerospace, and other industries, due to their high-rate of production combined with their ability to attain complex and intricate shapes. Among other high-rate thermoplastic manufacturing processes, injection-molding is one of the most common manufacturing methods due to fast production and high surface finishing of complex geometries. Fiber orientation in discontinuous fiber composites plays a pivotal role in determining the mechanical, electrical, and thermomechanical properties, underscoring the necessity to comprehend fiber orientation in injection molded parts. Among different fiber types, glass and carbon fibers are most common in the composite industries. The recent trend of hybrid composites comprising both glass fiber (GF) and carbon fiber (CF) is also gaining importance in the automotive industry. Hybrid fiber options allow designers to optimize the balance between glass and carbon fibers by leveraging the high durability and low cost of GF while the strength and lightweight properties of CF. Consequently, comparing the fiber oriented distribution (FOD) of injection molded composites containing GF, CF, and a hybrid of GF/CF is critical to investigating the local mechanical properties of intricate structures for high-end applications. In Phase I of this project, FOD in injection-molded panels with respect to distance from the gate was analyzed using X-ray computed tomography (X-CT) for GF, CF, and hybrid CF/GF (CGF) reinforced nylon 66. To understand the reason behind the FOD with different fiber types, computational fluid dynamics (CFD) and rheology were performed. Samples were extracted at three locations: near the gate, center, and opposite end. Thickness of the layers of typical skin-shell-core type FOD varies with fiber type and location. GF achieved flow direction alignment (in shell) earlier than viscous CF and CGF near the gate, whereas CF showed the highest flow-direction alignment at the center due to shear induced orientation. At the opposite end, GF experienced more backflow than others indicating faster mold filling owing to its lower viscosity. Hybrid CGF exhibited GF-dominated center and CF-dominated end region. The numerical model used to obtain FOD and rheological predictions for the CF and GF composites served to corroborate the trends observed in the experimental trials. The FOD responses across fiber types and location were reflected in their longitudinal and transverse properties. Only GF showed higher longitudinal modulus over transverse modulus near the gate attributed to rapid alignment, whereas CF and CGF exhibited opposite trend. However, fountain flow enhanced the longitudinal modulus over transverse modulus with the distance for all, particularly for CF. This study offers insights into mold filling behavior of different fibers which are critical in optimizing injection molding conditions for tailored final properties.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Framework and Tool for Artificial Intelligence & Machine Learning (AI/ML) Enabled Automated Non-Destructive Inspection of Composites Aerostructures Manufacturing

Vehicles and systems in the field of aerospace have two major requirements: a high demand for a large quantity and an expectation to perform for their lifetime with little to no failures. Thus, there is a need for a fast production rate of aerospace products with high quality. Improvements to production rate have many benefits, including a reduction in energy consumption per unit manufactured. This would be from factory energy usage, which is required to build and verify a product. Manufacturing process specifications require inspection of parts to determine if any flaws are present. Depending on factory planning and product quality, especially at higher rates, the evaluation process can pose a production rate bottleneck. This project was comprised of using artificial intelligence and machine learning (AI/ML) methods on inspection evaluations with the objective of reducing the required time to produce an aerospace structure or product and without reducing the final quality.

42 ENGINEERING↗
DOE OSTI2026

Thermal Regulation of CO 2 Activation Pathways via Interfacial Water Restructuring Enables Ampere-Level, Near-Unity CO Electrosynthesis

Electrochemical reduction of CO 2 to CO is a key step in carbon utilization technologies, yet maintaining high CO selectivity under elevated temperatures relevant to industrial membrane-electrode-assembly (MEA) electrolyzers remains challenging due to the competing hydrogen evolution reaction (HER). Additionally, the temperature dependence of CO selectivity on Cu-based catalysts has remained largely unexplored. Here, we demonstrate that incorporating atomic In or Sn into Cu fundamentally reshapes the selectivity of Cu catalysts at elevated temperatures. Dilute alloy catalysts, In 1 Cu and Sn 1 Cu, achieve >95% FE of CO over a broad current-density window (0.1−1.1 A cm −2 ) at 60 °C in MEA electrolyzers, far exceeding their performance at ambient temperature. In situ attenuated total reflection surface-enhanced infrared absorption spectroscopy suggests that elevating temperature depletes interfacial water activity, which favors a shift in CO 2 activation from a proton-coupled *COOH pathway toward an electron-driven *COO − -associated pathway, while also suppressing HER and CO hydrogenation. In contrast, benchmark CO-selective catalysts such as Ag exhibit minimal temperature-induced changes in CO production at 20−60 °C. These findings identify temperature as an unavoidable yet previously underutilized operating parameter in MEA electrolyzers for high-rate, selective CO production on Cubased catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

7 Innovations in high-rate composite manufacturing: integrating additive manufacturing with compression molding process

Advanced composites play a pivotal role in modern engineering, offering exceptional strength-to-weight ratios and tailored properties, essential for various industries. High-rate composite manufacturing techniques have rapid production capabilities, which are essential for meeting the demands of industries requiring cost-saving, efficiency, and quick turnaround times. This chapter explores the Additive Manufacturing- Compression Molding (AM-CM) system developed by Oak Ridge National Laboratory (ORNL) for advanced composites manufacturing. The AM-CM system integrates additive manufacturing with compression molding, facilitating the production of polymer composite parts with superior mechanical properties and meticulously controlled microstructures. This innovative system not only ensures precise material deposition but also operates as a fast composite manufacturing process, enhancing productivity and performance, which are needed attributes across industrial applications. Through comprehensive mechanical testing and microstructural analysis, AM-CM promotes remarkable fiber alignment and reduced porosity in composite parts compared to alternative thermoplastic high-rate composite manufacturing methods. Furthermore, AM-CM enables overmolding reinforcement using continuous carbon fiber and supports selective reinforcement through customizable toolpaths. It also facilitates the production of hybrid materials to achieve tailored mechanical properties. Future advancements in AM-CM technology aim to enhance process efficiency, broaden material versatility, and improve part performance. This involves exploring novel materials, advancing process monitoring, implementing automation technologies, and integrating artificial intelligence (AI) and machine learning (ML) for predictive modeling and real-time optimization in composite manufacturing. These developments will establish the AM-CM system as a transformative technology in composite manufacturing, driving innovation across industries.

Hassen, Ahmed [ORNL] (ORCID:0000000328521222)↗
DOE OSTI2025

Electrosynthesis of high purity ethylene using high-index facet Cu 2 O nanocrystals electrocatalyst

Electrochemical CO 2 reduction reaction (eCO2RR) to multi-carbon (C 2+ ) products with copper-based catalysts is often limited by poor selectivity. This challenge arises from the concurrent formation of various intermediates, dictated by the atomic arrangement and electronic properties of surface atoms. In this study, we found that copper (I) oxide (Cu 2 O) nanocrystals with 50 facets (50F-NC), predominantly featuring (211) facets that offers high density of under-coordinated sites, demonstrate superior ethylene (C 2 H 4 ) selectivity of 92% ± 2 with an overall current density of 212 mA/cm 2 at -650 mV vs RHE. Furthermore, after one month of storage in a 1 M KOH electrolyte, this catalyst demonstrated a C 2 H 4 Faradaic efficiency of 87% highlighting its stabile structure under strong alkaline environments. Here, operando electrochemical Raman spectroscopy revealed enhanced CO* intermediate coverage on the 50F-NC catalyst, correlating with improved C-C coupling. SEM, TEM, and XPS analyses, along with DFT calculations, suggested that Cu sites on the (211) facet of 50F-NC and those at the Cu/Cu 2 O interface formed in-situ due to the surface reconstruction during the reaction, are likely active sites for effective C-C coupling and sustained high-rate C 2 H 4 production.

Cu nano particle↗
DOE OSTI2026

Process Optimization and Real-Time Control of Synergistic Microalgae Cultivation and Wastewater Treatment (Final Technical Report)

The overarching goal of this work was to accelerate the commercialization of high productivity, mixed community microalgal treatment technologies for the synergistic treatment of wastewater and the production of biofuel feedstocks. This project addressed a critical barrier to the financial viability and energy efficiency of algal wastewater treatment: an inability to design and operate high-rate processes that reliably achieve target effluent qualities, areal productivities, and biochemical compositions (lipid, protein, carbohydrate content) despite fluctuations in wastewater composition, weather, and microbial communities. Key outcomes from this work include an optimized and controlled Advanced Biological Nutrient Recovery (ABNR) design as well as a suite of open-source tools that include a calibrated and validated algae process simulator in QSDsan and a novel low-cost, real-time microbial monitoring tool. These tools can be leveraged by other algal cultivation and wastewater treatment technology developers in future work.

09 BIOMASS FUELS↗
DOE OSTI2026

Measurement of 𝐵 meson production fraction ratios in proton-proton collisions at √𝑠 = 13 TeV using open-charm and charmonium decays

Production fraction ratios of 𝐵 + , 𝐵 0 , and 𝐵$^{0}_{𝑠}$ mesons are measured in proton-proton collisions at √𝑠 = 13 TeV using a special dataset recorded in 2018 with high-rate triggers designed to collect an unbiased sample of 1⁢010 𝑏 hadrons with the CMS experiment at the LHC. These data allow the study of the open-charm decays of 𝐵 mesons (𝐵 (𝑠) → 𝜋⁢𝐷 (𝑠) ) where the 𝐷 meson decays into fully hadronic final states. By utilizing known branching fractions and precise theoretical calculations, production fraction ratios as functions of 𝐵 meson transverse momentum (𝑝 T ) and rapidity (𝑦) are measured using open-charm decays in the kinematic range of 8 < 𝑝 T < 60 GeV and |𝑦| <2.25. In addition, the same dataset is used to measure the relative production fraction ratios with the charmonium decay channels [𝐵 (𝑠) →𝑋⁢𝐽/𝜓 with 𝑋 indicating a 𝐾 + , 𝐾*(892) 0 , or 𝜙⁡(1020) meson] where the 𝐽/𝜓 meson decays into a pair of muons. The open-charm results are used to normalize the relative production fraction ratios obtained from the charmonium samples. Measurements of the ratios of branching fractions of 𝐵 meson decays to charmonium and open-charm final states are also reported, which will improve the world-average values of these ratios. Finally, we test isospin invariance in 𝐵 meson production in proton-proton collisions and observe that it holds within the experimental precision.

Bottom mesons↗
DOE OSTI2025

Genesis of a novel high-rate composite manufacturing process using large-scale additive manufacturing – compression molding (AM-CM) system: Possibilities and limitations

Oak Ridge National Laboratory (ORNL) has developed a highly automated manufacturing process for thermoplastic composites that combines the benefits of Additive Manufacturing and Compression Molding (AM-CM) to produce high-performance functional composite structures at automotive production rates. Here, the AM-CM process creates highly precise preforms by additively placing extruded fiber-filled polymers (with controlled fiber orientations and multi-material configurations) in the desired mold location before undergoing a secondary compression molding process immediately before the preform cools down. Preforms can be in the form of short, long-chopped, or continuous fiber-filled thermoplastic polymers (e.g., CF/GF-filled ABS, PC, LM-PAEK, etc.). The AM-CM process combines the benefits of controlled fiber alignment, that is only achievable in AM-printed parts with the classical CM process, which eliminates porosity and good surface finish. A preform created using AM-CM can integrate various materials to enable additional architectural functionalities, including over-molding, selective stiffening, and the incorporation of electrically or thermally conductive channels. All these advantages come with a fast part production cycle time. The AM-CM process can manufacture multi-material, multi-functional parts in under 3 min, starting from raw material (pellets) to the final product. The novel AM-CM process offers superior microstructural control and enhanced multi-functionality previously unattainable with any other traditional high-rate thermoplastic composite manufacturing method. This work covers the manufacturing concept, system development, materials and applications of AM-CM process in detail.

Kumar, Vipin [Oak Ridge National Laboratory (ORNL)↗
DOE OSTI2026

Bioadaptive Ni single atoms unlock high rate microbial electrosynthesis of isopropanol from CO 2

Hybrid systems that integrate electrochemical CO 2 reduction with microbial upgrading offer a viable route to high value organic compounds from CO 2 at ambient conditions. However, electrocatalyst deactivation in microbial growth media remains a key barrier, limiting efficiency and increasing cost. Here we show that a bioadaptive single-atom nickel catalyst (Ni SAC), coupled with genetically engineered Clostridium ljungdahlii, enables robust electrosynthesis of isopropanol (IPA) from CO 2 via a CO-mediated pathway. Instead of relying on H 2 as an electron carrier, the system applies high-rate CO formation in complex growth media, maintaining a tunable CO Faradaic efficiency up to 92%, which is 9.4 to 52.7 times greater than conventional Ag catalysts. This performance supports stable IPA production at current density of 10.8 A/m 2 and production rate of 161.3 mg/L/day. In situ Raman and X-ray absorption spectroscopy, together with theoretical calculations, indicate that the Ni SAC can resist competing organic adsorption and retain its coordination structure during CO 2 reduction in bioelectrolytes, providing a mechanistic basis for the catalyst stability and integrated process performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1976

Contribution of the Spacelab data management system to lower cost space research

This paper reviews the design and operation of the Spacelab data management system as it has evolved. Significant improvements and extensions of the original baseline system have been incorporated and will be discussed. They include the capability for the remote control of Spacelab subsystems, improved remote data acquisition units, a high-rate digital data multiplexer, and an improved high-rate digital recorder. Emphasis will be placed on the overall system aspects, including considerations on the use of minicomputers as an adjunct to the basic Spacelab data system. The approach for experiment related software production and integration will be addressed as well. The paper focuses on the contributions of the data management system in reducing the cost of research in Spacelab.

Burger, J. J.↗
DOE OSTI2025

Electro-activated indigos intensify ampere-level CO 2 reduction to CO on silver catalysts

The electrochemical reduction of carbon dioxide (CO 2 ) to carbon monoxide (CO) is challenged by a selectivity decline at high current densities. Here we report a class of indigo-based molecular promoters with redox-active CO 2 binding sites to enhance the high-rate conversion of CO 2 to CO on silver (Ag) catalysts. Theoretical calculations and in situ spectroscopy analyses demonstrate that the synergistic effect at the interface of indigo-derived compounds and Ag nanoparticles could activate CO 2 molecules and accelerate the formation of key intermediates (*CO 2 – and *COOH) in the CO pathway. Indigo derivatives with electron-withdrawing groups further reduce the overpotential for CO production upon optimizing the interfacial CO 2 binding affinity. By integrating the molecular design of redox-active centres with the defect engineering of Ag structures, we achieve a Faradaic efficiency for CO exceeding 90% across a current density range of 0.10 − 1.20 A cm –2 . The Ag mass activity toward CO increases to 174 A mg –1 Ag . This work showcases that employing redox-active CO 2 sorbents as surface modification agents is a highly effective strategy to intensify the reactivity of electrochemical CO 2 reduction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Coal-derived carbon anodes for lithium-ion batteries: Development, challenges, and prospects

Lithium-ion battery (LIB) development has increased rapidly, requiring low-cost anode materials with a high capacity, high-rate performance, and stable lifespan. Carbon-based anodes possess various exceptional morphologies and structures, making them promising candidates for meeting the technical demands; however, conventional synthetic carbon anode processes need expensive feedstocks that increase anode cost and limit commercialization. Coal, the most affordable and abundant carbon resource, has attracted increasing attention as the primary feedstock for producing high-value carbon anode materials. This article reviews the lithium storage mechanisms, characteristics, and productions of some high-valuable carbon anode materials for LIBs from coal and coal derivatives. The high-value carbon anode materials reviewed in this article are graphite, graphene, mesophase microbeads (MCMB), carbon fiber, and hard carbons. Furthermore, the remaining challenges and prospects of using coal-derived carbon materials to create high-performance and low-cost lithium-ion batteries are also discussed.

25 ENERGY STORAGE↗
DOE OSTI2026

Zero-added-loss entanglement multiplexing using time-bin spectral shearing

High-quality quantum communications that enable important capabilities, such as distributed quantum computing and sensing, will require quantum repeaters for providing high-quality entanglement. To realize high-rate heralded entanglement for quantum repeaters, Chen et al . [Phys. Rev. Appl. 19 , 054029 (2023)] proposed a scheme for heralded-multiplexed generation of quasideterministic entangled photon pairs, called zero-added-loss multiplexing (ZALM). Here, we propose a design of the ZALM source using time-bin entanglement and spectral shearing. Additionally, we provide an analysis of experimentally relevant spectral-shearing parameters to optimize the spectral multiplexing. Moreover, we experimentally verify the compatibility of time-bin pulses and spectral shearing, as supported by observation of no appreciable phase shift when the same shearing is applied to both time bins. These results expand the benefits of applying a ZALM source to time-bin entanglement use cases. Moreover, more fully demonstrating time-bin and spectral shearing compatibility clears a path toward a broader use of spectral shearing that provides a deterministic frequency shift of high utility.

entanglement production↗