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DOE OSTI2024

Futures for electrochromic windows on high performance houses in arid, cold climates

This study investigates high performance electrochromic windows used on a passive house and residential dwelling to IECC 2021 (i.e., IECC dwelling). In the lab, the electrochromic film switches transmitted solar heat gain coefficient (SHGC) from 0.09 to 0.7 and visible transmittance from 0.15 to 0.82 with power consumption of 1.23 W/m 2 during switching times less than 3 minutes. We extrapolate these results to a window assembly. Building energy models of the houses were evaluated in Santa Fe, New Mexico. A Monte Carlo analysis for 2020, 2040, 2060, and 2080 was conducted for Shared Socioeconomic Pathways 2-4.5, 3-7.0, and 5-8.5. Cases with and without the electrochromic windows and with and without electricity were used to determine energy use intensity and hours beyond thermal safety thresholds. The passive house showed 1.3-3.1% mean energy savings and the IECC dwelling 4.4-5.1% with electrochromic efficiency benefits growing into the future for both cases. Even so, overall savings decrease into the future for the passive house, due to growth in cooling load being dominant, conversely overall energy savings increase into the future for the IECC dwelling due to heating loads being dominant. For thermal resilience, the passive house exhibited a mean percent decrease of 0.02-0.31% hours in the extreme caution (i.e., > 32.2 °C, ≤ 39.4 °C) range while the IECC dwelling exhibited 0.38-4.38%. The study therefore shows that electrochromic windows will have smaller benefits for the passive house in comparison to the IECC dwelling. The relationship between electrochromic windows is shown to have a complex relationship between house efficiency and climate change by these results.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Scaling Decarbonization Development Innovation with Emerging Community-Based Developers: Preprint

The building real estate development industry is being asked to lead in delivering building decarbonization solutions across the United States. However, creating decarbonized best practices and development innovation while increasing developer diversity and community ownership is often not a primary focus of this sector. To address these issues, we have created an incubator and support ecosystem specifically for the innovation scaling we have found in a leading group of emerging, small-scale developers. These leaders are not just working at the forefront of decarbonized development but addressing diversity and bolstering community generational wealth. We have found that small development firms are the ones who often take risks to innovate and demonstrate despite lacking a specific set of resources or support ecosystems focused on emerging decarbonization developers. Those with the fewest resources are being asked to lead our decarbonization innovation efforts. This paper documents the necessity of a cohort and incubator program to provide a decarbonization-specific ecosystem to support small developers and scale innovation. The incubator creates connections, fosters innovative strategies to access incentives and alternative funding, and assembles resources for small and emerging minority developers with the goal of sustainability and affordability. For instance, collaborative efforts with leading developers and utilities can enable the seamless integration of distributed energy resources through optimal metering and interconnection and significantly reduce the utility cost of electrification, benefiting the utility, the developer, and the tenant economically. The process described in this paper will result in case studies and how-to resources to provide tangible examples of innovation within the emerging development field.

carbon↗

DOE OSTI2024

Modular thermal and radiation shielding with passive heat removal

A housing assembly configured to house a reactor is disclosed. The housing assembly includes a plurality of modular walls configured to surround the reactor and a passive temperature control system. The plurality of modular walls includes a first modular wall. The passive temperature control system is coupled to the first modular wall. The passive temperature control system is configured to transfer heat between the reactor and an area around the housing assembly.

Trupiano, Anthony G.↗

DOE OSTI2020

Tardigrade: Summary (LL20-AM-sensor)

Tardigrade is an effort to create small, passive remote sensor for material detection and identification. The microbolometer based sensor design uses custom bandpass filter bands combined with tuned thermal expansion materials in a ruggedized lens housing to provide passive mechanical correction for optical changes across a wide temperature range. This requires developing computational tools to model and predict thermal performance of meta-materials composed of multiple structured base materials and void-space, along with matching and developing 3D print technology to demonstrate the housing. Current efforts in the project are in 3 areas: material design algorithm development (transitioning into full 3D material design space), multi-material additive manufacturing process exploration, and sensor/optics design and engineering.

42 ENGINEERING↗

DOE OSTI2024

Geophysical Signatures of Crack Network Coalescence in Rocks at Multiple Length Scales

The main goal of the research project was to identify the geophysical signatures of fracture growth in natural rocks by utilizing novel geophysical techniques. The research objectives were to (a) investigate the potential for geophysical methods to determine when cracks initiate, the types and locations of propagated cracks, and the coalescence of networks of cracks in natural rocks at multiple scales, (b) determine how damage at the microscale evolved into damage at the macroscale and then link the microscopic and macroscopic observations, (c) quantify crack coalescence in rocks under realistic stress conditions using coupled mechanical-geophysical-optical visualization, and (d) identify the precursors in geophysical signals to crack coalescence. The following research thrusts were explored to achieve the research objectives: (1) uniaxial compression testing of rock specimens with and without a set of pre‐existing flaws and (2) triaxial compression testing of natural rock specimens. These thrusts allowed for exploring fracturing in rocks under realistic in situ environments and at multiple scales. This project provided educational opportunities for nine graduate and undergraduate students and resulted in 27 peer-reviewed publications. This first research thrust focused on investigating the micromechanics of fractures in rocks through uniaxial compression testing combined with advanced geophysical and imaging techniques, specifically acoustic emission (AE) monitoring, ultrasonic imaging, and 2-dimensional Digital Image Correlation (2D-DIC). By examining damage processes under time-independent and time-dependent loading conditions, insights into damage localization, crack initiation, and fracturing mechanisms were gained. It was observed that the AE signals and the strain-based measurements directly reflect the state of damage in the rock specimen and could be used to identify the cracking levels, such as the crack initiation (CI) and crack damage (CD), and the mode of deformation. A novel calibration apparatus was developed to enhance the accuracy of AE sensors, allowing for the estimation of key parameters such as magnitude, source dimension, stress drop, and radiated seismic energy associated with the fractures. The findings highlighted significant variations in the temporal evolution of AE source parameters during the primary, secondary, and tertiary stages of creep, identifying tensile cracking as the primary deformation mode. The second research thrust focused on enhancing the understanding of fracturing processes in natural rocks through triaxial compression testing, real-time AE monitoring, and ultrasonic monitoring. We investigated the impact of various factors such as fracture propagation regimes, injection parameters, rock types, and pre-existing conditions on the hydraulic fracture (HF) behavior using scaled true-triaxially loaded specimens of Barre granite and Lyons sandstone. Custom sensor housing facilitated concurrent active and passive monitoring to analyze hydro-mechanical responses and microseismicity associated with different HF scenarios. A coupled investigation of passive microseismicity and active signal attributes permitted a detailed comprehension of the various HF processes (aseismic deformation, fracture initiation and propagation, fluid permeation, and leak-off) and their dependence on the specific rock type. The findings of this research demonstrated the effectiveness of AE monitoring techniques in providing valuable insights into the impact of various factors on the behavior and dynamics of HF processes. The advancements in monitoring techniques, offering a more thorough and precise approach, represent a significant step towards optimizing HF practices and ensuring sustainable resource extraction.

58 GEOSCIENCES↗

DOE OSTI2023

Atomic layer deposition with passivation treatment

A method includes: 1) performing an atomic layer deposition cycle including (a) introducing precursors into a deposition chamber housing a substrate to deposit a material on the substrate; and (b) introducing a passivation gas into the deposition chamber to passivate a surface of the material; and 2) repeating 1) a plurality of times to form a film of the material.

Prinz, Friedrich B.↗

DOE OSTI2026

Novel thermal energy storage component: Development, performance, and phase transition diagnosis

Thermal energy storage (TES) using phase change materials (PCMs) is a promising technology for capturing and storing excess thermal energy for later use. However, challenges such as poor heat transfer efficiency and a lack of modular, scalable designs have limited widespread adoption of TES in real-world applications. This study developed and evaluated modular brick-type and blade-type TES prototypes featuring an aluminum housing, an embedded serpentine coil for active or passive thermal exchange, and a cost-effective metal mesh to enhance PCM thermal conductivity. The blade-type TES achieved notable geometric efficiency, with a thickness-to-length ratio of 0.03 and a thickness-to-width ratio of 0.08, enabling highly compact and modular thermal storage suitable for space-constrained applications. The paper presents a detailed evaluation of the TES prototypes’ performance. The comparative analysis indicated that the TES prototypes provide a highly cost-effective, thermally optimized alternative for compact energy storage and load shifting. A novel diagnostic technique was also introduced: using a portable endoscope to capture real-time visualizations of PCM phase transitions inside the TES. This method provides critical insights into internal heat transfer mechanisms, identifies potential issues, and offers valuable support for optimizing the TES design and developing the control algorithm. Overall, the modular brick-type and blade-type TES designs demonstrated in this work provide a scalable, efficient, and economically viable solution for advancing TES across residential, commercial, and industrial sectors. The designs’ compact structure, enhanced thermal performance, and integrated diagnostic capabilities make them strong candidates for future deployment in energy-efficient systems.

Gao, Zhiming [ORNL] (ORCID:0000000271397995)↗

DOE OSTI2021

Laser-based Adhesion Strength Measurements for Advanced Manufactured Sensor Adhesion Characterization

As part of the advanced manufacturing (AM) focus of the Nuclear Energy Enabling Technologies (NEET) Advanced Sensors and Instrumentation (ASI) Program, new in-house capabilities to fabricate and test novel active and passive in-pile sensors are being developed at the Idaho National Laboratory (INL). These advanced-manufactured sensors, such as peak temperature monitors and strain gauges, must be miniaturized and be able to provide real-time feedback, all while withstanding the coupled extremes of temperature and radiation typically observed in the environment of a nuclear test reactor. Fabricating durable and robust in-pile sensors with high fidelity requires a fundamental understanding of the optimal process parameters required in the AM technique, as well as the effect of deviations from optimal process parameters on the sensor-substrate adhesion and the ultimate robustness of the sensor. This report presents the use of a laser-based, non-contact approach for characterizing the adhesion of sensors manufactured using aerosol jet printing (AJP) that comprise of silver nanoparticle inks deposited and sintered on austenitic stainless steel (SS) 316L substrates. The effect of substrate surface roughness, surface energy, ink sintering time and sintering temperature on the printed sensor topography and the sensor-substrate adhesion has been systematically investigated. The sensor-substrate interfacial adhesion strength was determined from the critical laser pulse energy required to ablate/ detach the printed sensor from the substrate. Measurements of the sensor topography using optical profilometry revealed that post-deposition sintering at 400°C for 60 minutes resulted in a reduced sensor thickness, while plasma treating the substrate prior to printing yielded sensors with uniform thickness profiles transverse to the print direction. Sintering temperature and time were found to be the dominant parameters that affected sensor-substrate adhesion, followed by substrate surface roughness. The laser-based and locally-destructive approach for adhesion strength measurements shows promise in overcoming the challenges and limitations of current standardized peel tests and can be developed into a post-fabrication process control protocol for evaluating the durability of AM printed sensors in a high throughput fashion. Future studies will investigate the use of laser-induced spallation techniques as well as non-destructive laser ultrasonic methods for sensor-substrate adhesion characterization on sensors manufactured using AJP and other AM techniques such as plasma jet printing (PJP).

42 ENGINEERING↗

DOE OSTI2025

Passive Wireless Sensors for Realtime Temperature and Corrosion Monitoring of Coal Boiler Components Under Flexible Operation (Final Technical Report)

Researchers at West Virginia University (WVU) propose to demonstrate inexpensive wireless, high-temperature sensors for real-time monitoring of the temperature and corrosion of metal components, which are commonly used in coal-fired boilers. This study presents the development of cost-effective wireless high-temperature sensors for real-time temperature and corrosion monitoring in coal-fired boilers' metal components. The focus is on fabricating and evaluating chipless radio-frequency identification (RFID) sensors capable of operating between 25-1300 ºC. Efforts were directed towards designing passive RFID sensor and interrogator antenna with a broad frequency range, optimizing a microstrip patch antenna sensor integrated into a "peel-and-stick" format for efficient application to various metal specimens without altering their geometry. Additionally, this research aimed to assess the sensor responses under accelerated high-temperature conditions, correlating corrosion and cracking mechanisms with sensor data. An investigation of through-wall data acquisition techniques was also planned, facilitating unobtrusive monitoring of sensor responses housed within metal enclosures. Ultimately, this work sought to establish a robust passive wireless sensor system for the continuous health monitoring of metal components in operational settings, thereby contributing to enhanced safety and efficiency in coal-fired power plants.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

Modeling backgrounds for the majorana demonstrator

The MAJORANA DEMONSTRATOR is a neutrinoless double-beta decay (0?ß ß ) experiment containing ~30 kg of p-type point contact germanium detectors enriched to 88% in 76Ge and ~14 kg of natural germanium detectors. The detectors are housed in two electroformed copper cryostats and surrounded by a graded passive shield with active muon veto. An extensive radioassay campaign was performed prior to installation to insure the use of ultra-clean materials. The DEMONSTRATOR achieved one of the lowest background rates in the region of the 0?ß ß Q-value, 15.7 ± 1.4 cts/(FWHM t y) from the low-background configuration spanning most of the 64.5 kg-yr active exposure. Nevertheless this background rate is a factor of five higher than the projected background rate. This discrepancy arises from an excess of events from the 232Th decay chain. Background model fits aim to understand this deviation from assay-based projections, potentially determine the source(s) of observed backgrounds, and allow a precision measurement of the two-neutrino double-beta decay half-life. The fits agree with earlier simulation studies, which indicate the origin of the 232Th excess is not from a near-detector component and have informed design decisions for the next-generation LEGEND experiment. Recent findings have narrowed the suspected locations for the excess activity, motivating a final simulation and assay campaign to complete the background model.

Haufe, Christopher R.↗

DOE OSTI2020

DOE Zero Energy Ready Home Case Study HIA 2020: TC Legend Homes, Everson Net Positive, Everson, WA

Case study of a DOE 2020 Housing Innovation Award winning custom home in a cold climate that got a HERS -19 with PV, with 2,538 square feet and a large south-facing roof, which is designed to hold over 80 solar panels, and the large south-facing windows, bringing in sunlight to warm the concrete floors and provide passive solar heating.

Building America, residential construction, home b↗

DOE OSTI2026

Personal and environmental predictors of polycyclic aromatic hydrocarbon exposure identified through repeated silicone wristband sampling

This study integrates quantitative data on personal exposure to polycyclic aromatic hydrocarbons (PAHs) in 162 silicone wristbands with demographics, behavioral information, and housing characteristics to explore contributions to residential exposure in a superfund-adjacent community over the course of a year. Forty-six residents completed questionnaires and wore silicone wristbands as personal passive samplers for seven consecutive days on up to four separate occasions in alternating months between November 2022 and June 2023. It was hypothesized that individual behaviors and housing characteristics are sources of dependence and correlation between personal PAH exposures. 50 PAHs were detected at least once, 17 of which were alkylated PAHs. Exposure to PAHs of similar molecular weight was often correlated, notably between naphthalenes (2-rings) and higher molecular weight PAHs (3 or more rings). Generalized linear mixed models identified flooring type, participant age, and sampling month as important predictors of increased PAH exposure, and flooring type, and use of wood stoves or heavy machinery as predictors of increased naphthalene exposure relative to higher molecular weight PAHs. Individual chemical models based on concentration data and detection frequencies corroborated these findings across multiple PAHs. We demonstrate that personal exposure is not static and the degree of variability in personal exposure is individual. Hence, identification of influential exposure factors through repeated measures of chemical exposure and characterization of variability in personal exposure as performed in this study, is important in the development of exposure mitigation strategies.

Bonner, Emily↗

DOE OSTI2023

252 Cf yield calibration method for nuclear material accountancy and safeguards practitioners

Californium-252 is an isotope commonly encapsulated as a physically small but strong spontaneous fission neutron source for applications in industry, academia, and research. Within the nuclear safeguards community, a well-characterized 252 Cf source is often used as an accessible alternative for plutonium in calibrations measurements, which require the absolute source strength. Current methods of source strength quantification can provide an accurate estimate, approximately 1% uncertainty under optimal conditions, but are typically costly and time consuming. An alternative method was developed to determine 252 Cf source strength using passive neutron correlation counting (PNCC). The PNCC method enables institutions and facilities to perform 252 Cf source calibration measurements in-house using detection systems that are common within the nuclear safeguards community. This novel method was previously successfully demonstrated using neutron multiplicity well counters. However, the previous evaluation utilized detection systems with high neutron detection efficiencies, greater than 60%. The purpose of the current study is to extend the previous evaluation and demonstrate the feasibility of the PNCC 252 Cf calibration method for suite of coincidence counters with lower neutron detection efficiencies, between 15% and 35%, which are more commonly encountered in the field, as well as to provide a step-by-step guide to using the method. The neutron source used in this evaluation was previously certified by the National Institutes of Science and Technology (NIST), which provides a reference for the accuracy of the PNCC method. In conclusion, the present source yield calculations demonstrate excellent agreement with a NIST calibration technique and achieve a standard uncertainty below the target 1%.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2020

Transparent window film with embedded nano-shades for thermoregulation

Every year, more than 20% of the energy consumption in the United States and more than 10% of the global consumption is used towards HVAC (Heating, Ventilating, Air-Conditioning) systems in buildings. Although continued efforts in advancing renewable energy, efficient appliances, and smart building systems are desired, the most critical factors that cause extensive indoor energy consumption are thermal leakage and thermal waste generation. We demonstrate a smart window film that allows natural lighting with a clear view while blocking oblique incident sunlight to make the building interior cooler without using electricity or generating heat. Building upon the concept of, often overlooked, traditional window shades and privacy window films, we emphasize and elevate the application and impact of using magnetically arranged nanoscale material for energy conservation purpose in buildings. By embedding vertically aligned Ni flakes (VANF) in a polymer matrix film, nanoscale mirror array serve as shades to block the high-angled incident sunlight, blocking approximately 73% of total solar irradiance and bringing down the indoor temperature by 1.92 °C during the daytime in a model house while providing nearly 90% transparency. Global application was simulated by applying the respective solar angle and intensity at selected latitudes, indicating their potential. This passively energy-conserving smart film is a low cost, maintenance free, and simple product for users and easy-to-manufacture product for the industry.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Passive Temperature Sensors for Nuclear Applications

In April 2007, the Department of Energy (DOE) designated the Advanced Test Reactor (ATR) a National Scientific User Facility (NSUF) to advance US leadership in nuclear science and technology. By attracting new users from universities, laboratories, and industry, this program supports basic and applied nuclear research to help address the nation's energy security needs. In support of this program, the Idaho National Laboratory (INL) established in-house capabilities to develop, fabricate, test, and qualify new and enhanced temperature sensors for irradiation testing. This effort is continuing today through the DOE?s Advanced Sensors and Instrumentation (ASI) program. Although most efforts emphasize sensors capable of providing real-time data, selected tasks have been completed to enhance passive sensors for irradiations where instrumentation leads cannot be included. These sensors include silicon carbide (SiC) monitors, melt wires and the sublime temperature monitor. SiC monitors are available to detect peak irradiation temperatures between 200°C and 800°C in reactor locations where instrumentation leads cannot be used. SiC monitors may be evaluated using specialized equipment installed at INL?s Measurement Sciences Laboratory (MSL). A melt wire inventory is also maintained at MSL. This inventory contains wires for specific use in irradiation experiments ranging in temperatures from 30°C to 1500°C. Melt wires and SiC monitors have had decades of research and application. Recent research has produced a passive monitor known as the sublime temperature monitor. This passive sensor has the capability of recording temperature gradients. This paper will discuss passive temperature sensors currently being researched and implemented under the ASI program.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Initial Temperature Testing of Advanced Manufactured Melt Wire Package

As a part of the In-Pile Instrumentation Program, The Idaho National Laboratory (INL) has recently established in-house capabilities to fabricate and test new advanced manufactured sensors for measuring the peak irradiation temperature inside a nuclear test reactor. Although nuclear test reactors can use standard methods of real-time temperature monitoring, such as thermocouples, the complexity of feedthroughs and attachment complications to collect real-time measurements greatly increases the cost of the experiment. Passive monitoring techniques may be utilized that exploit the melting point of well characterized material (standard melt wires), however, the limited space available for instrumentation during experiments is also a challenge. To accommodate the challenge, INL has expanded its temperature detection instrumentation capabilities paired with the advancement of in-house advanced manufacturing options to include printed melt wires for peak irradiation temperature measurement. The advanced manufactured melt wire package can determine peak temperatures in experiments that can fit the challenging space available during irradiation. Recent results and knowledge from this ongoing work have made it possible to develop unique temperature sensors that can accomplish user specific temperature ranges inside the harsh environments experienced during radiation testing. This report summarizes the initial temperature testing using fabricated melt wires with two different melting temperatures, silver (melting temperature of ~960 °C) and solder (melting temperature of ~160 °C), that were initially tested for their relative melting points using non-standard method of furnace and hot plate testing under normal air conditions. Future work will include more controlled way of testing printed melt wires under inert gas with multiple temperature measurements followed by comparison of standard melt wire package performance for baseline characterization.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

Housing-Performance Atlas of Baltimore Row Homes: Archetype-Based Multi-Hazard Baseline of Energy, Heat, Survivability, and Durability

Baltimore’s historic row-home neighborhoods face escalating risks to energy, heat, and durability under intensifying climate stress. This study develops a Housing-Performance Atlas that quantifies multi-hazard performance for eight representative archetypes using DesignBuilder/EnergyPlus Version 7.3.1.003, under Baltimore TMY3 boundary conditions. Performance is evaluated across the following four adaptation domains: energy use intensity, passive survivability during 72 h outage events, roof overheating exposure (>150 °F exceedance hours), and material service life derived from ISO 15686 and synthesized into Lean and Full Deficit Indices for comparative resilience ranking. Results show that EUI ranged from 46.7 to 67.6 kBtu ft −2 ·yr −1 , survivability from 0 to 23 h, and roof temperatures exceeded 150 °F for 150–210 h, shortening roof service life by up to 10 years. Composite Lean and Full Deficit Indices ranged 7.8–92.4, ranking Model 5 (end-unit, flat roof, two-story with basement) as the most resilient configuration and Model 8 (end-unit, pitched roof, three-story above-grade) as the least resilient due to compounded overheating and energy losses. Heat-related domains accounted for nearly 70% of overall resilience deficits, confirming thermal safety and roof reflectivity as retrofit priorities. The Housing-Performance Atlas establishes a reproducible diagnostic framework linking simulation, service life, and resilience metrics to guide cost-effective, climate-responsive retrofits in Baltimore’s aging urban housing stock.

Housing-Performance atlas↗

DOE OSTI2023

Model-based predictive control of multi-stage air-source heat pumps integrated with phase change material-embedded ceilings

This paper presents a model-based predictive control strategy to optimize the operations of phase change material (PCM) ceiling panels coupled with a multi-stage air-source heat pump. A three-stage prototype heat pump unit has been built and tested in the laboratory, with the low and medium stages designed for space heating/cooling and the high compression stage dedicated to charging of the PCM energy storage. To facilitate optimal control of the integrated heat pump system, a mixed-integer linear programming formulation is derived through linearization of the heat pump model and a mixed-integer reformulation of the PCM dynamic governing equations. A predictive control strategy is synthesized based on the resultant control formulation and implemented in a receding horizon scheme that optimizes the PCM charging and the zone temperature schedules simultaneously to leverage both the passive (associated with building construction materials) and active (PCM) storage capacities of a building. The control strategy has been tested along with three benchmarking control scenarios using a co-simulation platform for a prototypical detached house in Atlanta, GA. In this study, test results showed that application of the proposed control strategy to the PCM-integrated heat pump could provide 27.1% electricity cost savings while a fine tuned rule-based control strategy could achieve cost savings of 20.4%, compared to a baseline case without PCM storage, under a time-of-use rate tariff.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗