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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Power performance and loads characterization of laboratory-scale cross-flow rotors fabricated using additive manufacturing

Tidal energy conversion is a relatively new application for additive manufacturing (AM), where the focus has been on fabricating axial-flow turbine blades. AM techniques add material precisely where it is needed, creating more complex shapes with less waste. Cross-flow rotor geometry presents an opportunity for AM to improve rotor performance by fabricating features that cannot be created economically via conventional manufacturing. The challenges associated with using AM in cross-flow design include water resistance and degradation over time while retaining a level of quality equivalent to conventionally machined parts. In this work, AM materials were tested by environmentally conditioning samples in a seawater tank for 5 months, followed by performance and phase-resolved load testing of laboratory-scale rotors in a hydraulic flume. We found that while metals like titanium and Inconel have excellent performance in marine environments, achieving the desired geometry and performance is difficult. Thermoplastics degraded in seawater but were easier to form into desired geometries and could exceed the performance of an aluminum control rotor. Warping and surface finish were significant detractors from AM rotor performance. These results suggest that the primary benefits of using AM for cross-flow rotors is to quickly fabricate and test unconventional rotor geometries.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

Numerical simulation of frost formation and heat transfer on fin-and-tube heat exchangers in turbulent cross-flow

Frost formation in fin-and-tube heat exchangers in turbulent cross-flow presents significant challenges in industrial refrigeration applications, affecting heat transfer efficiency and operational reliability. The purpose of this work is to investigate frost deposition and growth on a staggered bank of a fin-and-tube freezer coil under turbulent forced convection conditions. The focus here is on investigating conditions that closely replicate real-world scenarios in large walk-in industrial freezers. Using a direct numerical simulation approach, we examine the flow dynamics and thermal behaviour in the presence of frost, considering turbulent regimes characterized by a Reynolds number in the range 1050 ≤ R e D , avg ≤ 4800 , with the characteristic length being the outer diameter of the tube and the velocity being the bulk fluid velocity between the plates (fins). Computational fluid dynamics simulations are employed to resolve the interactions between turbulent airflow and the frost layer. Our approach incorporates a modified immersed boundary method and a slow-time acceleration technique to address the complex dynamic interface between the continuously evolving frost layer and the flowing air stream. Our findings indicate that frost forms more on the sides of the finned surfaces (plates) and less on the tubes themselves. This article is part of the theme issue ‘Heat and mass transfer in frost and ice’.

Science & Technology - Other Topics↗
DOE OSTI2025

Confinement Exploiting Arrays of Cross-Flow Turbines (ConExT) (Final Scientific/Technical Report)

Final technical report for the ARPA-E SHARKS project: Confinement Exploiting Arrays of Cross-Flow Turbines (ConExT). This involved collaboration by the University of Washington, University of Wisconsin, National Renewable Energy Laboratory, and Oberon Insights. Cost-effective, large-scale utilization of tidal and river current resources requires turbine arrays. Most array concepts involve multiple, staggered rows of turbines analogous to wind farms. However, in water, turbines that have an appreciable projected area (i.e., the projected area over a full revolution) relative to a channel’s cross-sectional area can theoretically extract far more energy than when operating in isolation. This suggests substantial benefits to a confinement-exploiting approach to array layout, in which turbines are more densely clustered in a single row spanning a channel. The objective of this project was to move this concept from theory to practice, as well as establishing environmental and economic trade-offs. This objective was accomplished through scale-model experimentation, high-fidelity computational fluid dynamic simulation, and integrated techno-economic modeling.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

Lessons learned from the design and operation of a small-scale cross-flow tidal turbine

In 2023, a first-generation prototype of a small-scale marine current turbine was operated in Sequim Bay, Washington (USA) for 141 days. The system, referred to as the Turbine Lander, was the product of a laboratory-to-field effort to develop a system that enables enhanced ocean sensing or vehicle recharge in remote, energetic settings. The turbine consists of a vertical-axis, cantilevered rotor (1.19 m x 0.85 m) with four foils installed on a gravity foundation. A broader range of constraints including the deployment strategy, site characteristics, and estimated loads, drove the system’s design. This work presents the design, characterization, operation, and post-recovery engineering assessment of the Turbine Lander. Pre-deployment characterization efforts yielded a peak power coefficient of approximately 0.3 for the rotor, although system losses resulted in much lower water-to-wire efficiencies under most operating conditions. The results demonstrate the importance of co-design among key components of the powertrain and control systems to achieve acceptable system efficiency across operating conditions.

Co-design↗
DOE OSTI2026

Interpretable Models for Workflow Differentiation in High-Performance Scientific Networks

Scientific workflows in high-performance networks spawn hundreds of interdependent flows that must be managed collectively—yet existing network classifiers treat each flow in isolation, leading to fragmented QoS decisions and missed interflow patterns. We present a novel traffic classification solution that operates at the workflow level, distinguishing entire filetransfer operations from streaming analytics by capturing how concurrent flows interact and burst together. We introduce a workflow identification window (WIW) that ingests raw packet headers from parallel flows into unified tensors, preserving the spatial-temporal patterns that differentiate scientific workflows. This approach achieves 98.7% accuracy using CNN, LSTM, and hybrid architectures, while maintaining 84% accuracy on production traffic collected a week later—demonstrating robustness to temporal drift. By integrating SHAP and GradCAM explainability, we reveal that early-packet timing patterns and cross-flow correlations drive classification decisions, providing operators with interpretable insights. Our system enables coherent workflow-level QoS enforcement and dynamic bandwidth allocation in scientific networks, eliminating manual per-flow configuration while maintaining classification latency at millisecond level.

Giannakou, Anna [LBL, Berkeley]↗
DOE OSTI2024

One-dimensional temperature measurement of supersonic jet flow by resonantly ionized photoemission thermometry of molecular nitrogen

As the field of fluid dynamics progresses, the demand for sophisticated diagnostic methods to accurately assess flow conditions rises. In this work, resonantly ionized photoemission thermometry (RIPT) has been used to directly target and ionize diatomic nitrogen (N 2 ) to measure one-dimensional (1D) temperature profiles in a supersonic jet flow. This technique can be considered non-intrusive as the premise uses resonantly enhanced multiphoton ionization (REMPI) to target molecular nitrogen. This resonance excites N 2 into absorption bands of the P, Q, and R rotational branches of N 2 ( b 1 Π u ). The ideal (3 + 1) REMPI scheme excites from the ground state and ionizes N 2 ( b 1 Π u ← X 1 Σ g + ) where de-excitation results in photoemission from the first negative band of ionized N 2 + ( B 2 Σ u + → X 2 Σ g + ) as nitrogen returns to the ground state. The resulting emission can be observed using an intensified camera, thus permitting inference of the rotational temperature of ground-state molecular nitrogen. A linearly regressive Boltzmann distribution is applied based on previous calibration data for this technique to quantify the temperature along the ionized line. This work applies this technique to a pure N 2 supersonic jet in cross-flow and counter-flow orientations to demonstrate N 2 RIPT’s applications in a supersonic flow. Temperature variations are observed at different locations downstream of the exit in cross-flow, and axisymmetric in counter-flow, to generate profiles characterizing the flow dynamics. Due to the collisional effects resulting from the number density of N 2 at higher pressures, a (3 + 2) REMPI scheme is observed throughout this text.

Clark, Aleksander (ORCID:0009000855600042)↗
DOE OSTI2024

Improving Cost and Efficiency of the Scalable Solid Oxide Fuel Cells Power System

The objective of this project was to design and develop a 20kW range small-scale solid oxide fuel cells (SOFC) power system for applications such as data centers and commercial buildings. The original plan included a 5,000 hours demonstration and a Techno-Economic Analysis (TEA) which were dropped as part of project termination. The original project plan was to use a stack with a cross-flow cell design which had previously been tested for 500 hours at a community college in Malta, NY. However, it was decided to move to the advanced R-SOFC co-flow cell developed under Department of Energy Award DE-FE0031971. The advanced cell design has the advantage of a larger active area for the same manufacturing footprint which results in fewer required cells for the same stack power, hence a higher volumetric power density (kW/L) and lower cost per kW than the original cross-flow cell design. A full SOFC system Simulink model was developed and calibrated with testing data from a fuel cell stack and BOP (balance of plant) components. The simulation results from the calibrated model showed an acceptable match with the experimental data. A structural analysis conducted for various load scenarios indicated no high stress areas for all spatial directions. Major electrical system components were acquired, built and successfully tested. System sensors were verified and validated against controls. Safety checks, a diagnostic check, PID tuning, and control software commissioning tasks were also conducted. The power electronics prototype was delivered and trial testing completed. Balance of Plant component testing and simulation work was conducted to characterize Reformer-Heat Exchanger heat transfer and backpressure and reformer catalyst methane conversion and product selectivity. Simulations were conducted to design the Anode and Cathode fluid passages and size the air-air and fuel-fuel heat exchangers. A Burner operation map was created from test data and the Anode Gas Recirculation blower was tested to evaluate its durability. The SOFC system used a horizontal style design where components sit directly on a casting with a direct connection to the skid. This design has efficient packaging and a small footprint with approximate dimensions of 750 mm x 700 mm x 1700 mm. An SOFC system was built and successfully tested at the Malta, NY facility The system for over 500 hours under load of which over 300 hours was at full load of 20 kW.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2026

Comparison of URANS and LES predictions for the open phase of the OECD NEA CSNI fluid structure interaction CFD benchmark

The OECD NEA CSNI WGAMA CFD Task Group ran a benchmark in 2020 and 2021 to assess the predictive capabilities of coupled fluid structure interaction (FSI) CFD analysis methods. This paper presents the predictions made for the open phase of the benchmark using URANS and LES turbulence modelling approaches, and a comparison of the results to the experimental data. The benchmark comprised a channel containing two inline cylinders in cross-flow. The cylinders were fixed at one end, free at the other, and had measured resonant frequencies and damping properties. The URANS modelling used ANSYS Fluent 2-way coupled to ANSYS Mechanical. The LES modelling used Nek5000, 1-way coupled to Diablo. Comparisons with cross-channel velocity profiles are presented, both for the mean flow and its RMS. Comparisons are also made to the frequency spectra for point measurements of fluid velocity and pressure, and for the accelerations of the free end of each cylinder. URANS predicts the average velocity profiles relatively well, and is able to predict the velocity and acceleration spectra at the shedding frequency. However, the frequency content at the 4th harmonic of the shedding frequency is low in the URANS flow fields, and so does not excite accelerations at the resonant frequency of the cylinders. LES makes better predictions of the average profiles, and the velocity spectra agree well at both the shedding frequency and at higher frequencies. In conclusion, the 1-way coupled LES results show good agreement for acceleration spectra.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Modeling Flow and Mass Transfer within Hollow Fiber Packaging for Gas Separation

Hollow fiber membrane modules are used for gas purification by their selective permeation properties. Intensification of the process to minimize the retentate loss and gas pressure involves optimization at various scales. In this work, we outline a numerical investigation of the gas separation performance at the scale of fiber bundles and its impact on module performance. Flow channeling and anisotropy govern the mass-transfer coefficient in axial and cross-flow configurations. These effects are quantified in terms of a permeability tensor or an anisotropy ratio and the effective mass-transfer coefficient or the Sherwood number. The results show a trade-off between purification and recovery. While smaller fibers offer a large specific surface area to enable high purification, it comes at a huge penalty on the separation performance due to reduced penetration within bundles. Optimum performance indicators are emphasized.

Fibers↗
DOE OSTI2024

Mesofluidic Oil-Water Separation

Separating flowing multiphase solutions in process at industrial scale is challenging. A rapid continuous approach is desired. These mesofluidic oil-water separation tests were motivated by reports by Dijkshoorn et al [1] who reported separating droplets and particles using displacement with regularly spaced channels using a cross-flow microsieve.. Droplets, including deformable particles, larger than the channel migrate in one direction and thereby deplete in the other direction. Test flowrates were motivated by Burns et al. [4] who showed that separation could occur under laminar conditions, and Pease et al [8, 9] who extended the range to turbulent flow. Testing was conducted using two two-component oil-water mixtures at room temperature. Analysis showed separation of both mineral oils from their oil water mixtures at flowrates from 1-2 L/min and concentrations from 2-10 wt% oil in water.

cloud height, effective cleaning radius, effective↗
DOE OSTI2026

Observations of marine animal interactions with a small tidal turbine

The risk of collisions between animals and operating tidal turbines remains a concern in the scientific and regulatory communities. A sensor package including optical cameras was deployed to monitor animal interactions with a small-scale (1 m 2 ) cross-flow tidal turbine. The turbine was deployed in Washington State, USA for 141 days at a site with peak flow speeds of 2.5 m/s. We analyze optical camera imagery spanning 109 days of turbine operation. The analyzed images contain 1044 observations of fish, fish schools, seabirds, or seals in the vicinity of the turbine. No instances of collision with seabirds or seals were observed. Seabirds were only observed during daylight hours and while the turbine was stationary. Both seals and fish were observed during both day and night and while the turbine was stationary and rotating. Four fish were observed colliding with the moving turbine and in all but one case the animals swam away following the collision. Over the same period of time, over fifty times more fish (224 individual fish and 5 fish schools) were observed passing the moving turbine without collision. Fish encounters were likely under counted due to the difficulty in discerning small fish from plant matter in the water column. These observations represent the first optical camera imagery showing fish, bird, and marine mammal interactions with a tidal turbine in North America. In addition to quantitative and qualitative discussion of the implications of our observations for collision risk, we discuss lessons learned on sampling schemes and deployment of machine learning for detection of animals to inform future data collection strategies in future monitoring campaigns.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

Passive Acoustic Monitoring of a Riverine Turbine with Stationary Hydrophones

In this study, we characterize the sound generated by a cross-flow riverine turbine in the Kvichak River near Igiugig, Alaska, United States. To do this, we follow the International Electro-technical Commission (IEC) technical specification for characterization of the acoustic emissions from marine energy converters. While marine mammals do not inhabit the test site, the U.S. National Marine Fisheries Service (NMFS) guidelines for assessing the effects of anthropogenic sound on marine mammal hearing were implemented to provide context for the deployment of similar turbines in other areas. The results indicate that turbine sound at the measurement locations was not predicted to be harmful to marine mammals. Results also provide insight into the acoustic characteristics of current energy converters and the complex acoustic propagation in rivers.

13 HYDRO ENERGY↗
DOE OSTI2025

Simulation of a High-Confinement Tidal Energy Array (Abstract)

When the projected area of a current turbine array occupies a substantial fraction of a tidal or river channel cross-sectional area, the confinement associated with the channel boundaries substantially increases turbine efficiency. This effect can be exploited to substantially reduce the levelized cost of energy for current turbine arrays. However, the presence of such an array will affect inflow velocity, water depth, and circulation in the surrounding area. This has implications for array performance and environmental impacts. This project combines existing numerical modeling capability from PNNL with an understanding of confined array performance from UW. The work will 1) Simulate tidal currents and water surface elevation in a regional circulation model that includes the Knik Arm site at appropriate resolution; 2) Incorporate a varying thrust coefficient into this model that reflects the outcomes of tidal hydrodynamic simulations of confined turbine arrays; 3) Use the model to determine the effects of array operation on water levels and inflow conditions as a function of different blockage ratios and control strategies; and 4) Identify the “far field” environmental implications of operating an array of this type. UW will use the outputs from this model to evaluate the implications of “feedback effects” and variable inflow conditions on levelized cost of energy estimates for a confinement exploiting array of cross-flow turbines.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

Extended Heat Transfer Model Dataset

Data repository for the paper: Molerus and Wirth's Heat Transfer Model for Bubbling Fluidized Beds: Proposal for an Extended Model Including Immersed Tube Banks and Particle Cross-Flow Powder Technology 2025

contact time↗
NASA NTRS1995

Computation of three-dimensional mixed convective boundary layer flow

The paper presents the numerical solution of heat and mass transfer during cross-flow (orthogonal) mixed convection. In this class of flow, a buoyancy-driven transport in the vertical direction and a forced convective flow in the horizontal direction results in a three-dimensional boundary layer structure adjacent to the plate. The rates of heat and mass transfer are determined by a combined influence of the two transport processes. The equations for the conservation of mass, momentum, energy, and species concentration were solved along with appropriate boundary conditions to determine the distributions of velocity components, temperature, and concentration across the thickness of the boundary layer at different locations on the plate. Results were expressed in dimensionless form using Reynolds number, Richardson number for heat transfer, Richardson number for mass transfer, Prandtl number, and Schmidt number as parameters. It was found that the transport is dominated by buoyancy at smaller vertical locations and at larger distances away from the forced convection leading edge. Effects of forced convection appeared to be very strong at smaller horizontal distances from the leading edge. The cross stream forced convection enhanced the rate of heat and mass transfer by a very significant amount.

Gadepalli, Prashandt↗
NASA NTRS1939

Intercooler Design for Aircraft, Special Report

When an airplane is operating at high altitude, it is necessary to use a supercharger to maintain ground pressure at the carburetor inlet. This maintenance and high intake-manifold pressure tends to keep the power output of the engine at ground-level value. The air, being compressed by the supercharger, however, is heated by adiabatic compression and friction to a temperature that seriously affect the performance of the engine. It is thus necessary to use an intercooler to reduce the temperature of the air between the supercharger outlet and the carburetor inlet. The amount of cooling required of the intercooler depend on the efficiency of the supercharger installation. In this investigation, several types of intercoolers were compared and a design procedure that will give the best intercooler for a given set of conditions is indicated. The figure of merit used for the selection of the best design was the total power consumed by the intercooler. This value includes the power required to transport the weight of the intercooler as well as the power used to force the charge air and the cooling air through the intercooler. The cost, size and practicality of construction were not considered, inasmuch as it was thought that a survey of possibilities of improvement in design would be of interest, regardless of whether the improvement could be immediately realized. Three types of intercoolers are included in this survey: a counterflow intercooler with indirect cooling surface in the form of fins, a counterflow intercooler with direct cooling surfaces, and a cross-flow, tube-type intercooler.

Brevoort, M. J.↗