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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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Accelerating the Adoption of the Solid Panel Structural System

This report, "Accelerating the Adoption of the Solid Panel Structural System", explores the structural properties, capabilities, and applications for an innovative “studless” building system that uses a plate-like approach and “Perfect Wall” principles for an efficient, durable, and robust wall system. A comprehensive testing regime was completed to fully characterize the structural behavior of the Solid Panel Structural system. These results were used to develop an engineering guide that can be used by architects and engineers for design and code approval.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Machine Learning-Driven Optimization of Building Enclosures for Moisture Durability and Thermal Performance

The design of moisture-durable building enclosures with low embodied carbon often involves an iterative process of selecting the materials for the specific exposure conditions to meet the performance requirements. While hygrothermal simulations are commonly used to evaluate moisture durability, they often require advanced expertise for proper implementation. Machine learning (ML) provides a promising alternative by streamlining the design process and minimizing the reliance on complex simulations. This study presents a machine learning-based approach for predicting moisture durability in residential wall assemblies. The ML model was trained to estimate the mold index and maximum moisture content of various layers under typical exposure conditions. The model achieved a high predictive accuracy, with a coefficient of determination (R²) exceeding 0.90 when compared to traditional hygrothermal simulations on materials that were not part of training the ML model. Building on these results, the ML model was developed into a practical tool for optimizing wall assembly designs. This tool allows users to automatically optimize material selections based on energy, moisture, and carbon performance criteria. By incorporating multi-objective optimization, the tool identifies configurations that minimize embodied carbon while maintaining moisture safety and code-compliant thermal performance. Additionally, it provides insights into how material choices influence assembly durability, energy efficiency, and carbon reduction. The tool will be implemented in the Building Science Advisor (BSA) to enhance its performance and provide more granularity on the results. This research highlights the potential for ML-driven tools to simplify the design of high-performance building enclosures, offering architects and engineers a faster, more efficient way to balance critical performance factors.

Salonvaara, Mikael [ORNL] (ORCID:0000000318991554)↗

Measure Guideline: Deep Energy Enclosure Retrofit for Interior Insulation of Masonry Walls and Flat Roofs

Measure Guideline: Deep Energy Enclosure Retrofit for Zero Energy Ready House Flat Roofs BSC TO5 Task 7.4 Deep Energy Enclosure Retrofit (DEER) for Interior Insulation of Masonry Walls Lawrence, MA 01840 This Measure Guideline describes a deep energy enclosure retrofit solution for insulating mass masonry buildings from the interior. It describes the retrofit assembly, technical details, and installation sequence for retrofitting masonry walls. Interior insulation of masonry retrofits might adversely affect the durability of the wall. This guideline includes a review of decision criteria pertinent to retrofitting masonry walls from the interior and the possible risk of freeze-thaw damage. This Measure Guideline is intended to support contractors who are implementing an interior insulation-based high-performance enclosure retrofit for masonry buildings and designers who are looking to design such retrofits. It may also be helpful to building owners who wish to learn more about strategies that are available for deep energy enclosure retrofit of masonry residential buildings on the interior. This Measure Guideline is important to the high-performance retrofit industry because the solution described here provides an opportunity to retrofit masonry buildings with ambitious energy performance goals by insulating them from the interior without disturbing their exterior appearance. BSC TO5 Task 7.4 Deep Energy Enclosure Retrofit (DEER) for Zero Energy Ready House (ZERH) Flat Roofs House Jamaica Plain, MA 02130 This Measure Guideline provides design and construction information for a deep energy enclosure retrofit solution of a flat roof assembly. It describes the strategies and procedures for an exterior retrofit of a flat wood-framed roof with brick masonry exterior walls using exterior and interior (framing cavity) insulation. The approach supported in this guide could also be adapted for use with flat wood-framed roofs with wood-framed exterior walls. Designers, contractors, and building code officials will benefit from the information contained in this Measure Guideline. The guide may also be helpful to building owners who wish to learn more about strategies for deep energy enclosure retrofit of flat roofs. This Measure Guideline is important to the high-performance retrofit industry because it demonstrates techniques for retrofitting flat roofs from the exterior, which is less disruptive to the living space and allows the structure to remain occupied during the project. It also illustrates a solution for preparing homes to become zero energy ready.

Array↗

Moisture Performance of High-R Wall Systems

High-performance homes offer improved comfort, lower utility bills, and assured durability. The next generation of building enclosures is a key step toward achieving high-performance goals through decreasing energy load demand and enabling advanced space-conditioning systems. Yet the adoption of high-R enclosures and particularly high-R walls has been a slow-growing trend because mainstream builders are hesitant to make the transition. In a survey of builders on this topic, one of the challenges identified is an industry-wide concern about the long-term moisture performance of energy-efficient walls. This study takes a step toward addressing this concern through direct monitoring of the moisture performance of high-R walls in occupied homes in several climate zones. In addition, the robustness of the design and modeling tools for selecting high-R wall solutions is evaluated using the monitored data from the field. The information and knowledge gained through this research will provide an objective basis for decision-making so that builders can implement advanced designs with confidence.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Moisture Performance of High-R Wall Systems

High-performance homes offer improved comfort, lower utility bills, and assured durability. The next generation of building enclosures is a key step toward achieving high-performance goals through decreasing energy load demand and enabling advanced space-conditioning systems. Yet the adoption of high-R enclosures and particularly high-R walls has been a slow-growing trend because mainstream builders are hesitant to make the transition. In a survey of builders on this topic, one of the challenges identifi ed is an industry-wide concern about the long-term moisture performance of energy-effi cient walls. This study takes a step toward addressing this concern through direct monitoring of the moisture performance of high-R walls in occupied homes in several climate zones. In addition, the robustness of the design and modeling tools for selecting high-R wall solutions is evaluated using the monitored data from the field. The information and knowledge gained through this research will provide an objective basis for decision-making so that builders can implement advanced designs with confidence.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Mitigating Moisture with High-R Walls

Energy-efficient building enclosures are key to decreasing energy load demand and enabling advanced space-conditioning systems for high-performance homes. One efficient enclosure design solution is high-R walls, which feature increased insulation levels as an effective solution for reducing air leakage and permeance of material layers. To increase builder confidence and encourage greater market adoption of high-R walls, Home Innovation Research Labs sought to demonstrate the long-term moisture performance of several high-R wall configurations in cold climate zones. The team monitored 22 newly constructed, occupied homes located throughout climate zones 4–7, where a substantial vapor drive to the exterior is present during the winter.

buildings↗

Evaluating Moisture Control of Variable-Capacity Heat Pumps in Mechanically Ventilated, Low-Load Homes in Climate Zone 2A

The well-sealed, highly insulated building enclosures constructed by today's home building industry coupled with efficient lighting and appliances are achieving significantly reduced heating and cooling loads. These low-load homes can present a challenge when selecting appropriate space-conditioning equipment. Conventional, fixed-capacity heating and cooling equipment is often oversized for small homes, causing increased first costs and operating costs. Even if fixed-capacity equipment can be properly specified for peak loads, it remains oversized for use during much of the year. During these part-load cooling hours, oversized equipment meets the target dry-bulb temperatures very quickly, often without sufficient opportunity for moisture control. The problem becomes more acute for high-performance houses in humid climates when meeting ASHRAE Standard 62.2 recommendations for wholehouse mechanical ventilation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Development of a Test-Bed for Testing and Refining EarthEn’s Supercritical CO 2 Based Energy Storage System

EarthEn’s energy storage concept leverages supercritical carbon dioxide (sCO 2 ) as a working fluid and relies on compact, high-performance components operating at elevated pressures and temperatures. To accelerate component development and reduce technical risk prior to larger-scale demonstrations, Oak Ridge National Laboratory (ORNL) developed a 100 kW-scale sCO 2 test-bed under a Cooperative Research and Development Agreement with EarthEn (CRADA NO. NFE-24-10050). The objective of the work was to design and construct a flexible experimental facility capable of reproducing key thermodynamic state points and heat-transfer conditions relevant to EarthEn’s thermal energy storage (TES) cycle, with particular emphasis on enabling development and evaluation of next-generation heat exchangers and TES concepts. The test-bed consists of a closed-loop sCO 2 circulation system housed within an open-topped enclosure. In its as-installed configuration, dense-phase sCO 2 is recirculated through a printed circuit recuperator, an electrically heated section, a throttling device used to simulate turbine expansion, and a water-cooled printed circuit heat exchanger that rejects heat to the building chilled-water system before returning to the pump. The pump is driven by a variable frequency drive, enabling controlled adjustment of flow and operating point. A comprehensive instrumentation suite was integrated to support both safe operation and high-quality data collection. Installed sensors include Coriolis flow meters for sCO 2 flow rate and density, resistance temperature detectors and thermocouples distributed throughout the loop (including the heated section and key heat exchanger ports), and pressure transducers for absolute and differential pressure measurements. The facility was designed to support high-pressure (19 MPa nominal) and high-temperature (575°C nominal) operation with credited overpressure protection provided by a rupture disk. Nominal operating conditions were selected to support 100 kW-class testing while maintaining flexibility for non-heated and heated shakedown, control development, and future integration of advanced TES test sections. In parallel with facility development, a system-level thermal-hydraulic model was created using Modelica-based tools to support component sizing, anticipate performance over targeted test conditions, and establish a framework for future model calibration against experimental data. At the conclusion of the project performance period, the facility was in final assembly, and the pressure boundary was nearly completed. However, several practical challenges associated with high-pressure/high-temperature systems and specialized component procurement impacted schedule and prevented initial pump-driven operation and full commissioning within the available resources. This report documents the as-built design, operating capabilities, and instrumentation, and it summarizes key lessons learned related to heater fabrication and testing, first-of-a-kind assembly factors, specialty flange supply constraints, and fill pump corrective actions. Finally, it outlines a phased plan for future commissioning and experimental campaigns, including control and instrumentation shakedown, heater characterization, model calibration, and testing at state points representative of EarthEn’s TES cycle.

25 ENERGY STORAGE↗

Wall Upgrades for Residential Deep Energy Retrofits: A Literature Review

In the United States, 39% of total energy consumption comes from the building sector, 20% of which is attributed to residential buildings. New, high-performance homes incorporate a combination of tight building envelopes, mechanical ventilation and efficient components to ensure comfort, adequate airflow and moisture control. These systems work together to create energy efficient homes that employ measures to manage moisture and indoor pollutants. Older homes, built before 1992 when DOE’s Building Energy Codes Program was established represent approximately 68% of building stock in the country, and often have significant air leakage and inadequate insulation. Homes with little to no air sealing or insulation result in heating and cooling losses, which can represent a substantial portion of utility bills. Done correctly, deep energy retrofits (DERs) can significantly improve the energy performance of a home’s thermal envelope, decrease indoor pollutants and increase homeowner comfort. This literature review summarizes current practices for exterior wall retrofits for existing homes, provides an overview of techno-economic approaches to investigate residential wall systems, and discusses thermal and hygrothermal modeling strategies. Accompanying this literature review is a larger effort to identify state-of-the-art technologies for existing wall energy efficiency retrofit systems that can be applied over existing siding and are suitable for the cold/very cold climates.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Hamilton: Flexible, Open Source $10 Wireless Sensor System for Energy Efficient Building Operation

Sensors for improving building performance are rapidly populating the market, driven in part by the drive to reduce greenhouse gas emissions resulting from energy production as well as improve the interior environment for healthy and more productive spaces. UC Berkeley has led wireless sensor development over the past 25 years (e.g., Telos mote), with the Hamilton (named after Alexander Hamilton on the US $10 bill) as the most recent. The Hamilton sensor was designed as a low-cost high-performance sensor that is modular and interoperable. The objective of the Hamilton project was to create, evaluate and establish the technological foundations for secure and easy to deploy building energy efficiency applications utilizing pervasive, low-cost wireless sensors integrated with traditional Building Management Systems (BMS), consumer-sector building components, and powerful data analytics. The project included iterative hardware design, incorporating a high-performance database (BTrDb, http://btrdb.io/), creating and iterating the development of secure data middleware (BOSSwave, WAVE/WAVEMQ), working with and pushing the development of an open-source tiny operating system RiotOS, and implementing and improving protocols such as Thread/OpenThread and TCP/IP. The hardware benefited from careful design to drive down the cost; the design included a System-on-a-Chip (SoC), chip antenna, single crystal and five passive components. Careful design of the operating system created a low-power design to enable a long life with small batteries. The hardware included several sensors: temperature, radiant temperature, relative humidity, magnetometer, accelerometer, and light, with an optional occupancy (Passive InfraRed) sensor. The project was the basis of several applications, both internal to the research team and other researchers and professionals at other institutions. Several applications used the sensor hardware as the basis for other complex devices. Other applications used the sensors to improve building performance through interoperating with the building Heating Ventilation and Air-Conditioning (HVAC) system, such as using occupancy and/or distributed temperature sensing to reduce HVAC zone energy while still providing thermal comfort and to reduce peak loads in small commercial buildings. We demonstrated cloud-based energy analytics, implemented a schedule and a Model Predictive Controller in a small commercial building to optimize HVAC energy, occupancy and electricity price. Initial integration of these technological innovations was performed through the creation of execution containers containing the WAVE agent and various driver, proxy, or building system function logic. The research added to the understanding of efficient sensor hardware, secure middleware, time-series data management (high performance database), efficient communication protocols, and interoperating with applications and building systems. The project showed the technical effectiveness and economic feasibility of creating a low-cost, modular, and easy-to-deploy sensor. Through conversations with multiple end users, the research team discovered that many customers wanted data management and services in addition to the sensors. HamiltonIOT developed packages of sensors, border router, and data services to provide a seamless “plug-and-play” sensor deployment. Some customers were willing to pay for higher quality sensors (such as light); some customers wanted a robust enclosure (waterproof).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗