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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Scalable Two–Step Production of High–Efficiency Perovskite Solar Cells and Modules

Perovskite solar cells (PSCs) fabricated in laboratories have already achieved power conversion efficiency (PCE) comparable to market-dominant crystalline silicon solar cells. However, this promising photovoltaic technology suffers from severe loss of PCE during scaling up, limiting its progress toward commercialization. One critical question is to develop scalable, low-cost, high throughput, and well-controlled production methods to deposit high-quality perovskite films. Among various approaches, two-step sequential deposition methods have their unique advantages but have been long overlooked. This review provides an overview of two-step methods for fabricating efficient and stable perovskite solar modules (PSMs). We first discuss the mechanisms of two-step perovskite conversion and advanced engineering approaches to modulate the perovskite formation process. We survey the progress of efficient PSCs prepared by different two-step methods and compare the advantages and disadvantages of each method for scalable production of PSMs. Particularly, we highlight that the vapor-based two-step methods are promising for high-throughput in-line production of PSMs. Finally, we provide insights into the challenges and outlook of the industrialization of two-step processes for producing PSMs.

14 SOLAR ENERGY↗
DOE OSTI2025

A scalable and autoclavable oxygen nanosensor platform for metabolic monitoring of Saccharomyces cerevisiae in a bioreactor and other in situ systems

Polymer-encapsulated dye nanoparticle sensors are a valuable approach to achieving in situ analyte measurements with luminescence; however, typical emulsion-based nanosensors are poorly suited for large-scale biological samples due to limitations of synthesis scalability and stability. Branched polyethylenimine (PEI) is a versatile polymer scaffold ideal for constructing nanoparticles with various covalently conjugated moieties due to their high density of reactive primary amines, high water solubility, and biological stability. In this work, we used branched polyethylenimine as a scaffold-based approach for making a stable and scalable ratiometric oxygen sensor. Pt (II) tetracarboxyporphine was used as an oxygen-sensing dye and coumarin 343 as a reference dye, all covalently linked to the PEI scaffold producing a product that could withstand sterilization procedures and easily be scaled. To minimize toxicity from the PEI scaffold, we conjugated it with 2000 MW PEG. The applicability of the sensors was demonstrated in a 200 mL Saccharomyces cerevisiae yeast culture, using orthogonal luminescent and electrochemical oxygen measurements to validate sensor response and measure the metabolic activity of the yeast in our culture. Further, this approach was able to match the sensitivity of our electrochemical measurements while improving upon drawbacks of other luminescent methods of oxygen detection, demonstrating effective monitoring for at least 20 h. Our scaffold-based approach is a modular and easily translatable technology that could be useful in various biotechnological applications.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Scalable preconditioning for the stabilized contact mechanics problem

We present a family of preconditioning strategies for the contact problem in fractured and faulted porous media. We combine low-order continuous finite elements to simulate the bulk deformation with piecewise constant Lagrange multipliers to impose the frictional contact constraints. This formulation is not uniformly inf-sup stable and requires stabilization. We improve previous work by Franceschini et al. (2020) by introducing a novel jump stabilization technique that requires only local geometrical and mechanical properties. We then design scalable preconditioning strategies that take advantage of the block structure of the Jacobian matrix using a physics-based partitioning of the unknowns by field type, namely displacement and Lagrange multipliers. The key to the success of the proposed preconditioners is a pseudo-Schur complement obtained by eliminating the Lagrange multiplier degrees of freedom, which can then be efficiently solved using an optimal multigrid method. Numerical results, including complex real-world problems, are presented to illustrate theoretical properties, scalability and robustness of the preconditioner. A comparison with other approaches available in the literature is also provided.

58 GEOSCIENCES↗
DOE OSTI2025

Rapid scalable plasma processing of thin-film Li–La–Zr–O solid-state electrolytes

Solid-state electrolytes, such as lithium lanthanum zirconium oxide (LLZO), show promise as technologies for next-generation high-energy-density batteries, but commercial development has been hindered by a lack of scalable processing methods. Current fabrication methods are costly or require long annealing steps to create dense films. We report an atmospheric pressure blown-arc nitrogen plasma jet process to rapidly form sub-micrometer-thick, dense amorphous LLZO (a-LLZO) films from sol-gel precursors. Films are processed in less than 2 min, an order of magnitude faster than what has previously been reported. We demonstrate 500-nm-thick a-LLZO films processed at 350°C with an ionic conductivity of 2 × 10 −6 S/cm at 30°C and 2 × 10 −3 S/cm at 100°C and a conductance of 19 S at 100°C, the highest conductance of any LLZO phase to date. Here, the films exhibit outstanding smooth surface morphology with low defectivity, advancing atmospheric plasma processing as a scalable processing method for solid-state electrolytes.

25 ENERGY STORAGE↗
DOE OSTI2025

Scalability analysis of heavy-duty gas turbines using data-driven machine learning

With the increasing integration of variable renewable energy sources into power systems, the role of flexible power generation technologies like gas turbines (GT) in rapid grid balancing remains crucial. This sustained importance underscores the need for scaled and precise modeling of GT to ensure effective integration within evolving energy frameworks. While physics-driven GT models integrate thermodynamics, fluid dynamics, and combustion principles, they often rely on approximate mathematical representations to accommodate scaling that may not capture the actual complex dynamics for GTs and inertial effects associated to GTs with different ratings. In this study, a data-driven model is proposed using machine learning (ML) techniques to conduct GT scalability analysis and performance evaluation with high accuracy. The ML model, trained on data from various operating conditions and performance parameters, aims to uncover intricate relationships and patterns, resembling GT characteristics at different scales (ratings). The model is developed to capture complex system interaction and to adapt to changing operational scenarios at different capacities, providing valuable insights of power system dynamics. In this study, the real-time digital simulator platform was employed to generate training data for the ML model and assess its dynamic characteristics. The ultimate objective was to develop a detailed modeling framework based on governing equations and data-driven ML capable of predicting key performance indicators, in thermal systems such as GTs, including power output, speed, fuel consumption, and exhaust temperature under diverse operating conditions at different scales. The developed ML framework demonstrated high accuracy, with mean relative errors for GT power prediction, reference speed, exhaust temperature, and compressor pressure ratio (CPR) parameters consistently below 0.1% across typical load fluctuation scenarios. Maximum deviations were limited to approximately 0.5 K for exhaust temperature and 0.009 for CPR, underscoring the model’s ability to replicating dynamic GT behavior with high precision. The adaptability of the ML model enables its application across diverse operational conditions and its extension to other thermal systems. By leveraging advanced ML techniques, this study presents a robust and scalable modeling framework that enhances GT simulation precision, facilitating improved integration into evolving power systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Facile and Scalable Synthesis of Metal- and Nitrogen-Doped Carbon Nanotubes for Efficient Electrochemical CO 2 Reduction

Metal- and nitrogen-doped carbon (M–N–C) is a promising material to catalyze electrochemical CO 2 reduction reaction (CO 2 RR). However, most M–N–C catalysts in the literature require complicated synthesis procedures and produce small quantities per batch, limiting the commercialization potential. In this work, we developed a simple and scalable synthesis method to convert metal-impurity-containing commercial carbon nanotubes (CNTs) and nitrogen-containing organic precursors into M–N–C via one-step moderate-temperature (650 °C) pyrolysis without any other treatment nor the need to add metal precursors. Batches of catalysts in varied mass up to 10 g (150 mL in volume) per batch were synthesized, and repeatable catalytic performances were demonstrated. To the best of our knowledge, the 10 g batch is one of the largest batches of CO2RR catalysts synthesized in the literature while requiring minimal synthesis steps. The catalyst possessed single-atomic iron–nitrogen (Fe–N) sites, enabling a high performance of >95% CO product selectivity at a high current density of 400 mA/cm 2 and high stability for 45 h at 100 mA/cm 2 in a flow cell testing. The catalyst outperformed a benchmark noble-metal nanoparticle catalyst and achieved longer stability than many other reported M–N–C catalysts in the literature. The scalable and cost-effective synthesis developed in this work paves a pathway toward practical CO 2 RR applications. The direct utilization of metal impurities from raw CNTs for efficient catalyst synthesis with minimal treatment is a green and sustainable engineering approach.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Net-Zero Ethylene: On the Sustainability, Economics, and Scalability of Synthetic and Fossil Production Pathways

The ethylene industry has contributed over 260 million tons of CO 2 annually, warranting a more sustainable approach. The conversion of CO 2 and H 2 O into ethylene is an appealing technology capable of decoupling chemical production from fossil fuels. However, the large energy demand from this process can potentially lead to adverse environmental impacts. Here, in this article, we critically analyze the economic viability, environmental impact, and scalability of the conversion of CO 2 to ethylene via electrochemical reduction (CO 2 R) and compare this with those of CO 2 -neutral fossil routes utilizing carbon capture and direct air capture. Ethylene derived from CO 2 may be economically competitive under optimistic conditions; however, its large energy requirements pose environmental and scalability challenges. Meeting forecast 2050 ethylene demand using CO 2 R would require half of all electricity produced globally today, and, if powered by solar PV, may have greater CO 2 emissions than current petrochemical ethylene production, negating the purpose of this technology. Using Carbon Capture and Storage and Direct Air Capture to decarbonize petrochemical pathways would require roughly an order of magnitude less energy but would have disproportionate health and climate impacts. Lastly, the analysis highlights the importance of low-carbon energy sources to ensure sustainable CO 2 R ethylene production.

CO2R↗
DOE OSTI2019

Efficient Modeling of HIL Multi-Grid System for Scalability & Concurrency in CPS Security Testbed

Cyber-event-triggered power grid blackout compels utility operators to intensify cyber-aware and physics-constrained recovery and restoration process. Recently, coordinated cyber attacks on the Ukrainian grid witnessed such a cyber-event-triggered power system blackout. Various cyber-physical system (CPS) testbeds have attempted with multitude designs to analyze such interdependent events and evaluate remedy measures. However, resource constraints and modular integration designs have been significant barriers while modeling large-scale grid models (scalability) and multi-grid isolated models (concurrency) under a single real-time execution environment for the hardware-in-the-loop (HIL) CPS security testbeds. This paper proposes a meticulous design and effective modeling for simulating large-scale grid models and multi-grid isolated models in a HIL realtime digital simulator environment integrated with industry-grade hardware and software systems. We have used our existing HIL CPS security testbed to demonstrate scalability by the realtime performance of a Texas-2000 bus US synthetic grid model and concurrency by the real-time performance of simultaneous ten IEEE-39 bus grid models and an IEEE-118 bus grid model. The experiments demonstrated significant results by 100% realtime performance with zero overruns, low latency while receiving and executing control signals from SEL Relays via IEC-61850 protocol and low latency while computing and transmitting grid data streams including stability measures via IEEE C37.118 synchrophasor data protocol to SEL Phasor Data Concentrators.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

Efficient Scalable Parallel Higher Order Direct MoM-SIE Method With Hierarchically Semiseparable Structures for 3-D Scattering

A novel fast scalable parallel algorithm is proposed for the solution of large 3-D scattering problems based on: 1) the double (geometrical and current-approximation) higher order (DHO) method of moments (MoM) in the surface integral equation (SIE) formulation and 2) a direct solver for dense linear systems utilizing hierarchically semiseparable (HSS) structures. Namely, an HSS matrix representation is used for compression, factorization, and solution of the system matrix. In addition, a rank-revealing QR decomposition for memory compression is used, with a stopping criterion in terms of the relative rank tolerance value. One method for geometrical preprocessing of the scatterers based on the cobblestone distance sorting technique is employed in order to enhance the HSS algorithm accuracy and parallelization. Numerical examples show how the accuracy of the DHO HSS-MoM-SIE method is easily controllable by using the relative tolerance for the matrix compression. Furthermore, the examples demonstrate low memory consumption, as well as much faster simulation time, when compared to the direct LU decomposition. The method enables dramatically faster monostatic scattering computations than iterative solvers and reduced number of unknowns when compared to low-order discretizations. Finally, great scalability of the algorithm is demonstrated on more than one thousand processes.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Enabling Scalable and Extensible Memory-mapped Datastores in Userspace

Exascale workloads are expected to incorporate data-intensive processing in close coordination with traditional physics simulations. These emerging scientific, data-analytics and machine learning applications need to access a wide variety of datastores in flat files and structured databases. Programmer productivity is greatly enhanced by mapping datastores into the application process's virtual memory space to provide a unified “in-memory” interface. Currently, memory mapping is provided by system software primarily designed for generality and reliability. However, scalability at high concurrency is a formidable challenge on exascale systems. Also, there is a need for extensibility to support new datastores potentially requiring HPC data transfer services. In this article, we present UMap , a scalable and extensible userspace service for memory-mapping datastores. Furthermore, through decoupled queue management, concurrency aware adaptation, and dynamic load balancing, UMap enables application performance to scale even at high concurrency. We evaluate UMap in data-intensive applications, including sorting, graph traversal, database operations, and metagenomic analytics. Our results show that UMap as a userspace service outperforms an optimized kernel-based service across a wide range of intra-node concurrency by 1.22-1.9 × . We performed two case studies to demonstrate UMap 's extensibility. First, a new datastore residing in remote memory is incorporated into UMap as an application-specific plugin. Second, we present a persistent memory allocator Metall built atop UMap for unified storage/memory.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

Scalable Electrolytic Systems for Renewable Hydrogen Production (Cooperative Research and Development Final Report, CRADA Number CRD-18-747)

The project focuses on offshore wind energy which is an emergent renewable energy source in the United States. Onsite hydrogen production for this sector is not available. The overall goal of GTA's work is development of scalable multi-megawatt water electrolysis systems that exclude platinum group metals, are constructed from readily available commodity materials and are mass produced using advanced manufacturing and robotics. They fabricated and successfully tested a scalable TRL 4 laboratory prototype that demonstrated promising results for achieving the goal. They further performed calculations and prepared scale drawings for an envisioned onsite TRL 8 electrolytic hydrogen production system at an offshore 8 MW wind turbine. The work plan of the CRADA proposal between NREL and GTA focuses on validation of the current TRL 4 prototype with potential development and refinement for advancement to a TRL 5 system. GTA, Inc. proposes joining the H2@Scale consortium to leverage DOE funds, benefit from and contribute to the common knowledge-base and work with NREL as a CRADA partner.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Approaching the Radiative Efficiency Limit in Perovskite Solar Cells with Scalable Defect Passivation and Selective Contacts

This award aimed to enable perovskite solar cells to approach the radiative efficiency limit in scalable manufacturing environments by controlling recombination losses, especially surface recombination losses at electrodes and interfaces. The project combined organic molecular synthesis, perovskite film processing and characterization, and spectroscopic tool development for probing recombination centers. The project ultimately achieved record-low surface recombination velocity (SRV) in mixed cation methylammonium-free perovskite thin films, demonstrated photoluminescence as an effective process metrology tool to optimizing processing of device stacks, and showed that the aminopropyltrimethoxysilane (APTMS) is suitable for passivating the exposed perovskite interface in p-i-n stack devices. The project used combinations of phosphonic acids to modify the transparent conducting oxide and APTMS to passivate the perovskite/electron transport layer interface, thereby demonstrating reduction of SRVs in both partial and full device stacks. The project showed concomitant improvements in device performance, and demonstrated that APTMS passivation was compatible with large area coating of external stakeholder perovskite films using both scalable solution and vapor methods. Notably, the project also supplied surface passivating materials to a number of other US based and SETO-funded teams.

14 SOLAR ENERGY↗
DOE OSTI2025

Scalable and Regenerable Fibrous Amine-functionalized Matrix (FAM) sorbent for Efficient Enrichment of Critical Minerals from Coal Wastewaters

The poster presents the latest progress on utilizing a commercially scalable flat sheet sorbent for the effective enrichment of critical minerals from coal wastewater. It highlights the performance, scalability, and potential for industrial applications, addressing key challenges in critical recovery from complex wastewater streams.

critical metals↗
DOE OSTI2025

Ecobuoys for Scalable Oceanography

An approach to scalable surface-drifting buoys is needed to enable the high spatial and temporal resolution of oceanographic data that the science and meteorological communities are asking for. With the number of active buoys predicted to increase by a factor of 100 or more, the impact on the environment becomes even more important. Here, we present a pathway to a scalable and sustainable generation of buoys. We identify the main criteria to be used when developing such buoys to be low cost, with reliable data and neutral or even positive environmental impact. For each buoy subsystem—hull, electronics, energy generation and storage, sensors, and communication system—cutting-edge technological solutions are presented, many of them from emerging research in marine or other disciplines. We then assess the potential solutions against the design criteria and plot a path toward small, environmentally friendly, low-cost, and low-power buoys.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Scalable Substitutional Re‐Doping and its Impact on the Optical and Electronic Properties of Tungsten Diselenide

Abstract Reliable, controlled doping of 2D transition metal dichalcogenides will enable the realization of next‐generation electronic, logic‐memory, and magnetic devices based on these materials. However, to date, accurate control over dopant concentration and scalability of the process remains a challenge. Here, a systematic study of scalable in situ doping of fully coalesced 2D WSe 2 films with Re atoms via metal–organic chemical vapor deposition is reported. Dopant concentrations are uniformly distributed over the substrate surface, with precisely controlled concentrations down to <0.001% Re achieved by tuning the precursor partial pressure. Moreover, the impact of doping on morphological, chemical, optical, and electronic properties of WSe 2 is elucidated with detailed experimental and theoretical examinations, confirming that the substitutional doping of Re at the W site leads to n‐type behavior of WSe 2 . Transport characteristics of fabricated back‐gated field‐effect‐transistors are directly correlated to the dopant concentration, with degrading device performances for doping concentrations exceeding 1% of Re. The study demonstrates a viable approach to introducing true dopant‐level impurities with high precision, which can be scaled up to batch production for applications beyond digital electronics.

Kozhakhmetov, Azimkhan↗
DOE OSTI2022

Scalable Synthesis of Monolayer Hexagonal Boron Nitride on Graphene with Giant Bandgap Renormalization

Abstract Monolayer hexagonal boron nitride (hBN) has been widely considered a fundamental building block for 2D heterostructures and devices. However, the controlled and scalable synthesis of hBN and its 2D heterostructures has remained a daunting challenge. Here, an hBN/graphene (hBN/G) interface‐mediated growth process for the controlled synthesis of high‐quality monolayer hBN is proposed and further demonstrated. It is discovered that the in‐plane hBN/G interface can be precisely controlled, enabling the scalable epitaxy of unidirectional monolayer hBN on graphene, which exhibits a uniform moiré superlattice consistent with single‐domain hBN, aligned to the underlying graphene lattice. Furthermore, it is identified that the deep‐ultraviolet emission at 6.12 eV stems from the 1s‐exciton state of monolayer hBN with a giant renormalized direct bandgap on graphene. This work provides a viable path for the controlled synthesis of ultraclean, wafer‐scale, atomically ordered 2D quantum materials, as well as the fabrication of 2D quantum electronic and optoelectronic devices.

2D heterostructures↗
DOE OSTI2022

A Review of Scalable Hexagonal Boron Nitride ( h -BN) Synthesis for Present and Future Applications

Hexagonal boron nitride (h-BN) is a layered inorganic synthetic crystal exhibiting high temperature stability and high thermal conductivity. As a ceramic material it has been widely used for thermal management, heat shielding, lubrication, and as a filler material for structural composites. Recent scientific advances in isolating atomically thin monolayers from layered van der Waals crystals to study their unique properties has propelled research interest in mono/few layered h-BN as a wide bandgap insulating support for nanoscale electronics, tunnel barriers, communications, neutron detectors, optics, sensing, novel separations, quantum emission from defects, among others. Realizing these futuristic applications hinges on scalable cost-effective high-quality h-BN synthesis. Here, in this work, the authors review scalable approaches of high-quality mono/multilayer h-BN synthesis, discuss the challenges and opportunities for each method, and contextualize their relevance to emerging applications. Maintaining a stoichiometric balance B:N = 1 as the atoms incorporate into the growing layered crystal and maintaining stacking order between layers during multi-layer synthesis emerge as some of the main challenges for h-BN synthesis and the development of processes to address these aspects can inform and guide the synthesis of other layered materials with more than one constituent element. Finally, the authors contextualize h-BN synthesis efforts along with quality requirements for emerging applications via a technological roadmap.

2D materials↗
DOE OSTI2023

Silicon-Lattice-Matched Boron-Doped Gallium Phosphide: A Scalable Acousto-Optic Platform

The compact size, scalability, and strongly confined fields in integrated photonic devices enable new functionalities in photonic networking and information processing, both classical and quantum. Gallium phosphide (GaP) is a promising material for active integrated photonics due to its high refractive index, wide bandgap, strong nonlinear properties, and large acousto-optic figure of merit. Here, this study demonstrates that silicon-lattice-matched boron-doped GaP (BGaP), grown at the 12-inch wafer scale, provides similar functionalities as GaP. BGaP optical resonators exhibit intrinsic quality factors exceeding 25,000 and 200,000 at visible and telecom wavelengths, respectively. It further demonstrates the electromechanical generation of low-loss acoustic waves and an integrated acousto-optic (AO) modulator. High-resolution spatial and compositional mapping, combined with ab initio calculations, indicate two candidates for the excess optical loss in the visible band: the silicon-GaP interface and boron dimers. These results demonstrate the promise of the BGaP material platform for the development of scalable AO technologies at telecom and provide potential pathways toward higher performance at shorter wavelengths.

36 MATERIALS SCIENCE↗