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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Helium recovery system at IB3A

The growing demand for sustainable cryogenic operations at Fermilab has underscored the need to improve helium management, particularly at the Industrial Building 3A (IB3A) test facility. IB3A characterizes and tests superconductors, cables, and coils for projects such as the HL-LHC AUP and Mu2e, yet currently relies on 500 L Dewars whose boil-off is vented to atmosphere, wasting a critical, non-renewable resource and increasing the cost of testing. A project is therefore under way to link IB3A to an existing purification and liquefaction station in a neighboring building through a dedicated pipeline. Captured helium will be transferred, purified, reliquefied, and returned for reuse, cutting losses and operating costs. This paper details the first two project phases: "Design and Engineering" and "Procurement and Installation." The design phase finalizes pipeline specifications, establishes flow-control requirements, and resolves integration challenges with existing cryogenic infrastructure. The procurement and installation phase covers material sourcing, pipeline construction, and deployment of control and monitoring systems to assure reliable, efficient operation. Key technical hurdles-route optimization, pressure drop mitigation, and interface compatibility-are discussed alongside implemented solutions. Implementing the pipeline and upgrading IB3A will dramatically reduce helium consumption and therefore testing cost, strengthening Fermilab's capacity to support frontier science far into the future.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗
DOE OSTI2023

Grand challenges in the design, manufacture, and operation of future wind turbine systems

Abstract. Wind energy is foundational for achieving 100 % renewable electricity production, and significant innovation is required as the grid expands and accommodates hybrid plant systems, energy-intensive products such as fuels, and a transitioning transportation sector. The sizable investments required for wind power plant development and integration make the financial and operational risks of change very high in all applications but especially offshore. Dependence on a high level of modeling and simulation accuracy to mitigate risk and ensure operational performance is essential. Therefore, the modeling chain from the large-scale inflow down to the material microstructure, and all the steps in between, needs to predict how the wind turbine system will respond and perform to allow innovative solutions to enter commercial application. Critical unknowns in the design, manufacturing, and operability of future turbine and plant systems are articulated, and recommendations for research action are laid out. This article focuses on the many unknowns that affect the ability to push the frontiers in the design of turbine and plant systems. Modern turbine rotors operate through the entire atmospheric boundary layer, outside the bounds of historic design assumptions, which requires reassessing design processes and approaches. Traditional aerodynamics and aeroelastic modeling approaches are pressing against the limits of applicability for the size and flexibility of future architectures and flow physics fundamentals. Offshore wind turbines have additional motion and hydrodynamic load drivers that are formidable modeling challenges. Uncertainty in turbine wakes complicates structural loading and energy production estimates, both around a single plant and for downstream plants, which requires innovation in plant operations and flow control to achieve full energy capture and load alleviation potential. Opportunities in co-design can bring controls upstream into design optimization if captured in design-level models of the physical phenomena. It is a research challenge to integrate improved materials into the manufacture of ever-larger components while maintaining quality and reducing cost. High-performance computing used in high-fidelity, physics-resolving simulations offer opportunities to improve design tools through artificial intelligence and machine learning, but even the high-fidelity tools are yet to be fully validated. Finally, key actions needed to continue the progress of wind energy technology toward even lower cost and greater functionality are recommended.

17 WIND ENERGY↗
DOE OSTI2019

Falling particle solar receivers

Falling particle solar receivers, systems, and methods are disclosed that include one non-linear falling particle curtain or two or more falling particle curtains within a solar receiver that receives incident solar radiation. The particles heated in the solar receiver may be used to heat a secondary fluid. In an embodiment, the particles may be recirculated to improve energy capture and thermal efficiency. In other embodiments, an air curtain may be used across the aperture of the receiver, and flow-control devices may be used to evenly spread particles across the width of the receiver inlet. Finally, feed particles may be preheated using heat from the solar receiver.

14 SOLAR ENERGY↗
DOE OSTI2019

Effect of Impurities in CO2 at Supercritical Pressure on Alloy Compatibility (EPRI)

Direct-fired supercritical CO2 (sCO2) cycles are expected to result in sCO2 with higher impurity levels compared to indirect-fired cycles. Prior work at ambient pressure showed minimal effects of O2 and H2O additions, however, a new experimental rig has been built to have flowing controlled impurity levels at supercritical pressures at ≤800°C. Based on industry input, the first experiment was conducted at 750°C/300 bar in CO2+1%O2-0.25%H2O using 500-h cycles for up to 5,000 h. Compared to research grade sCO2, the results indicate faster reaction rates for Fe-based alloys like 310HN and smaller increases for Ni-based alloys like alloys 617B and 282. It is difficult to quantify the 310HN rate increase because of scale spallation. Characterization of the 5,000 h specimens indicated a thicker reaction product formed, which has not been observed in previous impurity studies at ambient pressure. These results suggest that more studies of impurity effects are needed at supercritical pressures including steels at lower temperatures.

Pint, Bruce↗
DOE OSTI2020

Incineration system and process

An incineration system includes an inlet channel supplying an inlet stream comprising a waste gas containing at least one volatile organic compound, a waste gas sensor measuring at least one property of the waste gas, an oxidizing gas supply controllably providing oxidizing gas to the inlet channel, an incinerator receiving the inlet stream from the inlet channel, an ignitor initiating combustion of the inlet stream in the reaction zone of the incinerator, and a controller receiving data from the waste gas sensor and controlling flow of oxidizing gas from the oxidizing gas supply into the inlet channel. The spiral heat exchanger defines a reaction zone, an incoming path from the inlet channels to the reaction zone, and an outgoing path from the reaction zone to an exhaust channel. The incoming path and the outgoing path extend in alternating concentric spirals with the incoming path being countercurrent to the outgoing path.

42 ENGINEERING↗
DOE OSTI2021

Expanding thermite reactions for downhole applications

Methods and apparatus for forming platforms and flow control features in underground wells is described, using modified thermite reactions to form a ceramic plug in place. The reactive package is engineered to expand laterally, filling the well, and may be used to form a ceramic bridge plug, porous ceramic screen sections, or mitigate lost circulation of drilling fluids. These objectives are achieved through the design of the reactive package and through use of carefully chosen reaction additives that control the molten product rheology, solidification temperature, and pore generations and sustainment.

Lowry, William Edward↗
DOE OSTI2022

Debris tolerant valve

A valve includes a valve body, a sleeve within the valve body and a rotatable valve element that has one portion within the sleeve to control flow of media through the valve and another portion extending from the valve body and coupled to an actuator that rotates the valve element. The valve element is rotatable to a first position to flow media to one port and to a second position to flow media to another port. The sleeve has a pair of side openings. Each side opening has an angled perimetrical edge and is aligned with a corresponding port member. A half dovetail shaped groove is formed by the angled perimetrical edge of each side opening, the corresponding port and the valve body. A seal is lodged within each groove to form a seal that exhibits reduced unswept volume and which wipes debris off the valve element as it rotates.

42 ENGINEERING↗
DOE OSTI2022

Falling particle solar receivers

Falling particle solar receivers, systems, and methods are disclosed that include one non-linear falling particle curtain or two or more falling particle curtains within a solar receiver that receives incident solar radiation. The particles heated in the solar receiver may be used to heat a secondary fluid. In an embodiment, the particles may be recirculated to improve energy capture and thermal efficiency. In other embodiments, an air curtain may be used across the aperture of the receiver, and flow-control devices may be used to evenly spread particles across the width of the receiver inlet. Finally, feed particles may be preheated using heat from the solar receiver.

Ho, Clifford K.↗
DOE OSTI2023

Graphics processor unit with opportunistic inter-path reconvergence

A graphics processing unit and methods for comping and executing instructions with opportunistic inter-path reconvergence are provided. A graphics processing unit may access computer executable instructions mapped to code blocks of a control flow for a warp. The code blocks may include an immediate dominator block and an intermediate post dominator block. The graphics processing unit may store a first thread mask associated with the first code block. The first thread mask may include a plurality of bits indicative of the active or non-active status for the threads of the warp, respectively. The graphics processing unit may a second thread mask corresponding to an intermediate code block between the immediate dominator block and intermediate post dominator block. The graphics processing unit may execute, with threads indicated as active by the first thread mask, instructions of the intermediate code block with a first operand or a second operand depending on the second thread mask.

Kulkarni, Milind↗
DOE OSTI2024

LSAFE: a Lightweight Static Analysis Framework for binary Executables

Static analysis is a widely used technique for analyzing various aspects of programs. However, as programs become more complex, static analysis tools require larger resources, such as CPU time and memory, to perform the same tasks. Moreover, the source code of programs may not always be accessible, requiring static analysis to be performed on the binary executable code directly. To overcome these challenges, we propose a lightweight static analysis framework called LSAFE, which constructs control flow graphs (CFGs) and data dependency graphs (DDGs) of target programs with optimized performance in terms of CPU and memory usage. We evaluated the proposed framework using both Spec benchmark programs and real-world industrial applications, and found that it outperformed Angr, an existing state-of-the-art static analysis tool. Additionally, we demonstrate a case study that utilizes the CFG generated by LSAFE to detect memory leaks.

Qu, Guangzhi↗
DOE OSTI2024

Systems and methods for application performance profiling and improvement

Methods for analyzing and improving a target computer application and corresponding systems and computer-readable mediums. A method includes receiving the target application. The method includes generating a parallel control flow graph (ParCFG) corresponding to the target application. The method includes analyzing the ParCFG by the computer system. The method includes generating and storing the modified ParCFG for the target application.

Leidel, John D.↗
DOE OSTI2026

Hardware Aware Mitigation of Timing Side-Channel Vulnerabilities in Critical Infrastructure Software

Program runtime/timing attacks exploit variations in a program’s execution times to extract sensitive information from the program (e.g. encryption keys, sensitive variable data, intellectual property). State-of-the-art solutions to runtime sidechannel attacks attempt to balance the execution time of the sensitive code for different control flow paths to eliminate the timing leakage. However, during the mitigation process, most techniques do not consider the underlying hardware/device on which the target program is supposed to run on. This can lead to over-fixing (unnecessary extra operations), under-fixing (not solving the imbalance properly), and even failures. We propose DISARM, a joint hardware-software methodology (unlike any existing solution) for mitigating runtime side-channel vulnerabilities that utilizes timing values from real embedded devices to generate targeted software fixes. We implement DISARM to support C/C++/Java source codes and validate it across 22 standard benchmarks. DISARM outperforms state-of-the-art solutions such as PENDULUM and DifFuzzAR in terms of execution time overhead (up to −46%), code size overhead (up to −10%), and correctness (no failures) on five different embedded/edge devices.

Suha, Tasneem [University of Maine]↗
DOE OSTI2025

Advanced Transmission Technologies – GETs and HPCs Session 1: ATT Foundations and Dynamic Line Ratings (DLRs)

The INL TADA GETs Cohort Session 1, held on November 4, 2025, convened experts to address the integration of advanced transmission technologies, including Grid-Enhancing Technologies (GETs) and High Performance Conductors (HPCs), with a focus on digital assurance challenges. The session highlighted the growing importance of cybersecurity, supply chain transparency, reliability, and business risk management in deploying GETs, especially Dynamic Line Ratings (DLRs). Participants examined how expanded attack surfaces, limited vendor pools, and new regulatory requirements—such as FERC Orders 881, 2023, and 1920—are influencing utilities and technology providers. The workshop underscored the need for cyber-informed engineering, secure-by-design principles, and practical risk management strategies, while fostering collaboration and knowledge sharing among industry peers. Technical discussions covered the evolution from static to dynamic line ratings, complexities of cloud-based architectures, and NERC CIP compliance challenges. The session concluded with a collaborative risk exercise and a preview of future workshops on advanced power flow control and transmission topology optimization, reinforcing the cohort’s commitment to advancing digital assurance in the energy sector.

24 - POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

A nanoscale photonic thermal transistor for sub-second heat flow switching

Abstract Control of heat flow is critical for thermal logic devices and thermal management and has been explored theoretically. However, experimental progress on active control of heat flow has been limited. Here, we describe a nanoscale radiative thermal transistor that comprises of a hot source and a cold drain (both are ~250 nm-thick silicon nitride membranes), which are analogous to the source and drain electrodes of a transistor. The source and drain are in close proximity to a vanadium oxide (VO x )-based planar gate electrode, whose dielectric properties can be adjusted by changing its temperature. We demonstrate that when the gate is located close ( < ~1 µm) to the source-drain device and undergoes a metal-insulator transition, the radiative heat transfer between the source and drain can be changed by a factor of three. More importantly, our nanomembrane-based thermal transistor features fast switching times ( ~ 500 ms as opposed to minutes for past three-terminal thermal transistors) due to its small thermal mass. Our experiments are supported by detailed calculations that highlight the mechanism of thermal modulation. We anticipate that the advances reported here will open new opportunities for designing thermal circuits or thermal logic devices for advanced thermal management.

42 ENGINEERING↗
DOE OSTI2024

A Simulated Evaluation of Powder Flowability Through a Partially Obstructed Consumable in Blown Powder Directed Energy Deposition Systems

Abstract In the interest of continued industrialization of metal additive manufacturing in modern production environments, cost is often referenced as a primary deterrent to new adopters. Conventional economic models for additive systems, processes, and supply chains often focus on specific process applications with little generalizability, or they neglect significant costs associated with production such as machine maintenance and consumable part replacement. Compounding the latter issue are substantial knowledge gaps in consumable part wear characterization for additive and other convergent manufacturing systems. In coaxial blown powder directed energy deposition systems, gas atomized metal powder is wasted during material deposition at a rate that is partly dependent on present wear phenomena in a consumable nozzle housed in the cladding head assembly. The price and lead time required to replace the nozzle incentivizes its reuse even when visibly worn. Often this initiates a process quality decline in the form of underbuilt geometry and internal defects due to losses in powder catchment efficiency. While depositing H13 steel using a hybrid manufacturing machine tool equipped with such a deposition system, a unique partial clog with a bridge-like structure formed at the consumable nozzle exit when supporting argon gas flows failed mid-process. To further understand coaxial multi-phase powder flow in the event of support gas failure, a computational fluid dynamics simulation is tailored to relevant process parameters, H13 powder material profile, and machine operator observations collected after the incident. The resulting differences in powder flow compared to control gas flow parameters is presented and discussed. The powder flowability and performance of the clogged nozzle is then assessed by using an optical profilometer to extract the profile of the clog and recreate the clog geometry within the simulation environment. In past work this simulation has been experimentally validated for a 316L steel powder material profile and used specifically for analyzing powder stream geometry and catchment efficiency. After the initial powder flow characterization, the clog is removed, and the nozzle is reprofiled. After removing the obstructing clog, the newly unobstructed nozzle geometry, the original off the shelf nozzle geometry, and additional nozzle profiles exploring different consumable refurbishment strategies are reevaluated in the simulation. Powder catchment efficiency for all variant nozzle geometries and relevant flow variables are compared and discussed, along with potential mitigation strategies for optimizing powder flowability with worn consumables. This work expands on the known morphology of blown powder obstructions and wear defects present in consumable coaxial nozzles while discussing pragmatic simulation driven responses to unanticipated subsystem failure in hybrid manufacturing machining platforms.

DeWitte, Lisa↗
DOE OSTI2024

Hydrologic windows into the crystalline basement and their controls on groundwater flow patterns across the Paradox Basin, western USA

Conceptual models of sedimentary basin groundwater flow systems typically assume that the crystalline basement acts as an impermeable boundary and can be neglected. In this study, we use hydrologic models constrained by isotopic and geochemical datasets to argue that the La Sal Mountains, Utah, USA, act as a hydrologic window into the Paradox Basin’s lower aquifer system and underlying crystalline basement. We conducted a sensitivity study in which we varied crystalline basement/laccolith permeability as well as fault zone connectivity along a cross-sectional transect from the La Sal Mountains to Lisbon Valley. When the crystalline basement/laccolith units are set at relatively permeable levels (10–14 m 2 ), simulated tracers that include total dissolved solids, oxygen isotopic composition of pore fluids (δ 18 O), and groundwater residence times are in closest agreement with field measurements. Model results indicate that pore fluids in the basal aquifer system underlying the Paradox Formation confining unit are a mixture of relatively young meteoric fluids and older Paradox Formation brines. The presence of faults did not significantly modify fluid exchange between the upper and lower aquifer systems. This was due, in part, to underpressuring within the Paradox Formation. Our study concludes that the Paradox Basin represents a regional recharge area for the Colorado Plateau, with groundwater discharge occurring along the Colorado River within the Grand Canyon some 375 km away to the southwest. This is only possible with a permeable crystalline basement. Our findings help explain the genesis of Mississippi Valley-type ore deposits of the US Midcontinent, where the presence of a permeable basement may be useful in addressing issues related to solute mass and energy balance.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Design, Deployment, and Characterization of the World’s First Flexible Large Power Transformer

As we know, power transformers are the most critical asset of the transmission network. Although highly reliable, they still can fail prematurely or ultimately retire at the end of their service life. In today’s design practices, transformers are tailored to their specific application and therefore cannot replace each other unless identical. Additionally, they provide minimal support to the grid operation and therefore limit the grid flexibility and resiliency when facing severe conditions. In this presentation, we will introduce the concept of flexible power transformer and demonstrate how one single unit can serve as a spare to multiple units in a given fleet, allow to control the power flow between transformers or lines operating in parallel and ultimately be used to limit subsequent faults in transmission lines. We will also introduce the world’s first prototype in operation, a 60MVA, 165kV flexible autotransformer.

flexible power transformer, autotransformer, varia↗