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NASA NTRS2018

Airspace Technology Demonstration 3 (ATD-3) Multi-Flight Common Route (MFCR) Technology Transfer Document Summary Version 2.0

Airspace Technology Demonstration - 3 (ATD-3) is part of NASA's Airspace Operations and Safety Program (AOSP) - specifically, its Airspace Technology Demonstrations (ATD) Project. ATD-3 is a multi-year research and development effort which proposes to develop and demonstrate automation technologies and operating concepts that enable air navigation service providers and airspace users to continuously assess weather, winds, traffic, and other information to identify, evaluate, and implement workable opportunities for flight plan route corrections that can result in significant flight time and fuel savings in en-route airspace. In order to ensure that the products of this tech-transfer are relevant and useful, NASA has created strong partnerships with the FAA and key industry stakeholders. This summary document and accompanying technology artifacts satisfy the second of three Research Transition Products (RTPs) defined in the Applied Traffic Flow Management (ATFM) Research Transition Team (RTT) Plan. The original transfer, completed in December 2017, consisted of NASA's Multi-Flight Common Route (MFCR) research for efficient route corrections for en-route weather avoidance. This transfer updates the Concept of Operations document to a publicly-available NASA Technical Memorandum. The MFCR concept builds on the experience of the legacy Dynamic Weather Routes (DWR) and focuses on a better balance of potential savings with ATC acceptability, common route corrections options for multiple flights on similar routings, and better use of existing and/or modern automation for communication and coordination of route change options. All of these capabilities are expected to improve system performance significantly in terms of actual delay-reducing clearances issued to flights compared to that of the DWR tool and operating concept.

Tech transfer↗

NASA NTRS2019

Effect of Out-Gassing on the Onset of Hypersonic Boundary Layer Transition

Prediction and control of the onset of transition and the associated variation in aerothermodynamic parameters in high-speed flows is key to optimize the performance and design of Thermal Protection Systems (TPS) of next-generation aerospace vehicles [1]. Boundary Layer Transition (BLT) characteristics can influence the surface heating budget determining the TPS thickness and consequently its weight penalty. Ablative heatshields are designed to alleviate the high heat flux at the surface through pyrolysis of their polymeric matrix and subsequent fiber ablation [2]. Pyrolysis leads to out-gassing and non-uniform ablation lead to surface roughness, both of which are known to influence the transition process. An ablator impacts BLT through three main routes: gas injecting into the boundary layer from the wall, changing the surface heat transfer due to wall-flow chemical reactions, and modifying surface roughness [3]. In preparation to Mars 2020 mission post-flight analysis, the predictive transition capability has been initiated toward hard-coupling porous material response analysis and aerothermal environment calculation.

Karimi, Mona↗

NASA NTRS1990

Transition control

A unified view of the different control methods available or contemplated to delay or advance transition is presented. Emphasis is placed on two-dimensional incompressible flows, although more complex situations are also briefly covered. The governing equations are developed first, the routes to transition are mapped, and elements of the linear stability theory are outlined. The four basic stability modifiers - wall motion, suction, shaping, and wall heat transfer - are discussed, along with wave cancellation. The benefits as well as drawbacks of each approach are considered.

Gad-El-hak, Mohamed↗

NASA NTRS2007

An Experimental System for a Global Flood Prediction: From Satellite Precipitation Data to a Flood Inundation Map

Floods impact more people globally than any other type of natural disaster. It has been established by experience that the most effective means to reduce the property damage and life loss caused by floods is the development of flood early warning systems. However, advances for such a system have been constrained by the difficulty in estimating rainfall continuously over space (catchment-. national-, continental-. or even global-scale areas) and time (hourly to daily). Particularly, insufficient in situ data, long delay in data transmission and absence of real-time data sharing agreements in many trans-boundary basins hamper the development of a real-time system at the regional to global scale. In many countries around the world, particularly in the tropics where rainfall and flooding co-exist in abundance, satellite-based precipitation estimation may be the best source of rainfall data for those data scarce (ungauged) areas and trans-boundary basins. Satellite remote sensing data acquired and processed in real time can now provide the space-time information on rainfall fluxes needed to monitor severe flood events around the world. This can be achieved by integrating the satellite-derived forcing data with hydrological models, which can be parameterized by a tailored geospatial database. An example that is a key to this progress is NASA's contribution to the Tropical Rainfall Measuring Mission (TRMM), launched in November 1997. Hence, in an effort to evolve toward a more hydrologically-relevant flood alert system, this talk articulates a module-structured framework for quasi-global flood potential naming, that is 'up to date' with the state of the art on satellite rainfall estimation and the improved geospatial datasets. The system is modular in design with the flexibility that permits changes in the model structure and in the choice of components. Four major components included in the system are: 1) multi-satellite precipitation estimation; 2) characterization of land surface including digital elevation from NASA SRTM, topography-derived hydrologic parameters such as flood direction. flow accumulation, basin, and river network etc.; 3) spatially distributed hydrological models to infiltrate rainfall and route overland runoff; and 4) an implementation interface to relay thc input data to the models and display the flood inundation results to the users and decision-makers. Early results appear reasonable in terms of location and frequency of events. Case studies of this experimental system are evaluated with surface runoff data and other river monitoring systems. such as Dartmouth Flood Observatory's "Surface Water Watch" array of river reaches that are measured daily via other satellite remote sensing data. A major outcome of this progress will be the availability of a global overview of flood alerts that should consequently improve the performance of Decision Support System. We expect these developments in utilization of satellite remote sensing technology to offer a practical solution to the challenge of building a cost-effective early warning system for data scarce and under-developed areas.

Adler, Robert↗

DOE OSTI2023

Finding middle ground: Flow regimes designed for salmon and energy value

In regulated rivers, shaping seasonal flows to recover species at risk depends on understanding when to expect conflicts with competing water users and when their interests are aligned. Multi-objective optimization can be used to reveal such conflicts and commonalities. When species are involved, multi-objective optimization is challenged by the need to simulate complex species responses to flow regimes. Previously, we addressed that challenge by developing a simplified salmon model (Quantus) that defines cohorts of salmon by the river section and time in which they were spawned. Salmon in these space-time cohorts are tracked from the time redds (nests) are constructed until the cohort exits the tributary en route to the ocean. In this study, we modeled seasonal patterns in energy value and developed a Pareto-optimal frontier of seasonal flow patterns to maximize in-river salmon survival and hydropower value. Candidate flow regimes were characterized by two pulse flows varying in magnitude, timing, and duration and constrained by a total annual flow near the historical median. Our analysis revealed times when economic and salmon objectives were aligned and times when they differed. Pulse flows that favored higher energy value were timed to meet demand during extreme temperatures. Both salmon and hydropower objectives produced optimal flow regimes with pulse flows in early summer, but only solutions favoring hydropower value included high flows in mid-winter. Solutions favoring higher age-0 salmon survival provided an extended pulse flow in late winter/early spring, which suggests that access to productive floodplain habitat allowed faster growth and earlier out-migration and reduced the need for higher temperature-moderating flows later in spring. Minimum flows were also higher among solutions favoring salmon over energy. The tools used to produce these results can help to design simplified seasonal flow regimes by revealing compromise solutions that satisfy both fish and energy producers and highlighting when potential conflicts are likely.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Throughput Optimization of Molybdenum Carbide Nanoparticle Catalysts in a Continuous Flow Reactor Using Design of Experiments

Transition metal carbides (TMCs) have attracted significant attention because of their applications toward a wide range of catalytic transformations. However, the practicality of their synthesis is still limited because of the harsh conditions in which most TMCs are prepared. Recently, a solution-phase synthesis of phase-pure a-MoC1-x nanoparticles was presented. While this synthetic route yielded nanoparticles with exceptional catalytic performance, the reaction parameter space was not explored, and catalyst throughput was not optimized for scale-up. Continuous flow platforms coupled with statistical design of experiments (DoE) can provide a powerful method for understanding the reaction parameter space for optimizations. Here, we demonstrate the use of statistical DoE in tandem with response surface methodology for a parametric screening analysis to optimize the throughput of a MoC1-x nanoparticle synthesis utilizing a millifluidic flow reactor. A full factorial design was implemented to evaluate four input variables (reaction temperature, flow rate, solvent fraction of oleylamine, and precursor concentration) that carry statistically significant effects on three responses (throughput, residence time, and isolated yield). A Doehlert matrix was implemented to investigate each significant variable at a higher number of levels to optimize throughput. Our results give a nonintuitive set of experimental conditions that resulted in an optimized throughput of 2.2 g h-1. This translates to a 50-fold increase in throughput compared to the previously reported batch method. The catalytic performance of the MoC1-x nanoparticles produced under optimized throughput was demonstrated in the CO2 hydrogenation reaction. This DoE screening analysis and throughput optimization of MoC1-x synthesis open the door to an increased feasibility for scale-up.

design of experiments↗

NASA NTRSDate not supplied

Spin Formability of High-Strength Aluminum Alloys for Aerospace Applications

Near-net-shape fabrication of launch vehicle tanks and aircraft fuselages is proposed to increase manufacturing rates of aerospace structures. Currently, cryogenic tank manufacturing relies on multi-piece construction requiring hundreds of meters of welds that increase both structural weight and inspection time. Metallic aircraft fuselages involve installation of tens of thousands of rivets resulting in long assembly times. NASA is pursuing spin and flow forming technologies for manufacturing such structures with minimal assembly. These processes enable domes and stiffened barrels to be fabricated using single-piece construction, offering significant manufacturing rate benefits over conventional methods. However, aluminum alloys with sufficient formability, such as Al 6061, tend to have insufficient strength for aerospace structural applications. In contrast, alloys with higher strength, such as Al 2139 and Al 2050, exhibit insufficient formability during ambient temperature forming. This study investigates the spin formability of competitive 5xxx- and 2xxx-series Al alloys, identifies defects impeding formability, and sheds light on future processing routes for successful forming.

Aluminum↗

NASA NTRS2012

An Evaluation of Controller and Pilot Performance, Workload and Acceptability under a NextGen Concept for Dynamic Weather Adapted Arrival Routing

In todays terminal operations, controller workload increases and throughput decreases when fixed standard terminal arrival routes (STARs) are impacted by storms. To circumvent this operational constraint, Prete, Krozel, Mitchell, Kim and Zou (2008) proposed to use automation to dynamically adapt arrival and departure routing based on weather predictions. The present study examined this proposal in the context of a NextGen trajectory-based operation concept, focusing on the acceptability and its effect on the controllers ability to manage traffic flows. Six controllers and twelve transport pilots participated in a human-in-the-loop simulation of arrival operations into Louisville International Airport with interval management requirements. Three types of routing structures were used: Static STARs (similar to current routing, which require the trajectories of individual aircraft to be modified to avoid the weather), Dynamic routing (automated adaptive routing around weather), and Dynamic Adjusted routing (automated adaptive routing around weather with aircraft entry time adjusted to account for differences in route length). Spacing Responsibility, whether responsibility for interval management resided with the controllers (as today), or resided with the pilot (who used a flight deck based automated spacing algorithm), was also manipulated. Dynamic routing as a whole was rated superior to static routing, especially by pilots, both in terms of workload reduction and flight path safety. A downside of using dynamic routing was that the paths flown in the dynamic conditions tended to be somewhat longer than the paths flown in the static condition.

Johnson, Walter W.↗

DOE OSTI2023

Open millifluidics based on powder-encased channels

Millifluidics, the manipulation of liquid flow in millimeter-sized channels, has been a revolutionary concept in chemical processing and engineering. The solid channels that contain the liquids, though, are not flexible in their design and modification, and prevent contact with the external environment. All-liquid constructs, on the other hand, while flexible and open, are imbedded in a liquid environment. Here, we provide a route to circumvent these limitations by encasing the liquids in a hydrophobic powder in air that jams on the surface, containing and isolating flowing fluids, offering flexibility and adaptability in design, as manifest in the ability to reconfigure, graft, and segment the constructs. Along with the open nature of these powder-contained channels that allow arbitrary connections/disconnections and substance addition/extraction, numerous applications can be opened in the biological, chemical, and material arenas.

36 MATERIALS SCIENCE↗

NASA NTRS2005

A Potentially Useful for Airborne Separation in 4D-Trajectory ATM Operations

An aircraft equipped with Airborne Separation Assistance System functions and 4- dimensional trajectory management capabilities can have significant, potentially transforming, value to Air Traffic Management at the local and system levels. This paper discusses how certain vital characteristics envisioned in the Next Generation Air Transportation System enable some Air Traffic Management functions to be distributed to properly equipped aircraft, and it defines and illustrates this equipage level in a potential application. The new equipage level, perhaps the most capable of many levels permitted, enables an effective implementation of both near- and long-term 4-dimensional trajectory operations in complex airspace, with the aircraft providing the near-term tactical functions and conforming to the long-term trajectory attributes coordinated with ground-based Traffic Flow Management authorities. NASA s recent research and development of this proposed aircraft equipage for en-route and terminal-arrival operations is summarized. The role the equipage level may play in addressing key implementation challenges of reducing ground infrastructure cost, building in security and safety, and scaling to traffic demand is discussed.

Wing, David J.↗

NASA NTRS2018

Airspace Technology Demonstration 2 (ATD-2) Phase 1 Concept of Use (ConUse)

This document presents an operational Concept of Use (ConUse) for the Phase 1 Baseline Integrated Arrival, Departure, and Surface (IADS) prototype system of NASA's Airspace Technology Demonstration 2 (ATD-2) sub-project, which began demonstration in 2017 at Charlotte Douglas International Airport (CLT). NASA is developing the IADS system under the ATD-2 sub-project in coordination with the Federal Aviation Administration (FAA) and aviation industry partners. The primary goal of ATD-2 sub-project is to improve the predictability and the operational efficiency of the air traffic system in metroplex environments, through the enhancement, development, and integration of the nation's most advanced and sophisticated arrival, departure, and surface prediction, scheduling, and management systems. The ATD-2 effort is a five-year research activity through 2020. The initial phase of the ATD-2 sub-project, which is the focus of this document, will demonstrate the Phase 1 Baseline IADS capability at CLT in 2017. The Phase 1 Baseline IADS capabilities of the ATD-2 sub-project consists of: (a) Strategic and tactical surface scheduling to improve efficiency and predictability of airport surface operations, (b) Tactical departure scheduling to enhance merging of departures into overhead traffic streams via accurate predictions of takeoff times and automated coordination between the Airport Traffic Control Tower (ATCT, or Tower) and the Air Route Traffic Control Center (ARTCC, or Center), (c) Improvements in departure surface demand predictions in Time Based Flow Management (TBFM), (d) A prototype Electronic Flight Data (EFD) system provided by the FAA via the Terminal Flight Data Manager (TFDM) early implementation effort, and (e) Improved situational awareness and demand predictions through integration with the Traffic Flow Management System (TFMS), TBFM, and TFDM (3Ts) for electronic data integration and exchange, and an on-screen dashboard displaying pertinent analytics in real-time. The surface scheduling and metering element of the capability is consistent with the Surface CDM Concept of Operations published in 2014 by the FAA Surface Operations Directorate.1 Upon successful demonstration of the Phase 1 Baseline IADS capability, follow-on demonstrations of the matured IADS traffic management capabilities will be conducted in the 2018-2020 timeframe. At the end of each phase of the demonstrations, NASA will transfer the ATD-2 sub-project technology to the FAA and industry partners.

integrated arrival↗

DOE OSTI2026

Rerouting reductant flux via protein tethering enhances biohydrogen production in Thermococcus kodakarensis

Microbes that generate copious amounts of hydrogen (H 2 ) via dark fermentation are a promising means to evolve and improve renewable biofuels. Many anaerobic hyperthermophilic archaea, such as the fast-growing, genetically tractable, heterotroph Thermococcus kodakarensis, produce generous quantities of H2 and provide an idealized platform to further optimize naturally high levels of biohydrogen reduction. Precise genetic manipulations and modifications to growth conditions have already resulted in substantial increases to H2 output but additional improvements are desired. An unexamined and potentially valuable route towards increased H 2 production is to tether select electron donor and acceptor proteins together to reroute and maximize the flow of electrons towards H 2 production. Such strategies have shown promise in Bacteria and Eukarya but have not yet been investigated in thermophilic Archaea. Here, we generate and evaluate twelve novel T. kodakarensis strains wherein a proteinaceous electron carrier (a ferredoxin, Fd) is physically tethered to the membrane-bound-hydrogenase (MBH), the sole H 2 producing enzyme, to direct electron flux towards biohydrogen generation. Growth assessments and H 2 output measurements demonstrate that strains encoding protein-fusions evolve up to ~ 40% more H2 per cell than the host strain. Eliminating H 2 consumption and alternative routes of electron sinks in concert with protein tethering further increased H2 output per cell for a maximum increase of ~ 66% over the host strain. Our results demonstrate that rerouting electron flux via protein tethering coupled with the elimination of reductant sinks is a promising means towards improved biohydrogen production in T. kodakarensis. KEY POINTS: Protein tethering between redox proteins can reroute electron flux in vivo. Enforced protein proximity results in ~ 40% increases in H2 production per cell. Protein-tethering provides a generalizable framework to redirect redox metabolism.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2024

Electrochemical Conversion of CO 2 to Methyl Formate in a Flow Electrolyzer with Mixed Propylene Carbonate/Methanol Catholyte

Despite the promise of electrochemical carbon dioxide reduction as a technology for the production of clean fuels and decarbonization of the chemical industry, research has mostly focused on aqueous systems with a relatively limited set of products that have been achieved via electrosynthesis. Increasingly, CO 2 electroreduction in nonaqueous solvents is being pursued to develop new avenues for expanding the suite of products that can be made with high selectivity. CO 2 reduction in alcohols coupled with in situ esterification to produce esters is one such route that utilizes nonaqueous electrolyte. To be practical, such electrochemical syntheses need to be translated to a high-performance reactor such as a flow electrolyzer. However, many organic solvents, such as alcohols, wet and flood porous electrodes, thus impeding reactor performance. In this work, methanol was mixed with propylene carbonate as a catholyte for a gas-fed CO 2 flow electrolyzer that avoided cathode flooding. Simultaneously, a dual aqueous anolyte was used for water oxidation as a scalable and sustainable anodic half-reaction. The performance effect of methanol concentration, catholyte acidity, CO 2 flow rate, and dilute water in the catholyte were investigated. With 10 vol % methanol in 90 vol % propylene carbonate, 63% faradaic efficiency for methyl formate ester product was sustained without cathode flooding. However, improvements are still needed to lower the cell resistance and further increase the operating current density.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Exact Coherent Structures and Phase Space Geometry of Preturbulent 2D Active Nematic Channel Flow

Confined active nematics exhibit rich dynamical behavior, including spontaneous flows, periodic defect dynamics, and chaotic “active turbulence.” Here, we study these phenomena using the framework of exact coherent structures, which has been successful in characterizing the routes to high Reynolds number turbulence of passive fluids. Exact coherent structures are stationary, periodic, quasiperiodic, or traveling wave solutions of the hydrodynamic equations that, together with their invariant manifolds, serve as an organizing template of the dynamics. We compute the dominant exact coherent structures and connecting orbits in a preturbulent active nematic channel flow, which enables a fully nonlinear but highly reduced-order description in terms of a directed graph. Using this reduced representation, we compute instantaneous perturbations that switch the system between disparate spatiotemporal states occupying distant regions of the infinite-dimensional phase space. Overall, our results lay the groundwork for a systematic means of understanding and controlling active nematic flows in the moderate- to high-activity regime.

36 MATERIALS SCIENCE↗

NASA NTRS1991

Hydraulic model of the proposed Water Recovery and Management system for Space Station Freedom

A model of the Water Recovery and Management (WRM) system utilizing SINDA '85/FLUINT to determine its hydraulic operation characteristics, and to verify the design flow and pressure drop parameters is presented. The FLUINT analysis package is employed in the model to determine the flow and pressure characteristics when each of the different loop components is operational and contributing to the overall flow pattern. The water is driven in each loop by storage tanks pressurized with cabin air, and is routed through the system to the desired destination.

Martin, Charles E.↗

NASA NTRS1978

Pipe Line Control

The array of tanks, pipes and valves in the photo below is a petroleum tank farm in Georgia, part of a petrochemical pipe line system that moves refined petroleum products from Texas and Louisiana to the mid-Eastern seaboard. The same pipes handle a number of different products, such as gasoline, kerosene, jet fuel or fuel oil. The fluids are temporarily stored in tanks, pumped into the pipes in turn and routed to other way stations along the pipe line. The complex job of controlling, measuring and monitoring fuel flow is accomplished automatically by a computerized control and communications system which incorporates multiple space technologies.

Source record↗

DOE OSTI2020

Hydropower Geotechnical Foundations: Current Practice and Innovation Opportunities for Low-Head Applications

Hydropower is a renewable energy resource that produces electricity from flowing water under pressure. Engineered hydropower structures, such as dams, are used to create a hydraulic head, enabling a turbinegenerator unit to convert pressurized flow into electricity. While hydropower has been a source of renewable energy since antiquity, new development in the United States has slowed in recent decades. Based on recent resource assessments, the largest opportunity to expand hydropower in the United States is from new stream-reach development (i.e., new hydropower development along stream-reaches that do not currently have hydroelectric facilities or other forms of infrastructure, such as dams). Roughly 75% of identified new stream-reach development potential is from low-head sites (less than 30 ft of head), which typically suffer from smaller power densities and higher normalized costs, given economies of scale. Hydropower developers and other stakeholders are thus interested in strategies to reduce initial capital costs while practicing sustainable development to maximize environmental compatibility with minimal disruption to natural aquatic life, sediment, and water flows. Historically, civil works have represented a significant cost driver for new hydropower development, with the foundation system representing a major cost component and source of uncertainty. The foundation system is the collection of engineered structural features (e.g. cutoff trenches, walls, grouting, anchors) constructed at or below the preconstruction ground surface that interfaces between the overlying structures (superstructures) and the bed material below (subsurface). Development of a hydropower foundation system must consider the various characteristics of the surrounding stream environment and subsurface while adhering to the engineering requirements of the superstructure that it supports. The care of water, excavation, and other construction activities are important features of foundation design and construction. The design and construction cost of the foundation system is largely dependent on the site geology and riverbed composition and is influenced by the level of geotechnical assessment required and conducted. Thus, a hydropower facility’s geotechnical foundation is often highly site-specific, with proper site selection and assessment being important to project success. The foundation system is designed to provide structural stability (of the foundation and dam), limit seepage, ensure public safety, and maintain functionality for the project life, during both construction and facility operations. Inadequate foundation or dam design can result in dam failure and the uncontrolled release of significant volumes of water, which could cause a high number of casualties and extensive property damage downstream of the failure. According to the Association of State Dam Safety Officials, approximately 30% of all historical dam failures in the United States are attributed to foundation or abutment defects, and another 20% are attributed to piping or seepage through the embankment, foundation, or abutment. To ameliorate these safety considerations, foundations often require massive amounts of construction material (e.g., grout, concrete, engineered dam fill) and long construction times. Foundation design also requires significant analysis prior to construction because the initial in-stream and abutment subsurface conditions are site-specific, and sufficient data for them often are lacking. Current practice requires on-site assessment, using expensive drilling and invasive and non-invasive investigation methods, to determine the expected cost of foundation material and treatment. Additionally, foundation construction often requires site dewatering (and other care of water activities), which involves constructing temporary diversion structures upstream and often downstream, called cofferdams, and water diversion systems that route water around the construction site. Cofferdams and water diversion systems can drastically increase construction costs and contribute to environmental disruption, including modification of flow patterns and benthic habitats. Given the technical, economic, and environmental challenges associated with hydropower foundations, opportunities exist to improve the current state of practice and to develop new and innovative solutions to Hydropower is a renewable energy resource that produces electricity from flowing water under pressure. Engineered hydropower structures, such as dams, are used to create a hydraulic head, enabling a turbinegenerator unit to convert pressurized flow into electricity. While hydropower has been a source of renewable energy since antiquity, new development in the United States has slowed in recent decades. Based on recent resource assessments, the largest opportunity to expand hydropower in the United States is from new stream-reach development (i.e., new hydropower development along stream-reaches that do not currently have hydroelectric facilities or other forms of infrastructure, such as dams). Roughly 75% of identified new stream-reach development potential is from low-head sites (less than 30 ft of head), which typically suffer from smaller power densities and higher normalized costs, given economies of scale. Hydropower developers and other stakeholders are thus interested in strategies to reduce initial capital costs while practicing sustainable development to maximize environmental compatibility with minimal disruption to natural aquatic life, sediment, and water flows. Historically, civil works have represented a significant cost driver for new hydropower development, with the foundation system representing a major cost component and source of uncertainty. The foundation system is the collection of engineered structural features (e.g. cutoff trenches, walls, grouting, anchors) constructed at or below the preconstruction ground surface that interfaces between the overlying structures (superstructures) and the bed material below (subsurface). Development of a hydropower foundation system must consider the various characteristics of the surrounding stream environment and subsurface while adhering to the engineering requirements of the superstructure that it supports. The care of water, excavation, and other construction activities are important features of foundation design and construction. The design and construction cost of the foundation system is largely dependent on the site geology and riverbed composition and is influenced by the level of geotechnical assessment required and conducted. Thus, a hydropower facility’s geotechnical foundation is often highly site-specific, with proper site selection and assessment being important to project success. The foundation system is designed to provide structural stability (of the foundation and dam), limit seepage, ensure public safety, and maintain functionality for the project life, during both construction and facility operations. Inadequate foundation or dam design can result in dam failure and the uncontrolled release of significant volumes of water, which could cause a high number of casualties and extensive property damage downstream of the failure. According to the Association of State Dam Safety Officials, approximately 30% of all historical dam failures in the United States are attributed to foundation or abutment defects, and another 20% are attributed to piping or seepage through the embankment, foundation, or abutment. To ameliorate these safety considerations, foundations often require massive amounts of construction material (e.g., grout, concrete, engineered dam fill) and long construction times. Foundation design also requires significant analysis prior to construction because the initial in-stream and abutment subsurface conditions are site-specific, and sufficient data for them often are lacking. Current practice requires on-site assessment, using expensive drilling and invasive and non-invasive investigation methods, to determine the expected cost of foundation material and treatment. Additionally, foundation construction often requires site dewatering (and other care of water activities), which involves constructing temporary diversion structures upstream and often downstream, called cofferdams, and water diversion systems that route water around the construction site. Cofferdams and water diversion systems can drastically increase construction costs and contribute to environmental disruption, including modification of flow patterns and benthic habitats. Given the technical, economic, and environmental challenges associated with hydropower foundations, opportunities exist to improve the current state of practice and to develop new and innovative solutions to challenges frequently encountered with traditional approaches. With this understanding, it is critically important to understand and document the current state of practice for hydropower geotechnical foundations, identify key challenges, and define opportunities for innovative solutions. To this end, this report documents the current state of practice across the three main phases of geotechnical foundation development: (1) geotechnical site assessment, (2) design, and (3) construction for hydropower systems. It also describes the major challenges with conventional approaches and identifies opportunities for innovation to reduce hydropower foundations costs, timelines, and risks. Key takeaways from this report include the following: Approximately 80% of available low-head sites are expected to have foundations on soil beds rather than rock beds, suggesting that rockfill and earthfill dams may be the most cost-effective conventional dam type for new projects.; Geotechnical and geologic investigation activities are time-consuming and expensive but are essential to define the parameters and criteria needed for foundation design.; Certain riverbed soil and bedrock types present significant technical challenges or require expensive foundation construction, which can prove financially prohibitive for low-head project development.; Modular hydropower design and prefabricated modular foundations represent a promising but unproven paradigm for new hydropower development. Design and construction approaches using optimized and highly repeatable, reliable components would benefit project cost, time, and risk but require additional research and development.; Temporary construction features for foundations, including cofferdams, water diversion, and water control systems, can prove costly and have inherent construction risk.; For economically viable development, hydropower geotechnical foundations should be limited to 4 to 15% of the project’s total initial capital costs. Many proposed projects have experienced cost overruns attributable to foundation difficulties or surprises during construction. These overruns may have been due to inadequate investigations, lack of adequate engineering effort to tailor the structures to site geology and topography, and/or contractual terms, among other considerations.; Challenges for hydropower foundations and opportunities for innovative technology solutions are identified in the following areas (consistent with the three main phases of foundation development): Geotechnical site assessment, Foundation design and materials, Construction methods and technology. Ultimately, this report aims to provide information about geotechnical foundations for low-head hydropower and to motivate transformative technologies to support hydropower growth.

13 HYDRO ENERGY↗

DOE OSTI2025

Rheo–Electric Foundations and Engineering of Carbon Slurry Flow Electrodes

Flowable carbon slurry electrodes promise continuous, scalable electrochemical desalination and energy storage when their rheology (flow and stability) and electronic connectivity are jointly optimized. This report integrates six complementary thrusts that we executed under the Laboratory Directed Research and Development (LDRD) project: (i) a fast, ex situ, centrifuge-compatible method to quantify pellet (packed slurry) electronic conductivity, with a validated cell constant (“shape factor”) and quantitative structure–property insights for carbon mixtures; (ii) a controlled circulation study showing that peristaltic pumping can irreversibly alter particle size and morphology over laboratory-relevant durations; (iii) development of a miniature jet pump that preserves particle integrity while achieving entrainment ratios of 2–4 at practical flow rates; (iv) a comprehensive mapping of how a representative non-ionic surfactant (Tween 20) collapses the carbon gel network, separating network-percolation losses from intrinsic particle contact resistance; (v) in-situ visualization revealing how gravitational settling and flow-driven mixing compete to control charge transport, with dynamic bed layers preventing saturation while achieving 30-fold local concentration enhancement; and (vi) a simple, widely adoptable fabrication route to structured, gas-nitrided titanium nitride (TiN) titanium current collectors that dramatically lower interfacial losses and enable geometry-driven performance gains. Together, these results provide a coherent toolchain and design rules to accelerate formulation screening, de-risk device prototyping, and standardize characterization for carbon slurry electrodes in flow-electrode capacitive deionization (FCDI), electrochemical flow capacitor (EFC), and related systems.

25 ENERGY STORAGE↗