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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Energy Efficient Material Processing through Automated Process Monitoring and Controls

Smart manufacturing is bound to play a crucial role in reducing global energy consumption while accelerating economic development. This phenomenon is evident in advanced sensing technology developments, data analytics and machine learning/AI, automated controls, cloud computing, etc. The immediate opportunity for smart manufacturing is to improve the energy efficiency of manufacturing operations through innovations in processes and controls. The manufacturing industry still consumes about 30% of total global energy production, which is significant. This program focused on the recommendation of heterogeneous sensors to monitor the Chemical Vapor Infiltration (CVI) process parameters, states, and key performance indices and utilize cloud computing to sort and analyze the real-time data. Learning through data analytics helps guide the control parameters affecting energy usage. The target process in the program is the CVI process at the Honeywell South Bend facility, which is one of the most energy-intensive manufacturing industries.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Existence of a robust optimal control process for efficient measurements in a two-qubit system

The verification of quantum entanglement is essential for quality control in quantum communication. In this work we propose an efficient protocol to directly verify the two-qubit entanglement of a known target state through a single-expectation-value measurement. Our method provides exact entanglement quantification using the concurrence measure without performing quantum state tomography. We prove the existence of a unitary transformation that drives a known initial state of a two-qubit system to a designated final state, where the trace over a chosen observable directly yields the concurrence of the initial state. Furthermore, we implement an optimal control process of that transformation and demonstrate its effectiveness through numerical simulations. We also show that this process is robust to environmental noise. Our approach offers advantages in directly verifying entanglement with low circuit depth, making it suitable for industrial-scale quality control of entanglement generation. Our results presented here provide mathematical justification for our earlier computational experiments.

Rodriguez, Ricardo [McPherson Coll.] (ORCID:000000↗
DOE OSTI2020

High Temperature Erosion Modeling in Particle Based CSP Systems

1. Introduction. Wear and erosion damage of materials from solid particle and surface interactions is a major issue in various industries. Although more common in mining and oil and gas production, erosion is becoming a critical issue in renewable technologies as well such as particle based concentrated solar thermal power (CSP) systems. In particle based CSP systems, solid particles are used to absorb solar energy and as thermal storage. However, these particles may cause significant amount of wear to system components while through the system at high temperatures. This damage can be costly, and therefore, requires a greater understanding of solid particle erosion in CSP systems. Throughout the years, models and tools have been developed to predict and control erosion in industries such as oil and gas production. However, these erosion models and erosion prediction tools have been mainly developed based on erosion data for much higher velocities and lower temperatures, i.e. the operating conditions for which the existing models have been built are not pertinent to those expected in CSP system. It is known that erosion depends on many factors such as material properties, erodent particle properties, and particle impact speed and angle. However, the effect of temperature on erosion is not vastly investigated. In this work, a temperature-based correlation is introduced that will be used to modify the existing erosion models to predict erosion rates at velocities and temperatures relevant to Gen3 CSP systems. The existing models are first validated against erosion experiments run at low temperatures and low velocities. Subsequently, a temperature correction term is developed that can extend the existing models to high temperatures, based on the available experimental data showing the effect of temperature on impact erosion. 2. Erosion Models. Continuing sequence of impacts from solid particles on surfaces would result in loss of material due to mechanical interaction between solid surface and particles. Erosion equations have been developed to predict erosion under different conditions and erosion mechanism, including cutting and deformation erosion. These models are mainly either mechanistic, empirical, and semi-mechanistic models, when the latter combine the theory of the erosion mechanism and particle motion with the available experimental data. One of the first empirical correlation was introduced by American Petroleum Institute (API) Recommended Practice (RP) 14E [1]. This correlation was very conservative, and several improved empirical and semi-mechanistic equations were developed in the years following. More recently, the models introduced by Erosion/Corrosion Research Center (E/CRC) at the University of Tulsa and Arabnejad. et al. [2] are frequently used in the literature and industry, as they account for many parameters affecting erosion including particle impact speed and angle, material density and hardness, and particle size and shape. However, both these models were developed based on data at relatively high velocities and also do not take into account any mechanical changes in material associated with thermal cycling at high temperatures. 3. Erosion Prediction at High Temperatures. In this work, the accuracy of Arabnejad et al. model and E/CRC model is investigated to predict impact erosion at conditions relevant to Gen3 CSP systems. Two significant deviations expected in Gen3 systems compared to operating conditions used to build these models are particle impact velocities and system temperature. As a first step, the performance of these models was validated at low velocities and temperatures. Impact erosion experiments were conducted on SS316 coupons using HSP 40/70 ceramic particles. Assuming particle rate of 1 kg/s/m, 0.0254 m of particle curtain thickness, and particle velocity of 1.5 m/s in the system, an overall erosion of 0.59 mm/year was calculated. The experimental results were subsequently compared to those from computational simulations and erosion of 0.47 mm/year was obtained using the Arabnejad et al. model. The results indicated that the models work well at low velocities and low temperature conditions. To account for temperature effect, a mathematical correlation was developed using data published by DUCOM [3] for Inconel 600 eroded by alumina particles at high velocities. The correlation was applied to both Arabnejad et. al model and the E/CRC model. The prediction results from these modified models were within 20% of this experimental data. Predictions of of erosion by the modified E/CRC model at three different temperatures are made. Similar to the calculation at low temperature, a typical CSP system with 1 kg/s/m of particle flow rate per unit length of the particle curtain and a curtain thickness of 0.0254 m is assumed. The annual thickness loss calculations were run for different particle impact velocities, assuming a uniform particle impact area equal to the cross-sectional area of the curtain (particle-particle interactions and dispersion of particles are not considered in obtaining the results). It is observed that erosion increases exponentially as temperature increases. Furthermore, it is also noted that, erosion changes non-linearly with impact velocity. Currently, experiments are also being conducted to measure erosion of SS316 at 800 ºC with HSP 40/70 particles at low impact velocities. We expect to use the results from high temperature testing to further improve the temperature correlation function. Similar models are also being developed for abrasion erosion resulting from particle sliding along the surfaces as well as attrition from particle to particle and particle to surface interactions. References. [1] Institute, A. P. (1991). API Recommended Practice for Design and Installation of Offshore Production Platform Piping System, API RP 14E. [2] Arabnejad, H., Mansouri, A., Shirazi, S. A., and McLaury, B. S. (2015a). Development of mechanistic erosion equation for solid particles. Wear, 332–333, 1044–1050. http://doi.org/10.1016/j.wear.2015.01.031. [3] https://ducom.com/high-temperature-erosion-evaluating-sample-wear/

14 SOLAR ENERGY↗
DOE OSTI2020

Report for 2.2.1 Task 5: Develop and Document a State-Based Alarm System for a Nuclear Power Plant Control Room Using Machine Learning

Idaho National Laboratory (INL) has contracted IFE to support human factors research and the development of leading-edge technology to support control room operators as the U.S. fleet undergoes modernization and digitalization in legacy plants and control rooms. As the nuclear industry starts to shift to more digital controls and systems, these upgrades provide more information to the main control room in the form of digital signals and values. Also, an increase in the number of alarms points is provided by the vendors. New digital control rooms shift from main control boards to soft controls, and alarm panels to a single display. This change to a single display has created a problem of alarm waterfall, a situation in which the addition of new alarm points causes an overload of information to the operator during either a plant disturbance or other than normal full power operations. IFE’s goal is to find a workable solution to assist operators in both handling and understanding incoming alarms during emergency situations under these waterfall conditions.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

UR 2 : Ultra-rapid reactivity test for real-time, low-cost quality control of calcined clays

To reduce cement's carbon footprint, there is growing interest in commercial adoption of sustainable SCMs such as calcined clays. However, the existing ASTM standard (R 3 test, C1897) to test the reactivity of such clays takes up to 7 days and cannot be used for real-time quality control in an industrial setting. We address this issue by introducing a 5-min Ultra-Rapid Reactivity (UR 2 ) test. By dissolving 47 clay specimens in 4 M NaOH solutions at 90°C, we report that a dissolution index of 1.54Al + Si correlates strongly to the 7-day R 3 heat (R 2 = 0.92, RMSE = 94.1 J/g). This dissolution index also correlates to the 28-day compressive strength for 14 clay mixtures (R 2 = 0.94, RMSE = 1.7 MPa). This UR 2 test relies on colorimetry and can be conducted via off-the-shelf, low-cost cameras. Overall, our new UR 2 test opens a pathway for real-time, low-cost quality control of calcined clays.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Large-Scale Interlaboratory DI-FT-ICR MS Comparability Study Employing Various Systems

We report ultra-high resolution mass spectrometry (UHR-MS) coupled with direct infusion (DI) electrospray ionization offers a fast solution for accurate untargeted profiling. Fourier transform ion cyclotron resonance (FT-ICR) mass spectrometers have been shown to produce a wealth of insights into complex chemical systems because they enable unambiguous molecular formula assignment even if the vast majority of signals is of unknown identity. Inter-laboratory comparisons are required to apply this type of instrumentation in quality control (for food industry or pharmaceutics), large-scale environmental studies or clinical diagnostics. Extended comparisons employing different FT-ICR MS instruments with qualitative direct infusion analysis are scarce since the majority of detected compounds cannot be quantified. The extent to which observations can be reproduced by different laboratories remains unknown. We set up a preliminary study which encompassed a set of seventeen laboratories around the globe, diverse in instrumental characteristics and applications, to analyze the same sets of extracts from commercially available standard human blood plasma and Standard Reference Material (SRM) for blood plasma (SRM1950), which were delivered at different dilutions or spiked with different concentrations of pesticides. The aim of this study was to assess the extent to which the outputs of differently tuned FTICR mass spectrometers, with different technical specifications, are comparable for setting the frames of a future DI-FT-ICR MS ring trial. We concluded that a cluster of five laboratories, with diverse instrumental characteristics showed comparable and representative performance across all experiments, setting a reference to be used in a future ring trial on blood plasma.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Large–Scale Syntheses of 2D Materials: Flash Joule Heating and Other Methods

In the past 17 years, the larger-scale production of graphene and graphene family materials has proven difficult and costly, thus slowing wider-scale commercial applications. Here, the quality of the graphene that is prepared on larger scales has often been poor, demonstrating a need for improved quality controls. Here, current industrial graphene synthetic and analytical methods, as well as recent academic advancements in larger-scale or sustainable synthesis of graphene, defined here as weights more than 200 mg or films larger than 200 cm 2 , are compiled and reviewed. There is a specific emphasis on recent research in the use of flash Joule heating as a rapid, efficient, and scalable method to produce graphene and other 2D nanomaterials. Reactor design, synthetic strategies, safety considerations, feedstock selection, Raman spectroscopy, and future outlooks for flash Joule heating syntheses are presented. To conclude, the remaining challenges and opportunities in the larger-scale synthesis of graphene and a perspective on the broader use of flash Joule heating for larger-scale 2D materials synthesis are discussed.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

Active and Stable PtPd Diesel Oxidation Catalysts under Industry‐Defined Test Protocols

Nanoparticle-supported Pt and Pd catalysts are employed industrially to convert CO and hydrocarbon residue from incomplete diesel fuel combustion into more environmentally-benign products. However, these catalysts deactivate over time due to sintering, especially for Pt nanoparticles which readily generate volatile species under high operating temperatures. Here, we turned the detrimental vapor-mediated sintering of Pt into an advantage by using a physical mixture of Pt and Pd catalysts prepared using a raspberry-colloid-templating (RCT) method. The RCT method produced Pt/Al 2 O 3 and Pd/Al 2 O 3 catalysts with partially embedded NPs to inhibit surface-mediated sintering pathways. As validated using an industry-defined emission control test protocol, aging a physical mixture of Pt/Al 2 O 3 and Pd/Al 2 O 3 at high temperature produced an alloyed PtPd/Al 2 O 3 catalyst that outperformed the fresh catalyst mixture and both individual catalysts for hydrocarbon conversion, while exhibiting high catalytic stability and resistance to sintering and to SO 2 poisoning. X-ray photoelectron spectroscopy revealed that in the aged catalyst mixture, half of the Pd content existed in the more active metallic state, compared to the less active oxide forms in the fresh mixture and both individual catalysts, explaining the unusual activity enhancement. Our results represent a practical approach to producing active and stable PtPd/Al 2 O 3 diesel oxidation catalysts for emission control applications.

Lim, Kang Rui Garrick [Harvard University, Cambrid↗
DOE OSTI2026

Bridging semantics, control specifications and assessment: A library for scalable demand flexibility controls

There is growing recognition that Demand Flexibility (DF) can play a major role in enhancing grid reliability, with building control applications emerging as key enablers for DF. However, the traditional approach to deploying new control applications in buildings, including those for DF, remains largely manual and tailored to individual buildings, making it difficult to scale. While research efforts have explored semantics-driven portability, DF controls specification, and assessment approaches, these initiatives are fragmented and limited in scope. This paper proposes a novel methodology, grounded in design science research, to integrate these elements and create a comprehensive DF controls library for both industry and academia. This approach is applied to develop the Demand FLEXibility controls LIBrary using Semantics (DFLEXLIBS), an extensible open-source library that provides DF controls for HVAC systems in Python. DFLEXLIBS enables portable, easy-to-deploy controls that abstract building-specific data points, facilitating assessment across diverse buildings. DFLEXLIBS features nine different control applications, and it is successfully implemented and tested across four virtual and two real buildings, bridging the gap between semantics-driven portability, DF controls specification, and rigorous performance assessment. Its benefits are measured by a reusability ratio greater than 90% and a functional overlap ratio of around 70% for the most common functions used in the library, significantly reducing time for deploying new controls.

Controls library↗
DOE OSTI2020

Metal-embedded fiber optic sensor packaging and signal demodulation scheme towards high-frequency dynamic measurements in harsh environments

Optical fiber-based sensors are commonly used for industrial monitoring and control processes due to their small size, resistance to electromagnetic interference, and ability to perform a wide variety of high-precision measurements. However, implementing optical fiber sensors in harsh environments is challenging because they are small and fragile. Proper packaging of fiber-optic sensors could extend their use to harsh environments, including at high temperature and under high radiation. Furthermore, conventional fiber optic-based measurement systems often use computationally expensive signal processing algorithms which hinder their use in high-frequency dynamic applications. This work reports on the design of an optical fiber-pressure sensor system based on low-coherence interferometry that uses a metal-embedded optical fiber to provide a robust sensor package. Additionally, a novel phase demodulation scheme is proposed to extract length changes from the deformation of a thin diaphragm within a Fabry–Pérot cavity to measure pressure. The sensor has been tested to ±100 kPa, has a theoretical linear response over a 270 kPa dynamic range (24 dB maximum signal-to-noise ratio), and can resolve pressure transients up to 3910 kPa/s. Sampling at 100 kHz, the present sensor can resolve 2 kPa dynamic pressures at frequencies up to 2 kHz. Faster transients on the order of tens to hundreds of kHz can theoretically be resolved at the expense of decreasing the maximum resolvable amplitude. A methodology for designing a LCI pressure sensor for a given application is outlined based on the limitations imposed by the Nyquist criterion, the diaphragm's resonant frequency, the LCI optoelectronics, and the phase demodulation scheme. The sensor is the first to implement a low-coherence light source and a Fabry–Pérot interferometer designed to provide real-time high-fidelity pressure measurements using a metal-embedded optical fiber. The demonstrated sensor provides a platform for sensing in harsh conditions such as in nuclear and energy applications.

47 OTHER INSTRUMENTATION↗
DOE OSTI2026

Chemically Separable Ruthenium Hydride Isomers with Distinct Hydride Transfer Properties

Transition metal hydrides are key intermediates in biological and industrial catalysis, where control over hydride donor ability (hydricity) is essential for optimizing reactivity. Herein, we report a series of isomeric ruthenium hydrides in which the ligand trans to the ruthenium hydride bond–either an N-heterocyclic carbene or pyridine–modulates the thermodynamic hydricity by up to 8 kcal mol –1 . These hydrides exhibited distinct reactivity toward CO 2 and various organic hydride acceptors, enabling detailed kinetic and mechanistic analysis. Stopped-flow experiments, isotopic labeling, and computational studies supported an outer-sphere hydride transfer mechanism. Linear free energy relationships (LFERs) and Marcus relationships were utilized to correlate the changes in thermodynamics and kinetics, revealing that ligands with strong trans effects and trans influence can disrupt conventional scaling relationships, which can be a powerful strategy for promoting new reactivity paradigms in hydride transfer reactions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Static to inducibly dynamic stereocontrol: The convergent use of racemic β-substituted ketones

The synthesis of stereochemically complex molecules in the pharmaceutical and agrochemical industries requires precise control over each distinct stereocenter, a feat that can be challenging and time consuming using traditional asymmetric synthesis. Although stereoconvergent processes have the potential to streamline and simplify synthetic routes, they are currently limited by a narrow scope of inducibly dynamic stereocenters that can be readily epimerized. Furthermore, we report the use of photoredox catalysis to enable the racemization of traditionally static, unreactive stereocenters through the intermediacy of prochiral radical species. This technology was applied in conjunction with biocatalysts such as ketoreductases and aminotransferases to realize stereoconvergent syntheses of stereodefined γ-substituted alcohols and amines from β-substituted ketones.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

SFAI and Related Technologies

Researchers at Los Alamos have developed Swept-Frequency Acoustic Interferometry (SFAI) a technology that enables businesses to have greater control over their industrial processes, allowing for significantly improved efficiency by giving operators vital composition and flow rate information in real-time. This technology fills the information gap by providing this data non-invasively and at a fraction of the cost of traditional composition meters. SFAI uses engineered ultrasound and advanced signal processing to characterize multiphase flow (e.g., liquids, gasses, multi-phase mixtures) and other flows inside sealed containers and flow pipes. By being both low-cost and non-invasive, this technology is set to disrupt the current oil field monitoring state-of-the-art by providing individual well-level composition data, compared to the multi-well macroscopic information that is currently available. We are seeking a commercialization partner to license the technology or fund us through a Cooperative Research and Development Agreement (CRADA) to a further develop a usable product for commercial purposes.

03 NATURAL GAS↗
DOE OSTI2025

Evaluation of IEC 62443 Standard Gaps for Electric Grid Substation Model Use Case

This report presents an evaluation of the IEC 62443 standards in the context of electric grid substations, as part of a collaborative effort among Sandia National Laboratories (SNL), Idaho National Laboratory (INL), and the National Renewable Energy Laboratory (NREL). The primary objective is to assess the applicability of these standards to enhance cybersecurity measures for industrial automation and control systems (IACS) within the energy sector. The evaluation identifies strengths, such as the scalability of security levels and the structured lifecycle guidance provided by IEC 62443. However, it also highlights significant gaps, including limited integration of physical security, insufficient guidance for legacy systems, and challenges in addressing emerging threats like supply chain vulnerabilities. Recommendations for refining the standards are proposed, including the need for tailored guidance for securing legacy systems, integrating physical security with cybersecurity frameworks, and enhancing interoperability across multi-vendor environments. By addressing these gaps, the IEC 62443 standards can be strengthened to ensure comprehensive cybersecurity for electric grid substations, thereby supporting the resilience and reliability of critical energy infrastructure.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Cybersecurity Center for Offshore Wind Energy (Final Project Report)

This project establishes a Cybersecurity Center for Offshore Wind Energy with the objective of designing and operating a cyber-physical testbed for wind energy farms (WEFs) that enables comprehensive cybersecurity research. The testbed incorporates a Supervisory Control and Data Acquisition (SCADA) system connected to turbine models via industrial-grade programmable logic controllers (PLCs) and remote terminal units (RTUs). It supports side-channel data acquisition, implementation and analysis of various cyberattack scenarios, and development of attack detection, mitigation, and best-practice guidance tailored to wind energy systems. During the project, the team expanded the number and fidelity of mathematical turbine models (MTMs), integrated these models with SCADA infrastructure, and deployed a scaled physical turbine and associated sensors. High-resolution operational and side-channel data streams were collected and used to refine machine-learning (ML)-based attack detection systems and to extend the WindCRAFT framework to multi-turbine threat scenarios. The project demonstrated a realistic, scalable environment for evaluating cyber threats, validated attack detection approaches using enriched datasets, and identified new multi-turbine and inter-turbine communication attack vectors. The resulting testbed, models, and security mechanisms provide a foundation for ongoing R&D and deployment of cyber-resilient offshore wind energy systems.

17 WIND ENERGY↗
DOE OSTI2022

Bassanite Grows Along Distinct Coexisting Pathways and Provides a Low Energy Interface for Gypsum Nucleation

Calcium sulfate is a naturally abundant and industrially important mineral; understanding its formation mechanism contributes to reconstructing geochemical record and controlling its scaling in industry. Formation of gypsum is shown to follow a multistage-processes via bassanite, but the evolution of bassanite and the mechanism by which it is replaced by gypsum are poorly understood. Here we outline a three-stage process: (i) growth of bassanite nanoparticles into nanorods or rosettes, (ii) extension of bassanite rosettes by addition of fundamental growth units and aggregation of bassanite nanorods into aggregates, and (iii) heterogeneous nucleation of gypsum on the tips of bassanite rosettes and aggregates. The findings demonstrate that bassanite grows via distinct coexisting pathways and provides a low energy interface for heterogeneous nucleation of gypsum, thus providing proofs that more than one growth pathway can operate simultaneously in a crystallization system and that the precursors in multistage crystallization processes can imprint their pattern of precipitation onto the final phase.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Roadmap for Wind Cybersecurity

The Roadmap for Wind Cybersecurity outlines the increasing challenges of cyber threats to the wind industry, its technologies, and control systems and presents a framework of activities and best practices that the wind industry can use to improve its cybersecurity.

17 WIND ENERGY↗