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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 OSTI2026

Sensitivity analysis of design parameters in RowWise borehole layout for ground heat exchangers

Ground source heat pump systems offer a promising pathway toward energy-efficient building heating and cooling. The performance and cost-effectiveness of these systems heavily depend on the design of the ground heat exchanger (GHE), particularly the spatial placement of boreholes used in large commercial buildings. Among various borefield layout strategies, the RowWise approach generates and optimizes borehole configurations within irregular polygonal land boundaries, providing land-use efficiency and installation flexibility. While multiple geometric design parameters constrain the RowWise layout, their influence on the system thermal performance and total drilling requirements remains unclear. Thus, this study presents a sensitivity analysis of key design parameters influencing the RowWise layout of vertical borehole GHEs, including the perimeter spacing ratio, borehole spacing, borehole field rotation angle, and borehole length. GHEDesigner and Ray Tune are employed to generate and assess different RowWise configurations. A series of parametric simulations was conducted to quantify the impact of each parameter on geometric distribution, economic cost, and computational speed. The results provide critical insights into the sensitivity and relative importance of different design parameters of RowWise method, offering practical guidance for designers aiming to optimize GHE layouts by balancing thermal efficiency, land constraints, and economic feasibility.

Xu, Dikai [Purdue University]↗
DOE OSTI2026

Status and performance of the GlueX DIRC

In support of the future physics program at Ce+BAF, we propose a prototype positron target. The prototype target consists of a tungsten disk mounted on a water-cooled copper support structure to enhance heat removal. The primary goals of this work are to benchmark CFD simulations, ensure vacuum integrity at the 10^-6 Pa level, achieve stable target rotation up to 10 Hz, and implement efficient water-based cooling for sustained high-power operation. To manage the thermal load, the target is designed to rotate, allowing the deposited heat to spread over a larger region, and thereby reducing localized thermal stress while maintaining the maximum temperature below 1000 K. To experimentally evaluate the thermal performance and structural stability of the target, we plan to conduct high-power laser heating tests at Laser Lab 5, LERF Building, JLab. These tests will serve as a stepping-stone for the positron production target at CEBAF.

Stevens, J.R. [College of William and Mary, Willia↗
DOE OSTI2025

Refining seasonal performance metrics for room air-conditioning in emerging markets: Integrating building simulations with real-world equipment performance data

Buildings significantly impact worldwide energy consumption, emphasizing the need to reduce the cooling energy demand, especially in warm climates. Minimum energy performance standards (MEPS) and seasonal performance metrics such as the Cooling Seasonal Performance Factor (CSPF) are crucial for improving room air conditioning (RAC) efficiency. However, challenges remain, particularly in emerging markets like Brazil, where seasonal performance metrics have recently been introduced. This study assesses the factors influencing country-level seasonal efficiency metrics and proposes a framework to refine these calculations by considering local climates and expected RAC usage in real-world households via building simulations. Key considerations include outdoor air temperature binning for different climates, RAC usage patterns (i.e., daytime and nighttime usages), envelope thermal performance of households, and urban heat island (UHI) effects. The results reveal that CSPF values can vary significantly based on climate conditions, with observed CSPF ranging from 4.10 to 11.59 Wh/Wh across 577 Brazilian climates. The inclusion of UHI effects led to a reduction in CSPF values by up to 29% during nighttime operations in hot urban areas. Additionally, building envelope efficiency showed contrasting impacts on RAC performance, with CSPFs reaching up to 15.35 Wh/Wh under specific optimized conditions. These findings highlight the need for transparent policymaking in RAC performance databases, facilitating the application of approaches like those proposed in this study and supporting diverse stakeholders in decision-making.

Bavaresco, Mateus↗
DOE OSTI2021

3-D Prismatic Packaging Methodologies for Wide Band Gap Power Electronics Modules

In a power module the parasitic inductance limits the dynamic high-frequency performance, and the area of the cooling surfaces limits the power capability. This paper presents a new 3D power electronic design methodology based on the concept of mutual inductance cancellation and multi-sided heat transfer. New 3D prismatic packaging concepts are proposed for Wide Band Gap (WBG) power devices, where the devices can be mounted at acute angles to adjacent interconnects or other devices. Discussion is given on electrical and thermal path optimization in a 3D space. To validate the 3D prismatic packaging methodology, a 1200V/50A SiC half-bridge power module is fabricated and tested for electrical and thermal performance and results are compared with simulations. The power density calculated for the module is 12 kW/in3 (including heatsink) and shows a 31.3% inductance reduction compared to a 2D planar module. Finally, design guidance suggested for utilizing prismatic structures is provided, together with suggested future work in the area. This paper presents the first reported true 3D power module.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Enabling Industrial Re-Use of Large-Format Additive Manufacturing Molding and Tooling

Large-format additive manufacturing (LFAM) is an enabling manufacturing technology capable of producing large parts with highly complex geometries for a wide variety of applications, including automotive, infrastructure/construction, and aerospace mold and tooling. In the past decade, the LFAM industry has seen widespread use of bio-based, glass, and/or carbon fiber reinforced thermoplastic composites which, when printed, serve as a lower-cost alternative to metallic parts. One of the highest-volume materials utilized by the industry is carbon fiber (CF)-filled polycarbonate (PC), which in out-of-autoclave applications can achieve comparable mechanical performance to metal at a significantly lower cost. Previous work has shown that if this material is recovered at various points throughout the manufacturing process for both the lab and pilot scale, it can be mechanically recycled with minimal impacts on the functional performance and printability of the material while significantly reducing the feedstock costs. End-of-life (EOL) CF-PC components were processed through industrial shredding, melt compounding, and LFAM equipment, followed by evaluation of the second-life material properties. Experimental assessments included quantitative analysis of fiber length attrition, polymer molecular weight degradation using gel permeation chromatography (GPC), density changes via pycnometry, thermal performance using dynamic mechanical analysis (DMA), and mechanical performance (tensile properties) in both the X- and Z-directions. Results demonstrated a 24.6% reduction in average fiber length compared to virgin prints, accompanied by a 21% decrease in X-direction tensile strength and a 39% reduction in tensile modulus. Despite these reductions, Z-direction tensile modulus improved by 4%, density increased by 6.8%, and heat deflection temperature (HDT) under high stress retained over 97% of its original value. These findings underscore the potential for integrating mechanically recycled CF-PC into industrial LFAM applications while highlighting the need for technological innovations to mitigate fiber degradation and enhance material performance for broader adoption. This critical step toward circular material practices in LFAM offers a pathway to reducing feedstock costs and environmental impact while maintaining functional performance in industrial applications.

additive manufacturing↗
DOE OSTI2022

Divertor Component Testing

Power exhaust is an immense challenge in tokamaks. Commonwealth Fusion Systems (CFS), in collaboration with MIT and others, is working on the design of a compact (R 0 = 1.85 m), high-field (B 0 = 12 T) tokamak for the demonstration of net fusion energy, called SPARC. Empirical scaling laws indicate that the unmitigated heat flux in the boundary plasma will exceed 10 GW/m 2 . Such high heat fluxes will be a formidable challenge. The scope of this work is to utilize the HHF testing expertise maintained by ORNL, used in support of NSTX-U and to demonstrate the thermal performance of tungsten-coated graphitic foam targets, to help CFS and its collaborators to assess the performance of (1) base materials (tungsten and its alloys) and (2) divertor mockups under SPARC-like divertor heat flux conditions. These activities will be performed by ORNL personnel using electron beam exposure facilities at the Pennsylvania State University’s Applied Research Laboratory (ARL). ARL is a Department of Defense University Affiliated Research Center where ORNL has successfully executed NSTX-U and graphitic foam high heat flux testing using electron beam (e-beam) facilities, which is a nonstandard service. For the assessment of base materials, CFS will do an initial thermal analysis, in consultation with ORNL, to understand under what scenarios the materials are most likely to fail. CFS will supply to ORNL various tungsten-based material samples to test with testing taking 3 weeks. ORNL will thermally stress the samples under SPARC divertor-like conditions to either failure or to a prescribed number of pulses. ORNL will record experimental data, including IR surface temperature and embedded thermocouple readings, and report results to CFS

36 MATERIALS SCIENCE↗
DOE OSTI2023

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

High temperature operation of wide bandgap devices continue to be a challenge for the power electronics packages. Thermal performance and reliability are important factors that determine the viability of a bonded interface for operation at high temperatures. In this presentation, we present the technical approach and key results from the research on sintered silver, transient liquid phase alloy, and polymeric materials. A lifetime prediction model that incorporates the thermomechanical behavior of sintered silver at 200C was developed. The copper-aluminum transient alloy completed 350 thermal cycles from -40C to 200C and little increase in the defect level was observed. In addition to material research, we initiated a time-series analysis on the scanning acoustic microscope images of eutectic solder to explore statistical forecasting methods and machine learning techniques. Initial results that report the accuracy of a few different statistical models are presented.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

From viruses to protists: temperature response of the neglected components of microbial controls on peatland nutrient cycling

The response of plant-associated microbial communities to rising temperatures likely plays a key role in global Carbon (C) and Nitrogen (N) biogeochemical cycles. Mosses of the genus Sphagnum, in particular, sequester 25% of all terrestrial C as recalcitrant peat. However, their ability to sequester C is mediated by interactions with microbes that fix N and pass it to the moss to grow in otherwise oligotrophic systems. Two important biotic controls on this processes are likely to respond to rising temperatures –predation by protists and infections by viruses– but whether and how this might occur is not well understood. This proposal addressed these questions using a combination of genomics and mathematical modeling with both field data from whole-ecosystem warming experiments, and laboratory-based microcosm experiments. We have discovered 1) mechanistic links between cell traits and thermal performance in protists, which 2) enabled predictions from populations to ecosystems, 3) we have identified eco-phenotypic feedbacks that determine protist–bacterial predator–prey dynamics, 4) have documented concomitant compositional and trait shifts in protist communities with warming in the field, 5) revealed consistent interactive effects of temperature and nutrients on bacterial and protist communities; 6) characterized the Sphagnum virome, and 7) made modeling predictions on its implications for thermal responses of microbial communities in peatlands globally. This award also substantially strengthened U.S. scientific capacity and workforce development.

Gibert, Jean Philippe [Duke University]↗
DOE OSTI2025

Material extrusion additive manufacturing of wood pulp-reinforced epoxy composites

Direct ink writing (DIW) is an extrusion-based form of 3D-printing that has gained popularity over the last decade. DIW uses thixotropic fluid extrusion to form a particular shape. In order to form stable structures, the rheology of the paste is important to allow for extrusion from the syringe, stability of the growing print, and prevention of unwanted seeping flow during jog moves. In this work, we use wood pulp as a bio-based filler that can provide shear thinning properties to the ink, which produces a stable ink for DIW processing. Additionally, the filler imparts improved mechanical and thermal performance compared to neat resin. The wood pulp provided the shear thinning behavior necessary for DIW printing, and pulp loadings greater than 6 wt%, provided sufficient yield stress so that the composite could self-support during printing. Nanoclay was utilized to further improve ink rheology and appearance to enable larger scale printing. Overall, this work showed successful DIW of an epoxy resin with a sustainable filler improving its stiffness and thermal properties and provides an avenue for further development of bio-based inks for DIW towards various applications.

Lamm, Meghan E. [Oak Ridge National Laboratory (OR↗
DOE OSTI2020

The influence of lattice defects, recombination, and clustering on thermal transport in single crystal thorium dioxide

Thermal transport is a key controlling property for thorium dioxide in many applications where defect-generating radiation fields are present. An understanding of the effect of nanoscale lattice defects on thermal transport in this material is currently unavailable due to a lack of high-quality, single crystal material from which unit processes may be investigated. In this work, a series of thorium dioxide single crystals are exposed to 2 MeV proton irradiation at room temperature and 600°C to create microscale regions with varying densities and types of point and extended defects. Defected regions are investigated using spatial domain thermoreflectance to quantify the change in thermal conductivity as a function of ion fluence as well as transmission electron microscopy and Raman spectroscopy to interrogate the structure of the generated defects. Together, this com- bination of methods provides important initial insight into defect formation, recombination, and clustering in thorium dioxide and the effect of those defects on thermal transport. These methods also provide a promising pathway for the quantification of the smallest-scale defects which cannot be captured using traditional microscopy techniques and play and outsized role in degrading thermal performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Microstructure-Based Understanding of High-Temperature Deformation Behaviors in Laser Powder Bed Fusion (LPBF) 316H Stainless Steel

This report presents the results of high-temperature mechanical property testing and microstructural analysis of laser powder bed fusion (LPBF) 316H stainless steel (SS) conducted during Fiscal Year 2025 (FY25) under the U.S. Department of Energy, Office of Nuclear Energy’s Advanced Materials and Manufacturing Technologies (AMMT) program. The study builds upon prior work by expanding the mechanical property test matrix and advancing a microstructure-based mechanistic understanding of LPBF 316H SS performance, with a focus on the solution annealed (SA, 1100°C for 1 hour) materials. High-temperature tension, creep, fatigue, and creep-fatigue tests were performed. Thermal aging studies were conducted. Advanced characterization techniques, including scanning electron microscopy (SEM), scanning transmission electron microscopy (STEM), and high-energy synchrotron X-ray diffraction, were employed to investigate the microstructural evolution during thermal aging and mechanical testing. It was discovered that the as-built (AB) LPBF 316H SS exhibited precipitation kinetics during thermal aging that are 10–100 times faster than its wrought counterpart due to the presence of high densities of preferred nucleation sites, while the precipitation kinetics in SA LPBF 316H was under investigation. The accelerated precipitation of embrittling phases such as sigma phase in LPBF 316H SS compared to its wrought counterpart led to significant impacts on creep ductility. The influence of laser printing parameters and build orientations on fatigue and creep-fatigue performance was observed. In assessing the creep-fatigue performance, it was discovered that the SA LPBF 316H samples failed in less than 200 cycles under 595°C, 0.5% (strain amplitude) with a 60-minute hold time. This work establishes a mechanistic framework for predicting the long-term behavior of LPBF 316H SS, supporting its rapid qualification under the ASME BPVC. The findings contribute to the broader goal of enabling the deployment of advanced materials in next-generation nuclear energy systems. An outlook for FY26 work, including continued aging studies, mechanical testing, and microstructural characterization, is provided.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Enhancing EnergyPlus capabilities to model dynamic building envelopes using python plugin

Nearly half of the energy consumption in the United States is related to buildings, resulting in an urgent need to develop innovative technologies to improve building energy efficiency. Dynamic building envelopes, comprising switchable insulation and thermal energy storage materials, have been proposed recently as a promising solution to reduce buildings' heating and cooling loads by thermally coupling the indoor environment with the ambient environment when beneficial while decoupling them when outdoor conditions are not favorable. Although various related technologies are still underway, the whole-building energy modeling tools, like EnergyPlus, do not have the capability to simulate the transient and dynamic nature of dynamic envelope materials and components to accurately predict their impact on building energy use. The objective of this study is to formulate a method in EnergyPlus simulation engine to model multilayer envelopes, comprising dynamic building materials with variable thermophysical properties, and discuss the changes made to the program using a Python plugin. Furthermore, the thermal performance of the dynamic envelopes using the proposed method is compared and verified with the results from a well-established commercial code, COMSOL Multiphysics. A parametric assessment is also conducted to evaluate the energy efficiency benefits of dynamic envelopes in a single-family residential building, demonstrating total annual energy savings up to 11.6 %, when a dynamic envelope operates alone, and up to 18.2 % when it is combined with a thin layer of phase change material as a thermal storage medium. Finally, a United States wide energy efficiency assessment is presented to showcase the geographical spread of the energy savings. The method designed and implemented in this study provides the researchers with the ability to implement their dynamic insulation methods in EnergyPlus and evaluate the whole building energy impact.

25 ENERGY STORAGE↗
DOE OSTI2025

Non-dimensional performance and safety parameters for heat pipes

The use of heat pipes in safety-critical systems such as nuclear microreactors dictates the development of generalized, practical, scalable performance and safety parameters. Traditional dimensional metrics, while informative, lack the universality required for comparative analysis across varying designs and operating regimes. Here, this work introduces a comprehensive set of non-dimensional parameters to characterize heat pipe performance and safety, including capillary performance, effective thermal conductivity, response time, exergetic efficiency, allowable temperature gradients, allowable rate of temperature change, priming coefficients, and factor of safety. A reference heat pipe design representative of microreactor applications was analyzed via the developed parameters using both traditional analytical models and Sockeye simulations under transient and steady-state conditions. Sodium, potassium, and water were evaluated as working fluids to demonstrate the applicability of the framework across a broad temperature range. The proposed non-dimensional parameters effectively captured key thermal-hydraulic behaviors and safety concerns, as was demonstrated via Sockeye simulations. This framework supports the development of design optimization strategies, operational protocols, and safety assurance practices for advanced reactor systems and other high-reliability applications.

42 - ENGINEERING↗
DOE OSTI2024

Manufacturing of Continuous Core–Shell Hydrated Salt Fibers for Room Temperature Thermal Energy Storage

The encapsulation of salt hydrate phase change materials (PCMs) in uniform microscale bodies has yet been reported in research due in part to the delicate relationship between thermal performance and water-to-salt ratios which are easily altered during manufacturing. Herein, core–shell composite fibers comprised of a salt hydrate PCM core and a poly(acrylonitrile) (PAN) shell are wet spun in a continuous process using a syringe pump and coaxial die. The PCM phase comprises calcium chloride hexahydrate (CaCl 2 ·6H 2 O) with strontium chloride hexahydrate(SrCl 2 ·6H 2 O) (3 wt%) and fumed silica(SiO 2 ) (2 wt%) as additive, a composition that is prepared from homogenous melt at 40 °C. 15 wt% PAN in dimethylsulfoxide solvent is used to prepare the shell-forming polymer gel. PCM and polymer gel injection rates of 10–40 mL h –1 are used to spin coaxial fibers through a coagulation bath, yielding continuous microtubules with diameters in the range of 850–1500 μm. Cyclic testing shows that after 1000 cycles, melting enthalpies incurred only a 3.5% decline from 131.46 to 126.9 J g –1 . In conclusion, success here overcomes several coincidental drawbacks of PCM fiber performance and manufacturing and delivers the first example of scalable roll-to-roll PCM fiber produced by wet spinning for building material applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Experimental validation of a co-simulation architecture for modeling whole-building and detailed electrical distribution performance

This article presents an experimental validation of a co-simulation architecture for simultaneously modeling whole-building energy performance and detailed building electrical distribution system performance. The co-simulation architecture consists of a whole-building energy model (EnergyPlus®) embedded within a Modelica-based building electrical distribution system library called the Building Electrical Efficiency Analysis Model (BEEAM) using the Functional Mock-up Interface standard. We validate the model using experimental data collected at a full-scale test cell within Lawrence Berkeley National Laboratory’s FLEXLAB® facility. In conclusion, we show that the co-simulation model accurately predicts the electrical, mechanical, and thermal performance of the test cell for typical loads with both an AC and a DC electrical distribution topology.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Multi-scale and multi-physics analysis, design optimization, and experimental validation of heat exchangers utilizing high performance, non-round tubes

Air-to-refrigerant heat exchangers (HXs) are fundamental components in HVAC&R systems, and considerable research has been dedicated designing continually smaller, lighter, and more efficient HX designs. In recent years, researchers have leveraged advancements in Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), and optimization algorithms to consider primary tube shape and topology optimization to design highly compact, high performance HXs for a multitude of applications. In this research, we present a computationally efficient, comprehensive, multi-scale, and multi-physics analysis and optimization method for air-to-refrigerant HXs featuring automated CFD and FEA simulations and approximation-assisted optimization. This methodology was utilized to design HXs with shape-optimized, non-round tubes which outperform current state-of-the-art tube-fin HXs without compromising structural integrity. The optimal HXs were shown to deliver similar thermal performance to the baseline HXs while also achieving more than 20% reductions in airside pressure drop and core envelope volume and more than 30% reduction in internal volume. Comprehensive experimental validation of the optimization methodology was conducted through the testing of two prototypes in a standardized wind tunnel facility under multiple operating conditions. For prototype #1 under dry evaporator conditions, the predicted heat load agreed within ± 10% of measured values and the predicted airside pressure drop agreed within ± 30%, while for dehumidifying conditions, the predicted sensible and latent heat loads agreed within ± 10% and ± 20% of the measured values, respectively. For prototype #2, the predicted condenser heat load agreed within ± 3.0% of measured values, and the predicted airside pressure drop agreed within ± 27%. The acceptable agreement between simulation and experimental results for the present application highlights the flexibility of the novel optimization methodology to design next generation HXs with improved performance and reduced volume, weight, and environmental impact.

42 ENGINEERING↗
DOE OSTI2023

Effects of Part-to-Part Flow Variations on Overall Effectiveness and Life of Rotating Turbine Blades

Abstract As firing temperatures in gas turbine engines continue to increase to achieve high efficiencies, components in the main gas path must be protected with cooling flows to ensure lifing targets are met. Manufacturing variations, however, influence the performance and life characteristics of components with the same nominal design. This study presents blade flow and overall cooling effectiveness measurements for nine true-scale, aero engine turbine blades with realistic manufacturing variations. Flow measurements were made through each blade at a fixed pressure ratio to determine flow variability between holes and between blades. Infrared thermography was used to capture spatially-resolved temperature measurements reported as overall effectiveness on the same nine blades under high-speed rotating conditions at the Steady Thermal Aero Research Turbine Laboratory. Thermal performance was correlated with blade flow performance indicating substantial blade-to-blade variations resulting from manufacturing differences. Measurements also indicated wide variations in cooling jet trajectories as well as overall cooling effectiveness. Finally, the observed blade-to-blade variations in effectiveness were scaled to engine conditions with lifing estimates showing some blades would be expected to last only half as long as others due to manufacturing variability.

Engineering↗
DOE OSTI2021

Thermal and Mechanical Design of a High-Voltage Power Electronics Package

This paper presents the thermal and mechanical design aspects of a power electronics package with 5-kV GaN devices. Through finite element analyses, we investigated the impact of different cooling configurations and device locations on the thermal performance and reliability of the package. We found that placing the devices closer to the direct bond copper substrate as opposed to a centered approach in the proposed double-sided cooling configuration resulted in improved heat dissipation. This approach also reduced the total number of attachment layers, thereby likely improving the reliability of the package. Furthermore, simulations revealed that the device location had a negligible impact on the thermomechanical behavior of the attachment layers, as they are more prone to the local coefficient of thermal expansion mismatch.

electronic packaging↗