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DOE OSTI2024

A Tandem Electrolysis Process for Multi-Carbon Chemical Production from Carbon Dioxide (Final Technical Report)

a two-step CO 2 electroreduction process for selective production of acetate and ethylene was successfully developed at the kW-scale. The CO 2 and CO electrolyzers were first investigated individually on the Watt-scale to achieve high current densities and more durable operation by using a reinforced GDL. High CO 2 conversion was obtained in the first CO 2 electrolyzer to produce a CO-dominant gas stream with minimal CO 2 , and highly pure acetate stream was produced in the second CO electrolyzer by using NiFe anode, which promoted alcohol oxidation to carboxylates. The two-step process operated stably for 200 h with acetate and ethylene as the major C 2+ products. Degradation mechanism study revealed that the flooding and the salt formation in the GDL is likely the biggest contributor to the performance degradation for both CO 2 and CO electrolyzers. A 1,000 cm 2 CO electrolyzer stack was then designed, fabricated, and operated up to a total current of 300 A along with a 500 cm 2 CO 2 electrolyzer stack which was operated up to a total current of 100 A. The CO electrolyzer stack demonstrated good stability at 300 A for at least 125 h at a carbon selectivity >96%. The impact of CO 2 , O 2 , N 2 , SO x , and NO x gas impurities on the CO electrolyzer stack was studied and a relatively high resistance to these contaminants was demonstrated. Electroreduction of CO 2 into acetic acid was also demonstrated to be environmentally favorable when compared to the traditional production of acetic acid when powered by renewable electricity. Additionally, electricity cost was identified as the primary source of cost sensitivity indicating substantial economic improvements could be achieved by continuing to drive down the cost of renewable electricity. Overall, the presented approach demonstrates the feasibility of the two-step electrochemical CO 2 reduction process for the effective production of C 2+ products at the kW-scale which should inspire future scaling efforts accelerating commercialization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Rapid Cycling ReBCO Dipole Magnet Concept for Muon Acceleraion

We present a concept of the rapid-cycling 1.7 T ReBCO magnet for 1 to 10 kT/s ramping range as required for muon acceleration in a future muon collider presently under study. This approach is based on the 6 kA CORC-like cable constructed with 12 superconducting ReBCO tapes of 2 mm width. Based on theoretical prediction there is a linear scaling of the ReBCO cable hysteresis loss with the crossing magnetic field possibly generating power loss independent of the magnetic field ramping speed. This feature makes this ReBCO cable suitable for the construction of rapid-cycling magnets. In this work we outline the design of a dipole magnet for 1.7 T gap magnetic field and discuss the helium coolant parameters for the minimal electric power.

Piekarz, Henryk [Fermilab] (ORCID:0000000194225662↗

DOE OSTI2025

Impacts of PV Module Connector Failures on Cost and Performance of Utility Scale Photovoltaic Systems

The reliability, cost and performance of electrical connectors are a concern in all types of electrical systems, and demands on connectors used on photovoltaic (PV) systems include that connectors maintain electrical conductivity and physical strength, endure ultraviolet sunlight and high ambient temperature, and resist moisture and chemical intrusion over a very long (>25 year) performance period. Connector failures increase operation and maintenance (O&M) costs and reduce plant production, but connector failure can also cause safety and liability problems, which are of greater concern. This work results from a three-year collaboration between Sandia National Laboratories (SNL), the Electric Power Research Institute (EPRI), and the National Renewable Energy Laboratory (NREL) and funded by the U.S. Department of Energy (DOE) Solar Energy Technology Office (SETO) under Agreements #39035 and #38531 "Connector Reliability Across the US Solar Sector." a multi-pronged investigation of PV connector health across the US (see https://energy.sandia.gov/pvconnectors/). This report presents derivation of a Techno-Economic Analysis (TEA) that models failure modes and frequencies (how often failure occurs), estimates O&M costs and lost production associated with connector failures, and then calculates the effect that PV module connectors can have on Levelized Cost of Energy (LCOE). The model is informed with initial data from quantitative assessment of failure rates, root causes and mechanisms, in-situ diagnostics and data collection, lab-based forensics, and interviews with PV connector manufacturers and plant operators. SNL conducted site inspections at multiple utility-scale sites in different climates and subjected field samples of new, used, and degraded connectors to visual and electrical characterization. EPRI conducted metallurgical analysis of the pin and sleeve conductors to study failure-induced morphological and compositional changes. There is in general a shortage of statistically valid data, but data from PVROM database maintained by SNL was sufficient to ascertain failure rates and lost production as well as provide qualitative insight in its curated maintenance records. This report details the structure of the mathematical model but the sources of data to inform the model will continue to evolve. Analysis of a 100 MW PV plant is provided as an example of the use of the model, with results indicating that connectors are responsible for Annualized O&M Costs of $\$$71,933/year; Annualized Unit O&M Costs of $\$$0.72/kW/year; that a Reserve Account of $\$$187,220 should be available to fund repairs related to connectors; that connectors add $\$$1,494,004 to the Net Present Value of the O&M Costs (project life); and that O&M related to connectors adds about $\$$0.00088/kWh to the Levelized Cost of Energy. The impact of this model is to provide a tool to make the US solar sector more robust by quantifying and monetizing the reliability risks to utility-scale PV systems posed by poorly installed, mismatched and/or poorly designed and manufactured connectors. The TEA provides a model incorporating failure statistics, O&M cost data, and lost production into a single figure of merit, informing decisions and enabling practitioners to optimize cost and performance trade-offs. Stakeholders include connector manufacturers, system designers and equipment specifiers, standards bodies, installers and O&M providers, investors and insurance underwriters. This report supports continued growth of PV predicated on assurances that properly installed and maintained PV system connectors are safe and reliable. The project team is proposing future work including accelerated testing of connectors and expanding the approach taken here to other PV system components, such as TEA for rapid shut-down devices.

14 SOLAR ENERGY↗

DOE OSTI2025

Tailoring composition and deformation modes at the microstructural level for next generation low-cost high-strength austenitic stainless steels

The objective of this project is to enable deliberate development of cost-effective, hydrogen resistant alloys by establishing detailed relationships specific to the effects of alloy composition, short-range order (SRO), and microsegregation in the presence of hydrogen on the transition between homogeneous deformation and localized plasticity in shear bands. In collaboration with the International Institute for Carbon-Neutral Energy Research, I2CNER, at Kyushu University in Japan, we conceptualized, designed, and manufactured four austenitic alloys that maintain corrosion resistance and ensure lower cost relative to baseline commercial alloys. The mechanical properties and deformation modes of the novel alloys (KU alloys) were assessed in the presence of hydrogen (H). Correlations between composition and performance revealed that two of the KU alloys are suitable replacements for 316 steel, while another is a viable replacement for 304 steel at room temperature. We found that, in the presence of other austenite stabilizing elements namely Mn and N, replacing Ni with Cu does not lead to martensite formation as has been previously reported.1–3 Furthermore, we found that the addition of Cu leads to an earlier onset of multiple slip resulting in an relative earlier onset of a higher work hardening rate (WHR). Greater understanding of the relationships between alloy composition and SRO required the development of a novel advanced electron diffraction methodology to characterize SRO in complex FCC alloys. This innovative approach, which combines fluctuation and correlation analyses of diffuse-scattering signals, successfully differentiated between SRO and long-range ordering (LRO). Further investigations into annealed austenitic stainless steels could provide insights into manipulating SRO and its effects on material properties. Atomistic simulations provided understanding of SRO behavior that was difficult to capture experimentally. This project created the first spin cluster expansion model that is able to capture and describe SRO effects in Fe-Ni-Cr FCC alloys, accounting for the non-negligible effects of magnetism. An automated computational workflow was established to provide reliable predictions of SRO in Fe-Ni-Cr austenitic alloys, both with and without the presence of H atoms. Analysis of the propensity for SRO in Fe-Ni-Cr alloys revealed that H tends to cluster with specific, well-defined SRO domains. The computational framework is general purpose and can be extended to realistic stainless steels across diverse composition ranges. With confidence that SRO is possible in austenitic stainless steels, we developed a discrete dislocation finite element code to understand the interaction of dislocations with SRO in the presence of H. By incorporating H effects on the dislocation emission and SRO stress field we show that the critical stress for the dislocation pileup to breakthrough the SRO domain decreases in the presence of H, which directly contributes localized deformation at the macroscale. Through the simulation of a uniaxial tension test, we demonstrated that H-induced weakening of SRO stress field and H-enhanced dislocation emission can lead to the onset of shear localization at lower macroscopic strains. As a whole, this project identified three novel alloys that show improvements in performance and cost efficiency for H-facing applications by studying correlations between alloy chemistry and deformation behavior. We also made significant advancements to experimental and computational methodologies necessary to study the chemistry and distribution of SRO across a range of alloys, which in turn allowed us to demonstrate how deformation mechanisms change due to the contributions of SRO in austenitic alloys in the presence of H. The combined advancements in fundamental understanding with novel alloy development in this project has increased the viability of next generation H-technologies for the broader public through accessible low-cost alloys and accelerated development towards future H-infrastructure.

08 HYDROGEN↗

DOE OSTI2023

An Overview of Challenges and Strategies for Stabilizing Zinc Anodes in Aqueous Rechargeable Zn-Ion Batteries

Aqueous rechargeable zinc ion batteries (ZIBs) have been revived and are considered a promising candidate for scalable electrochemical energy storage systems due to their intrinsic safety, low cost, large abundance, mature recyclability, competitive electrochemical performance, and sustainability. However, the deployment of aqueous rechargeable ZIBs is still hampered by the poor electrochemical stability and reversibility of Zn anodes, which is a common, inherent issue for most metal-based anodes. This review presents a comprehensive and timely overview of the challenges and strategies of Zn anodes toward durable ZIBs. First, several challenges that significantly reduce the Coulombic efficiency and cycling stability of Zn anodes are briefly discussed including dendrite formation, hydrogen evolution, and corrosion. Then, the mitigation strategies are summarized in terms of modifying the electrode/electrolyte interfaces, designing electrode structures, and optimizing electrolytes and separators. Further, we comprehensively discuss the mechanisms behind these issues and improvement strategies with respect to the anodes, electrolytes, and separators. Lastly, we provide perspectives and critical analyses of remaining challenges, outlook, and future direction for accelerating the practical application of aqueous rechargeable ZIBs.

25 ENERGY STORAGE↗

DOE OSTI2025

Rapid-cycling ReBCO dipole magnet concept for muon acceleration

Piekarz, Henryk [Fermilab] (ORCID:0000000194225662↗

DOE OSTI2026

Expert Elicitation for Tidal Energy Levelized Cost of Energy: Present and Future

In accordance with the Government Performance and Results Act (GPRA), H2O annually assesses marine energy technology development resulting from government-funded research and development programs and strategy. For GPRA reporting, H2O uses the levelized cost of energy (LCOE) - which represents the total system cost per unit of energy produced - to measure the progression of marine energy technology development, assess the impact of their research and development programs, and identify future research priorities. To support H2O's GPRA reporting requirements and inform future strategy, the National Laboratory of the Rockies conducted a tidal energy LCOE expert elicitation study to estimate present and future LCOE[AB2.1]. This report describes the motivation and background for the elicitation study, the methodology used to conduct the study, and the study results. It also provides future recommendations for accelerated tidal energy LCOE reduction based on feedback from study participants.

16 TIDAL AND WAVE POWER↗

NASA NTRS1992

Patterns of seismic activity preceding large earthquakes

A mechanical model of seismic faults is employed to investigate the seismic activities that occur prior to major events. The block-and-spring model dynamically generates a statistical distribution of smaller slipping events that precede large events, and the results satisfy the Gutenberg-Richter law. The scaling behavior during a loading cycle suggests small but systematic variations in space and time with maximum activity acceleration near the future epicenter. Activity patterns inferred from data on seismicity in California demonstrate a regional aspect; increased activity in certain areas are found to precede major earthquake events. One example is given regarding the Loma Prieta earthquake of 1989 which is located near a fault section associated with increased activity levels.

Shaw, Bruce E.↗

NASA NTRS1993

Microgravity vibration isolation technology: Development to demonstration

The low gravity environment provided by space flight has afforded the science community a unique area for the study of fundamental and technological sciences. However, the dynamic environment observed on space shuttle flights and predicted for Space Station Freedom has complicated the analysis of prior 'microgravity' experiments and prompted concern for the viability of proposed space experiments requiring long term, low gravity environments. Thus, isolation systems capable of providing significant improvements to this random environment have been developed. This dissertation deals with the design constraints imposed by acceleration sensitive, microgravity experiment payloads in the unique environment of space. A theoretical background for the inertial feedback and feedforward isolation of a payload was developed giving the basis for two experimental active inertial isolation systems developed for the demonstration of these advanced active isolation techniques. A prototype six degree of freedom digital active isolation system was designed and developed for the ground based testing of an actively isolated payload in three horizontal degrees of freedom. A second functionally equivalent system was built for the multi-dimensional testing of an active inertial isolation system in a reduced gravity environment during low gravity aircraft trajectories. These multi-input multi-output control systems are discussed in detail with estimates on acceleration noise floor performance as well as the actual performance acceleration data. The attenuation performance is also given for both systems demonstrating the advantages between inertial and non-inertial control of a payload for both the ground base environment and the low gravity aircraft acceleration environment. A future goal for this area of research is to validate the technical approaches developed to the 0.01 Hz regime by demonstrating a functional active inertial feedforward/feedback isolation system during orbital flight. A NASA IN-STEP flight experiment has been proposed to accomplish this goal, and the expected selection for the IN-STEP program has been set for Jul. of 1993.

Grodsinsky, Carlos M.↗

NASA NTRS1994

OARE flight maneuvers and calibration measurements on STS-58

The Orbital Acceleration Research Experiment (OARE), which has flown on STS-40, STS-50, and STS-58, contains a three axis accelerometer with a single, nonpendulous, electrostatically suspended proofmass which can resolve accelerations to the nano-g level. The experiment also contains a full calibration station to permit in situ bias and scale factor calibration. This on-orbit calibration capability eliminates the large uncertainty of ground-based calibrations encountered with accelerometers flown in the past on the orbiter, thus providing absolute acceleration measurement accuracy heretofore unachievable. This is the first time accelerometer scale factor measurements have been performed on orbit. A detailed analysis of the calibration process is given along with results of the calibration factors from the on-orbit OARE flight measurements on STS-58. In addition, the analysis of OARE flight maneuver data used to validate the scale factor measurements in the sensor's most sensitive range is also presented. Estimates on calibration uncertainties are discussed. This provides bounds on the STS-58 absolute acceleration measurements for future applications.

Blanchard, Robert C.↗

NASA NTRS1993

Benefits gained and lessons learned from NASA's Small Explorer (SMEX) Program

NASA's Small Explorer Program (SMEX) is a sustained program of scientific satellites limited in mass to 200-300 kg (depending on orbital inclination) for a 500-km circular orbit. The SMEX program was undertaken to obtain the benefits of scientific yield, short development time, and high flight rate, with the goal to launch a mission every year. NASA also uses the program to train engineers and managers in designing and developing spacecraft. The phases of a SMEX mission life cycle are described including the competitive selection of missions through announcement of opportunity and evaluation of proposals, the definition of mission and system requirements, design and development of the spacecraft, testing, launch, and operations. Program content of some SMEX missions is then reviewed. The first SMEX mission was the Solar, Anomalous, and Magnetospheric Particle Explorer, which confirmed that anomalous cosmic rays are only partially ionized atoms. The Fast Auroral Snapshot Explorer was intended to measure the electric, magnetic, and time-variable fields and to record particle flow in the auroral acceleration region. A future mission is the Submillimeter Wave Astronomy Satellite to examine low-level molecular transitions.

Gilman, David↗

NASA NTRS1995

Orbital Acceleration Research Experiment: Calibration Measurements

The Orbital Acceleration Research Experiment (OARE), which has flown on STS-40, STS-50, and STS-58, contains a three-axis accelerometer with a single, nonpendulous, electrostatically suspended proofmass, which can resolve accelerations to the 10(sub -9) g level. The experiment also contains a full calibration station to permit in situ bias and scale-factor calibration. This on-orbit calibration capability eliminates the large uncertainty of ground-based calibrations encountered with accelerometers flown in the past on the Orbiter, and thus provides absolute acceleration measurement accuracy heretofore unachievable. This is the first time accelerometer scale-factor measurements have been performed on orbit. A detailed analysis of the calibration process is given, along with results of the calibration factors from the on-orbit OARE flight measurements on STS-58. In addition, the analysis of OARE flight-maneuver data used to validate the scale-factor measurements in the sensor's most sensitive range are also presented. Estimates on calibration uncertainties are discussed. These uncertainty estimates provides bounds on the STS-58 absolute acceleration measurements for future applications.

Blanchard, Robert C.↗

NASA NTRSDate not supplied

GeneLab: Current and Future Omics Data Integration Between Space Biology and HRP

For the past five years, the Biological and Physical Sciences Division has pioneered Open Science in Space Biology by funding the NASA GeneLab project. Along with the Ames Life Sciences Data Archive, GeneLab has quickly become the world leader in archiving and scientifically curating spaceflight and spaceflight relevant multi-omics data. Specifically, the GeneLab Data System has become a full enterprise solution providing advanced mining capabilities, several application programming interfaces for data federation and machine learning approaches, and delivering to the world an analytical and visualization platform which has enabled collaboration within the scientific community. Over the past three years, large meta-analysis and modeling studies have been published by the GeneLab Analysis Working Groups (AWGs), which are comprised of ~200 volunteer scientists. One natural extension of GeneLab data reuse has recently turned towards linking animal data with human data, which is the next necessary step to further validate animal models for inferring biological risks to humans conducting LEO, lunar or Martian missions. As such, data from the Human Research Program are an essential component of GeneLab and ALSDA. At the moment, simulated space radiation experiments conducted at Brookhaven National Laboratory make the most of HRP GeneLab data, and the scientific community has been eager to also link their animal spaceflight results to actual Astronaut data and human analog data. We will discuss further the current status of knowledge and future approaches to accelerate our basics understanding of the impact of space stressors on humans using latest omics technology.

omics↗

NASA NTRSDate not supplied

Initial Exploratory Study of the Impacts of Climate Change on Air Traffic Operations

Climate change is already happening and is projected to accelerate in the future. It will persist for the foreseeable future, even with optimistic projections of technological advances and behavior changes. It will make aviation more and more challenging over time. Among other things, it is expected to cause increased severe weather, more extreme temperatures, and rising sea levels that constrain when, where, and how aircraft can fly. NASA has many prior, ongoing, and upcoming efforts towards mitigating the impacts of aviation on climate change. There is also a need to perform a comprehensive investigation of the reverse: that is, the impacts of climate change on aviation. This is an initial exploratory study on this topic utilizing the NAS Digital Twin—composed of the ATM TestBed simulation platform and NAS Digital Twin airspace management algorithms—to run NAS-wide simulations with Convective Weather Avoidance Model polygons at different avoidance thresholds to emulate the increase in severe weather that could manifest due to climate change. It was found that air traffic management may be able to limit the impact of climate change in terms of delay and fuel burn. However, increased severe weather due to climate change can make separation—particularly, aircraft-to-weather separation—more challenging by reducing available airspace and constraining the solution space. Challenging situations were identified and corresponding potential solutions were proposed towards ensuring air traffic operations continue to be robust and resilient to the impacts of increased severe weather due to climate change.

climate change, weather, air traffic operations↗

DOE OSTI2019

Experimental Demonstration of the Henon-Heiles Quasi-Integrable System at IOTA

IOTA is a research electron and proton storage ring recently commissioned at Fermilab to test novel techniques for improving bea m stability and quality, notably the concept of non -linear integrable optics . We present the first results of experimental investigation of a quasi -integrable system with one invariant of motion, a Henon Henon-Heiles type system implemented with octupole magnets . Good agreement with simulations is demonstrated on key parameters of achievable tune spread and dynamic aperture preservation . Resilience to perturbations and imperfections in the lattice is shown. We also outline research plans and discuss applicability to future high intensity accelerators.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2024

Evaluating Emerging AI/ML Accelerators: IPU, RDU, and and NVIDIA/AMD GPUs

As the size and complexity of AI/ML workloads continue to increase, the demand for specialized hardware accelerators has grown rapidly. To better understand the landscape of commercial AI/ML accelerators, we evaluate and compare several popular platforms, including Graphcore IPU, Sambanova RDU, and GPUs, on a range of AI workloads. Our research aims to help researchers and developers understand the unique features of commercial AI/ML accelerators and provide reference design and performance numbers for research prototypes. By shedding light on the current landscape of commercial AI/ML accelerators, we hope to offer insights into the future development of specialized hardware accelerators for AI/ML.

Peng, Hongwu↗

DOE OSTI2020

Southeast Regional CO 2 Utilization and Storage Acceleration Partnership (SECARB-USA): A Sub-Basin Framework for Future CO 2 Infrastructure Development (Task 4.1.a)

The “Southeast Regional CO 2 Utilization and Storage Acceleration Partnership” (SECARB-USA) project supports the U.S. Department of Energy (DOE) Office of Fossil Energy's (FE) mission to help the United States meet its need for secure, affordable, and environmentally sound fossil energy supplies by utilizing the advancements made since 2003 by the Regional Carbon Sequestration Partnership (RCSP) Initiative to continue to identify and address knowledge gaps. The SECARB-USA regional initiative encompasses the states of Alabama, Arkansas, Florida, Georgia, Louisiana, Mississippi, North Carolina, South Carolina, Tennessee, Virginia, and portions of Kentucky, Missouri, Oklahoma, Texas, and West Virginia as noted in Figure 1.1. The primary objective of the project is to identify and address regional onshore storage and transport challenges facing commercial deployment of carbon dioxide (CO 2 ) capture, utilization, and storage (CCUS) technologies.

42 ENGINEERING↗

DOE OSTI2025

Fermilab's controls development with virtual accelerator

Control Systems development is often the last thing considered when designing and building new equipment, e.g. a new detector or superconducting RF LINAC; however when the new equipment is installed, it is the first thing desired to be operational for testing. Due to frequent delays in building new equipment and project deadlines, control system development and testing is often curtailed. A way to alleviate this problem is to simulate the control system, though this will be challenging for complex systems.The Fermilab PIP-II (proton improvement plan - II) project is being constructed at Fermilab to deliver $800\,MeV$ protons of $>1\,MW$ beam power to replace the present LINAC for the remainder of the existing accelerator complex. The new LINAC consists of a warm front end (WFE), 23 superconducting RF cryomodules (of 5 types), and a beam transfer line (BTL) to the existing complex.The accelerator physics group has a parallel project to create a digital twin (DT) of the PIP-II accelerator. We have coupled the EPICS controls to this DT and are developing both the DT and EPICS software in parallel. This will allow us to develop the EPICS software framework, the HMIs, sequences, high level physics applications, and other services for use in a fully functional control system.This presentation will detail the work that we have performed to date and show demonstrations of controlling and monitoring the status of the accelerator, as well as future plans for this work.

Hanlet, Pierrick [Fermilab]↗