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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

“Green” Fabrication of High-performance Transparent Conducting Electrodes by Blade Coating and Photonic Curing on PET for Perovskite Solar Cells

This study presents an innovative material processing approach to fabricate transparent conducting electrodes (TCEs) on polyethylene terephthalate (PET) substrates using blade coating and photonic curing. The hybrid TCEs consist of a multiscale Ag network, combining silver metal bus lines and nanowires, overcoated by an indium zinc oxide layer, and then photonically cured. Blade coating ensures film uniformity and thickness control over large areas. Photonic curing, a non-thermal processing method with significantly lower carbon emissions, enhances the conductivity and transparency of the coated layers. Our hybrid TCEs achieve an average transmittance of (81 ± 0.4)% referenced to air ((90 ± 0.4)% referenced to the PET substrate) in the visible range, an average sheet resistance of (11 ± 0.5) Ω sq−1, and an average surface roughness of (4.3 ± 0.4) nm. We benchmark these values against commercial PET/TCE substrates. Mechanical durability tests demonstrate <3% change in resistance after 2000 bending cycles at a 1 in radius. The scalable potential of the hybrid TCE fabrication method is demonstrated by high uniformity and excellent properties in 7 in × 8 in large-area samples and by performing the photonic curing process at 11 m min−1. Furthermore, halide perovskite solar cells fabricated on these hybrid TCEs achieve average and champion power conversion efficiencies of (10.5 ± 1.0) % and 12.2%, respectively, and significantly outperform devices made on commercial PET/TCEs. This work showcases our approach as a viable pathway for high-speed “green” manufacturing of high-performance TCEs on PET substrates for flexible optoelectronic devices.

Bonner, Justin C↗
DOE OSTI2022

Semi-monolithic Integration of All-Chalcopyrite Multijunction Solar Conversion Devices via Thin-Film Bonding and Exfoliation

Here we report on a semi-monolithic integration method to circumvent processing incompatibility between materials of dissimilar classes and combine them into multijunction devices for photovoltaic and photoelectrochemical applications. Proof-of-concept all-chalcopyrite tandems were obtained by consecutive transfer of fully integrated unpatterned 1.85 eV CuGa 3 Se 5 and 1.13 eV CuInGaSe 2 PV stacks from their Mo/soda lime glass substrates onto a new single host substrate. This transfer approach consists of two key steps: (1) bonding of the solar stack (face down) onto a handle (e.g., SnO 2 :F, FTO) using a transparent conductive composite and (2) delamination of the solar stack at the chalcopyrite/Mo interface by employing a wedge-based exfoliation technique. Upon transfer onto FTO, a CuGa 3 Se 5 champion device demonstrated near-coincident photocurrent density-voltage characteristic with a baseline measurement. Then, the exfoliated CuGa 3 Se 5 single-junction stack transferred onto FTO served as the new host onto which a second fully processed CuInGaSe 2 stack was bonded (face down) onto and liberated from its Mo/SLG substrate, leading to a complete transfer of both sub-cells onto one FTO substrate. A champion semi-monolithic tandem device exhibited a power conversion efficiency of 5.04% with an open-circuit voltage, a short-circuit current density, and a fill factor of 1.24 V, 7.19 mA/cm 2 , and 56.7%, respectively. This first-time demonstration of a fully operational semi-monolithic device provides a new avenue to combine thermally, mechanically, and/or chemically incompatible thin-film material classes into tandem photovoltaic and photoelectrochemical devices while maintaining state-of-the-art sub-cell processing.

14 SOLAR ENERGY↗
DOE OSTI2023

High Performing Inverted Flexible Perovskite Solar Cells via Solution Phase Deposition of Yttrium-Doped SnO 2 Directly on Perovskite

Solution processing of flexible perovskite solar cells (f-PSCs) provides an avenue for scalable, high-throughput printing of lightweight, scalable, and cost-effective flexible solar cells. However, the deposition of fully solution-processed metal oxide charge transport layers on perovskites has been limited by solvent incompatibilities and high processing temperatures for metal oxide nanoparticles. In this study, we present high-performance, inverted f-PSCs from the direct deposition of yttrium doped SnO 2 nanoparticles functionalized with acetate on top of perovskite as an ink in anhydrous ethanol via blade coating. Yttrium doping improved device performance by improving the charge extraction leading with a decreased series resistance leading to improvements in the open-circuit voltage and fill factor. Furthermore, the champion power conversion efficiency for 0.1 cm 2 devices increased from 14.3% for undoped SnO 2 to 18.2% with 2% Y:SnO 2 doping, which is unprecedented for f-PSCs on ITO-PET substrate employing SnO 2 as an ETL.

14 SOLAR ENERGY↗
NASA NTRS2023

Assessing Flow Formability of Aerospace Aluminum Alloys via DIC Tensile Testing

Over the past decade, NASA Langley Research Center (LaRC) has championed integrally stiffened cylinder (ISC) technology for single-piece, cryogenic tank barrels on launch vehicles. The current investigation aims to extend the hybrid spin/shear/flow forming process to aircraft fuselage structures, a damage tolerance critical application. The WF Maschinenbau VUD-600® vertical spin/flow forming facility recently established at LaRC represents a reasonable sub-scale facsimile of the ISC deformation process for research and development (R&D) purposes. The objective of this study is to explore whether tensile testing with digital image correlation (DIC) is an effective way to rank the formability of candidate aerospace Al alloys and expedite empirical forming trials. Specific tensile data, such as reduction of area, strain hardening exponent, and modulus of resilience, are used as formability metrics for a variety of alloy/temper/product form combinations. Results from high-strength aluminum alloys AA 2139, AA 2050, AA 2043 and AA 2219 are compared with the medium-strength, highly formable AA 6061 benchmark. Rolled, forged and cast preform materials in both the -O temper (fully annealed) and -T4 temper (solution-treated, quenched, and naturally aged) conditions are evaluated. AA 2139 plate in the -T4 temper emerges as the top-ranked material, based on the criteria selected. Starting with preforms in the -T4 temper will result in flow-formed material exhibiting mechanical properties closer to aircraft fuselage requirements. The optimum balance between strength and damage tolerance may also be achieved via post-forming procedures that avoid quenching and stretching.

Aluminum alloys↗
DOE OSTI2024

Machine learning enhanced characterization and optimization of photonic cured MAPbI 3 for efficient perovskite solar cells

Photonic curing (PC) can facilitate high-speed perovskite solar cell (PSC) manufacturing because it uses high-intensity light pulses to crystallize perovskite films in milliseconds. However, optimizing PC conditions is challenging due to its many variables, and using power conversion efficiency (PCE) as the optimization metric is both time-consuming and labor-intensive. This work presents a machine learning (ML) approach to optimize PC conditions for fabricating methylammonium lead iodide (MAPbI 3 ) films by quantitatively comparing their ultraviolet-visible (UV-vis) absorbance spectra to thermal annealed (TA) films using four similarity metrics. We perform Bayesian optimization coupled with Gaussian process regression (BO-GP) to minimize the similarity metrics. Refining PC conditions using active learning based on BO-GP models, we achieve a PC MAPbI3 film with an absorbance spectrum closely matching a TA reference film, which is further verified by its crystalline and morphological properties. Thus, we demonstrate that the UV-vis absorption spectrum can accurately proxy film quality. Additionally, we use an AI-based segmentation model for a more efficient grain size analysis. However, when we use the optimized PC condition to fabricate PSCs, we find that interaction between MAPbI 3 and the hole transport layer (HTL) during PC critically degrades the PSC performance. By adding a buffer layer between the HTL and MAPbI 3 , the optimized PC PSCs produce a champion PCE of 11.8%, comparable to the TA reference of 11.7%. Using UV-vis similarity metrics instead of device PCE as the objective in our BO-GP method accelerates the optimization of PC processing conditions for MAPbI 3 films.

14 SOLAR ENERGY↗
NASA NTRS1993

Analysis of a successful inspection program

Litton Data Systems has institutionalized the inspection process, and achieved dramatic results in terms of defect prevention and cost savings thus far. Additionally, several findings have been gleaned from an analysis to optimize the process. Over 300 inspections have been performed over the last two years on many types of documents, and this paper describes some quantitative results to-date from the initial 'champion' project.

Madachy, Ray↗
DOE OSTI2026

Molecular Additive Engineering for Process-Humidity Robustness and Reproducible Fabrication of Perovskite Solar Cells and Modules

The commercialization of perovskite solar cells (PSCs) faces significant challenges due to their sensitivity to environmental humidity, which compromises film crystallization and device stability. Here, we introduce diphenylvinylphosphine (DPVP) as a Lewis base additive that enhances the performance and reproducibility of PSCs fabricated under ambient-air conditions. DPVP suppresses moisture-induced defect formation and stabilizes crystallization within realistic process-humidity ranges (20–40% relative humidity) commonly encountered in laboratory and pilot-scale manufacturing environments. It improves film uniformity, reduces trap densities, and yields highly reproducible device performance, enabling champion PCEs of 24.2% in small-area devices and 20.5% in blade-coated 12 cm 2 mini-modules. Furthermore, DPVP-assisted modules exhibit enhanced stability, retaining over 85% of their initial efficiency after 900 h of maximum power point tracking (MPPT) at 65 °C. This study demonstrates a humidity-resilient and scalable additive strategy for ambient-air perovskite photovoltaic manufacturing.

defect passivation↗
DOE OSTI2024

Generative AI for Power Grid Operations

Generative artificial intelligence (AI) has captured into the mainstream, demonstrating capabilities that once belonged solely to the realm of human cognition. From defeating world champions in complex games to generating human-quality text and images, Generative AI has proven its potential to revolutionize countless industries. The electric power grid is no exception. Generative AI's ability to process vast amounts of data rapidly, assist decision support and identify patterns could significantly enhance power grid operations. For example, Generative AI could improve state estimation where measurements are not available or integrate renewable energy sources more efficiently with probabilistic forecasting. The key contributions of this whitepaper are outlined below: (1) Comprehensive overview of Generative AI's applications in power grid operations: It highlights the opportunities in areas such as forecasting, state estimation, and demonstrating the potential for enhancing efficiency, reliability, and resilience. (2) Expanding Generative AI's impact through synergies with emerging technologies: The paper introduce NREL developed eGridGPT and explores how AI orchestration, multi-agent systems, and Digital Twins can collaborate to optimize grid operations, addressing the complexities of a decarbonized and electrified future. (3) In-depth analysis of challenges in implementing Generative AI: This includes considerations like data availability and quality, model validation, certification, and ethical concerns, ensuring responsible AI deployment. (4) Emphasizing human-AI collaboration: The whitepaper underscores the importance of trustworthy, transparency, and explainability in AI systems to promote seamless interaction between human operators and AI, ultimately improving decision-making. (5) Exploring future research and development: It identifies critical areas for further advancement to fully realize Generative AI's potential in power grid operations. This whitepaper serves as a valuable resource for researchers, practitioners, and policymakers looking to harness Generative AI for a more reliable, stable, and cost-effective power grid.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Rational Regulation of Layer‐by‐Layer Processed Active Layer via Trimer‐Induced Pre‐Swelling Strategy for Efficient and Robust Thick‐Film Organic Solar Cells

Thick-film (>300 nm) organic solar cells (OSCs) have garnered intensifying attention due to their compatibility with commercial roll-to-roll printing technology for the large-scale continuous fabrication process. However, due to the uncontrollable donor/acceptor (D/A) arrangement in thick-film condition, the restricted exciton splitting and severe carrier traps significantly impede the photovoltaic performance and operability. For this work, combined with layer-by-layer deposition technology, a twisted 3D star-shaped trimer (BTT-Out) is synthesized to develop a trimer-induced pre-swelling (TIP) strategy, where the BTT-Out is incorporated into the buried D18 donor layer to enable the fabrication of thick-film OSCs. The integrated approach characterizations reveal that the exceptional configuration and spontaneous self-organization behavior of BTT-Out trimer could pre-swell the D18 network to facilitate the acceptor's infiltration and accelerate the formation of D/A interfaces. This enhancement triggers the elevated polarons formation with amplified hole-transfer kinetics, which is essential for the augmented exciton splitting efficiency. Furthermore, the regulated swelling process can initiate the favorable self-assembly of L8-BO acceptors, which would ameliorate carrier transport channels and mitigate carrier traps. As a result, the TIP-modified thin-film OSC devices achieve the champion performance of 20.3% (thin-film) and 18.8% (thick-film) with upgraded stability, among one of the highest performances reported of thick-film OSCs.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Constraining Inputs to Realistic Kilonova Simulations through Comparison to Observed r -process Abundances

Kilonovae, one source of electromagnetic emission associated with neutron star mergers, are powered by the decay of radioactive isotopes in the neutron-rich merger ejecta. Models for kilonova emission consistent with the electromagnetic counterpart to GW170817 predict characteristic abundance patterns, determined by the relative balance of different types of material in the outflow. Assuming that the observed source is prototypical, this inferred abundance pattern in turn must match r -process abundances deduced by other means, such as what is observed in the solar system. We report on analysis comparing the input mass-weighted elemental compositions adopted in our radiative transfer simulations to the mass fractions of elements in the Sun, as a practical prototype for the potentially universal abundance signature from neutron star mergers. We characterize the extent to which our parameter inference results depend on our assumed composition for the dynamical and wind ejecta and examine how the new results compare to previous work. We find that a dynamical ejecta composition calculated using the FRDM2012 nuclear mass and FRLDM fission models with extremely neutron-rich ejecta ($Y_e$ = 0.035) along with moderately neutron-rich ($Y_e$ = 0.27) wind ejecta composition yields a wind-to-dynamical mass ratio of $M_w$/$M_d$ = 0.47, which best matches the observed AT2017gfo kilonova light curves while also producing the bestmatching abundance of neutron capture elements in the solar system, though, allowing for systematics, the ratio may be as high as of order unity.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1993

Integrated risk management

The purpose of this report is to first present a basis or foundation for the building of an integrated risk management plan and them to present the plan. The integration referred to is across both the temporal and the hierarchical dimensions. Complexity, consequence, and credibility seem to be driving the need for the consideration of risk. Reduction of personal bias and reproducibility of the decision making process seem to be driving the consideration of a formal risk plan. While risk can be used as either a selection tool or a control tool, this paper concentrates on the selection usage. Risk relies on stated purpose. The tightness of the definition of purpose and success is directly reflected in the definition and control of risk. Much of a risk management plan could be designed by the answers to the questions of why, what, who, when, and where. However, any plan must provide the following information about a threat or risk: likelihood, consequence, predictability, reliability, and reproducibility. While the environment at NASA is seen as warm, but not hot, for the introduction of a risk program, some encouragement is seen if the following problems are addressed: no champion, no commitment of resource, confused definitions, lack of direction and focus, a hard sell, NASA culture, many choices of assessment methods, and cost. The plan is designed to follow the normal method of doing work and is structured to follow either the work break down structure or a functional structure very well. The parts of the plan include: defining purpose and success, initial threat assessment, initial risk assessment, reconciling threats and parameters, putting part of the information down and factoring the information back into the decision process as it comes back up, and developing inferences. Two major suggestions are presented. One is to build an office of risk management to be used as a resource by managers in doing the risk process. Another is to form a pilot program to try out the details in the plan and modify the method where needed.

Hunsucker, J. L.↗
DOE OSTI2023

Oak Ridge National Laboratory Annual Sustainability Report 2023

ORNL, managed under contract by UT-Battelle LLC, is DOE’s largest science and energy laboratory and, as such, executes the widest range of mission capabilities. Diverse expertise spans a broad range of scientific and engineering disciplines, enabling research and science achievements to accelerate the delivery of solutions to the marketplace. ORNL supports DOE’s national missions of scientific discovery, clean energy, and security. To execute these activities, ORNL has grown significantly over 80 years of continuous operations, consisting of facilities with commissioning dates ranging from the 1940s to the present—an extraordinary set of distinctive scientific facilities and equipment. The complexities of such a variety of facilities require teamwork among divisions, a wide variety of conservation projects, and creative strategies to achieve the desired energy and water savings. Such a diverse and unique set of major facilities, totaling over 5.5 million square feet, with 6,000 employees, requires an innovative plan to accomplish advancements in operational efficiencies. ORNL is tasked with the management of an extraordinary set of distinctive scientific facilities and equipment for DOE. ORNL is mission-driven, and its mission has grown substantially over the decades. ORNL’s core research capabilities provide broad science and technology support for DOE in the areas of energy, environment, and national security. Currently, ORNL is a world leader in materials, neutron, and nuclear science and engineering, and in high-performance computing and data analytics. ORNL’s vast portfolio of research facilities must be maintained and carefully upgraded to protect the nation’s investment in scientific analysis. The goal of sustainable and resilient operations is to enable more effective execution of ORNL’s science and technology mission. Sustainable operational practices and enhanced resilience strive for excellent results while remaining diligent in energy conservation, environmental stewardship, asset management, and community engagement. The Sustainable ORNL Program (Sustainable ORNL) Continuous improvements in operational and business processes must be integrated into the fabric of the ORNL culture to maximize the return from the investment made in modernizing facilities and equipment. The Sustainable ORNL program promotes the legacy of system-wide best practices, management commitment, and employee engagement that will lead ORNL into a future of efficient, resilient, and sustainable operations. ORNL leadership and Sustainable ORNL champions receive regular status reports on the progress of each project and focus area (i.e., roadmap) and periodic summary reports. More information can be found at the program’s website. The Sustainable ORNL roadmap structure endorses 15 vital roadmaps. The figure below summarizes the current project assignments and demonstrates that each project contributes to the wellbeing of the whole. Continuous employee engagement and regular status reports confirm the ideals of the program. The roadmap structure is not static; as the science mission advances and the needs of the organization evolve, the Sustainable ORNL roadmap structure elements are modified to align with developing priorities. In 2022, Sustainable ORNL made roadmap changes to better align ORNL to support new federal requirements that have been issued.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2019

Aerojet Engineering Corporation: Stimulation and Creation, 1935-1942

There are multiple published accounts of the stimulation and creation of the Aerojet Engineering Corporation that are inconsistent, incomplete, or erroneous in significant details, describing principals involved, timing, and funding of the creation process. This paper corrects the record and offers a well-documented and reliable history of the creation of the Aerojet Engineering Corporation. A small group of academic researchers and technicians, joined by an attorney, working at the California Institute of Technology (Caltech), accomplished the formation and creation of the corporation. The group of six men incorporated and served as initial officers of the Aerojet Engineering Corporation—Dr. Theodore von Karman; Dr. Frank Malina; Dr. Martin Summerfield; John Parsons; Edward Forman; and a Washington, DC, attorney, Andrew Haley. A government-funded program definition study at Caltech generated a proposal to produce a means of providing superior aircraft performance capabilities using rocketry, often referred to as jet propulsion, due to engineering disrepute of “rocketry" prior to WWII. Caltech successfully conducted flight demonstrations at March Field (Riverside, California) in the summer of 1941, leading Drs. von Karman and Malina to discuss and explore the best method to provide for production of jet-assisted takeoff (JATO) rockets with established industrial leaders, as well as industrial organizational alternatives. Von Karman, Malina, Summerfield, Parsons, and Forman continued these discussions until von Karman decided, in early 1942, to solicit the legal advice of Andrew Haley on how to proceed. After meetings at von Karman's home in Pasadena, on Haley's recommendation and using his volunteered initial corporate funding, it was agreed to incorporate the group. Articles of incorporation were drawn up by Haley and on 19 March 1942 were formally filed with the Delaware Secretary of State, establishing the Aerojet Engineering Corporation. Many accounts previously published have distorted or misreported many of the details of the process followed by the group that created the company. It is intended that this paper will be regarded as a fully researched historical account of the creation of the Aerojet Engineering Corporation. Included are the historical environment, the industrial motivations, descriptions of key players, the role of government, and the ultimate confluence of these factors with the motivation of a champion and the availability of the required resources.

Doyle, Stephen E.↗
DOE OSTI2023

Revisiting Temporal Blocking Stencil Optimizations

Iterative stencils are used widely across the spectrum of High Performance Computing (HPC) applications. Many efforts have been put into optimizing stencil GPU kernels, given the prevalence of GPU-accelerated supercomputers. To improve the data locality, temporal blocking is an optimization that combines a batch of time steps to process them together. Under the observation that GPUs are evolving to resemble CPUs in some aspects, we revisit temporal blocking optimizations for GPUs. We explore how temporal blocking schemes can be adapted to the new features in the recent Nvidia GPUs, including large scratchpad memory, hardware prefetching, and device-wide synchronization. We propose a novel temporal blocking method, EBISU, which champions low device occupancy to drive aggressive deep temporal blocking on large tiles that are executed tile-by-tile. We compare EBISU with state-of-the-art temporal blocking libraries: STENCILGEN and AN5D. We also compare with state-of-the-art stencil auto-tuning tools that are equipped with temporal blocking optimizations: ARTEMIS and DRSTENCIL. Over a wide range of stencil benchmarks, EBISU achieves speedups up to 2.53x and a geometric mean speedup of 1.49x over the best state-of-the-art performance in each stencil benchmark.

Zhang, Lingqi↗
NASA NTRS2020

Dust from Mars-Analog Plains (Iceland): Physico-Compositional Properties as a Function of Grain-Size Fraction

Dust is a key component of the geological and climatic systems of Earth and Mars. On Mars, dust is ubiquitous. It coats rocks and soils, and, in the atmosphere, it interacts strongly with solar and thermal radiation. Yet, key questions remain about the genesis and fate of martian dust, as well as its sources, composition, and properties. We collected wind-blown dust from basaltic plains in SW Iceland at Skjaldbreiðauhraun that represent a geologic Mars-analog environment. Icelandic dust differs from the typical continental sources (e.g. Sahara, Asia) because of its basaltic volcanogenic origin, which is similar to Mars. Dust collection took place in July of 2019 as a complementary project to the SAND-E: Semi-Autonomous Navigation for Detrital Environments project. Here we report preliminary analyses of this Mars-analog dust material, with the goal of understanding the processes that control the physico-chemical proper-ties of the different grain-size fractions.

Nachon, Marion↗
NASA NTRS1991

Human life support during interplanetary travel and domicile. III - Mars expedition system trade study

Several alternative configurations of life-support systems (LSSs) for a Mars missions are compared analytically on a quantitative basis in terms of weight, volume, and power. A baseline technology set is utilized for the illustrations of systems including totally open loop, carbon dioxide removal only, partially closed loop, and totally closed loop. The analytical model takes advantage of a modular, top-down hierarchical breakdown of LSS subsystems into functional elements that represent individual processing technologies. The open-loop systems are not competitive in terms of weight for both long-duration orbiters and short-duration lander vehicles, and power demands are lowest with the open loop and highest with the closed loop. The closed-loop system can reduce vehicle weight by over 70,000 lbs and thereby overcome the power penalty of 1600 W; the closed-loop variety is championed as the preferred system for a Mars expedition.

Seshan, P. K.↗