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DOE OSTI2022

Integration of Superconducting Magnetic Energy Storage (SMES) Systems Optimized with Second-Generation, High-Temperature Superconducting (2G-HTS) Technology with a Major Fossil-Fueled Asset

Utility companies and fossil fueled generation assets are seeking combinations of “hybrid energy storage” to allow power to be provided in advance of, and to otherwise complement, peaking natural gas-fired generation. American Maglev Technology of Florida Inc. (AMT) learned during the Phase I program based on interactions with NRG Energy (NRG) that energy storage such as superconducting magnetic energy storage (SMES) can qualify as a Black Start unit in most markets, ensuring orderly re-start of grid operations and fossil fueled power plants and serving as an important asset of hybrid energy storage technology. In conjunction with the University of Houston (UH), AMT and NRG are working together to scale up low-cost, high- efficiency, second-generation high-temperature superconducting (2G-HTS) technology for deployment across several markets, with a primary focus on the commercial development of utility grid-scale SMES (g-SMES) systems. Ultimately the program confirmed that the novel g-SMES design can meet the performance and financial requirements of the fossil power plant industry, while exhibiting continuous grid-voltage regulation; cost-effective, peak-hour energy storage with almost infinite life; increased input/output efficiency; and the capability to undergo millions of charging cycles, without degradation, representing a significant improvement over lithium ion and other conventional storage technologies. We believe wide scale deployment of this technology is feasible and practical when compared to the higher life cycle cost and relatively short lifespan of chemical batteries. Based on these findings, the future for deployment of SMES at many fossil-fueled power plants exceeding 100MW capability is bright. Further de-risking g-SMES technology would pave the way for the construction of a subscale prototype. Eventually, scaled-down versions of SMES are expected to be competitive with the multi-billion-dollar lithium-ion market for a wide range of commercial, industrial, and transportation uses. There is long-term potential for commercialization and widespread deployment of this disruptive technology, which would spawn a new worldwide supply chain and create domestic, high-tech manufacturing jobs in the green industry.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Exploring the future energy-mobility nexus: The transportation energy & mobility pathway options (TEMPO) model

Not Available

Muratori, Matteo↗

DOE OSTI2021

The Transportation Energy and Mobility Pathway Options (TEMPO) Model: Overview and Validation of V1.0 [Slides]

This presentation documents the approaches and methods used in the Transportation Energy & Mobility Pathway Options™ (TEMPO) model to evaluate passenger and freight demand for transportation and mobility services, project vehicle ownership and technology adoption decisions, and determine transport mode choices to derive scenarios of future energy use and emissions. TEMPO is an all-inclusive transportation demand model that covers the entire United States, with an implicit spatial resolution and an hourly temporal resolution that allows for generating time-resolved energy use profiles to assess multisectoral integration aspects. Key features of the TEMPO model include the ability to perform endogenous out-of-sample forecasting to extrapolate recent emerging trends and analyze impacts of disruptive technological breakthroughs and behavioral changes. TEMPO employs an innovative representation of passenger mobility demand stemming from household-level decisions that determine vehicle adoption, ownership, and use based on sociodemographics (e.g., income, household composition), technology attributes (e.g., travel cost, time), geography (e.g., urban, suburban, rural) and population-specific multiday mobility and travel requirements. This representation enables a more forward-looking perspective on the use of new mobility options and the adoption of alternative fuel vehicles, as well as a more accurate representation of their energy usage profiles than previous modeling approaches. A comparison with the U.S. Energy Information Administration’s Annual Energy Outlook showcases the ability of TEMPO to accurately replicate widely accepted projections by representing the key elements of the entire transportation sector at the appropriate level of resolution. TEMPO is intended to generate future scenarios of technology adoption, energy use, and emissions in the transportation sector to compare alternatives, inform decision makers, and assess integration with energy infrastructure and supply systems at an appropriate spatiotemporal resolution.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Developing Technology Performance Level Assessments for Early-Stage Wave Energy Converter Technologies: Preprint

The advantage of using Technology Performance Level (TPL) in conjunction with Technology Readiness Level (TRL) assessments in guiding technology development trajectories to successful outcomes in less time, at less overall cost, and with less encountered risk has been well articulated in the literature. In partnership with industry and international collaborators, a TPL assessment methodology for grid-connected applications has been developed through the application of the systems engineering approach. Metrics under seven different categories have been developed, weighted based on their relative relevance, and combined to yield a composite score. The methodology has been implemented in a spreadsheet tool plus a web application specifically aimed at assessing early stage (TRL 1-3) concepts. The target use cases are (a) technology developers improving their design, to find fatal flaws early, to get feedback on current design, to identify areas of improvement that will yield the highest return on investment, (b) reviewers assessing technologies in competitions or for making funding decisions, (c) investor or project developer doing due diligence, (d) policy makers landscaping the technology domain for formulating R&D strategy. The methodology and the tools are undergoing continuous improvement based on the experience and lessons learnt from applying it to internal and external marine energy technology development projects. The methodology is also being adapted for assessing WECs servicing markets outside the continental grid - broadly categorized as Powering the Blue Economy (PBE) applications. Such applications have vastly different functional requirements entailing a modification of the methodology to account for their higher risk tolerance, reduced price sensitivities, lower power needs, different permitting protocols, etc. This paper presents the latest status of the TPL assessment methodology and tools, describes its adaptation to select PBE markets, and explores its extension to other domains where it could provide a comprehensive and holistic measure of a nascent or disruptive technology's technoeconomic performance potential.

metrics↗

DOE OSTI2021

Developing Technology Performance Level Assessments for Early-Stage Wave Energy Converter Technologies

metrics↗

DOE OSTI2023

Nanocrystal‐Enabled Perovskite Heterojunctions in Photovoltaic Applications and Beyond

Abstract Heterojunctions are used to tailor the properties of semiconductors in optoelectronic devices, yet for emerging devices composed of metal halide perovskites, fabricating perovskite/perovskite heterojunctions has proved challenging due to solvent incompatibilities and rapid homogenization due to ion migration. Recent studies have demonstrated various strategies for using perovskite nanocrystals as a component to fabricate perovskite/perovskite heterojunctions, either with a perovskite thin film or a second nanocrystal layer. Heterojunctions such as these can impart many advantages of both bulk and nanocrystalline perovskite morphologies. This perspective focuses on recent developments of solution‐processed perovskite heterojunctions for solar cells and novel optoelectronic devices, in particular, highlighting the demonstrated and potential advantages of nanocrystal‐enabled fabrication strategies. A central tenet of this perspective is that the synthesis and dispersion of perovskite nanocrystals in non‐polar organic solvents offers a key processing advantage over traditional perovskite precursor solutions in polar solvents since the former allows for layer‐by‐layer deposition without dissolving an underlying perovskite film or crystal. This processing advantage, coupled with nanocrystal size control and ligand chemistry, enables perovskite heterojunctions with highly tunable optical and electrical properties. Such heterojunctions may enable disruptive technological advances in broad classes of devices such as solar cells, photodetectors, sensors, and (in)coherent photon sources with tunable polarization.

14 SOLAR ENERGY↗

DOE OSTI2022

Multilayered Network Models for Security: Enhancing System Security Engineering with Orchestration

Security engineering approaches can often focus on a particular domain—physical security, cyber security, or personnel security, for example. Yet, security systems engineering consistently faces challenges requiring socio-technical solutions to address evolving and dynamic complexity. While some drivers of this complexity stem from complex risk environments, innovative adversaries, and disruptive technologies, other drivers are endogenous and emerge from the interactions across security engineering approaches. In response, INCOSE's Systems Security Working Group identified the need to better coordinate “disparate security solutions [that] operate independently” as one of eleven key concepts in their IS21 FuSE Security Roadmap. From this perspective, this need for “security orchestration” aligns with the perspective that security is a property that emerges from interactions within complex systems. Current efforts at Sandia National Laboratories are developing a systems security engineering approach that describes high consequence facility (HCF) security as a multidomain set of interacting layers. The result is a multilayered network (MLN)-based approach that captures the interactions between infrastructure, physical components, digital components, and humans in nuclear security systems. This article will summarize the MLN-based approach to HCF security and describe two preliminary results demonstrating potential benefits from incorporating interactions across disparate security solutions. Here, leveraging the logical structure of networks, this MLN model-based approach provides an example of how security orchestration provides enhanced systems security engineering solutions.

42 ENGINEERING↗

DOE OSTI2023

Enhancing Early Systems R&D Capabilities with Systems —Theoretic Process Analysis

Systems engineering today faces a wide array of challenges, ranging from new operational environments to disruptive technological — necessitating approaches to improve research and development (R&D) efforts. Yet, emphasizing the Aristotelian argument that the “whole is greater than the sum of its parts” seems to offer a conceptual foundation creating new R&D solutions. Invoking systems theoretic concepts of emergence and hierarchy and analytic characteristics of traceability, rigor, and comprehensiveness is potentially beneficial for guiding R&D strategy and development to bridge the gap between theoretical problem spaces and engineering-based solutions. In response, this article describes systems–theoretic process analysis (STPA) as an example of one such approach to aid in early-systems R&D discussions. STPA—a ‘top-down’ process that abstracts real complex system operations into hierarchical control structures, functional control loops, and control actions—uses control loop logic to analyze how control actions (designed for desired system behaviors) may become violated and drive the complex system toward states of higher risk. By analyzing how needed controls are not provided (or out of sequence or stopped too soon) and unneeded controls are provided (or engaged too long), STPA can help early-system R&D discussions by exploring how requirements and desired actions interact to either mitigate or potentially increase states of risk that can lead to unacceptable losses. This article will demonstrate STPA's benefit for early-system R&D strategy and development discussion by describing such diverse use cases as cyber security, nuclear fuel transportation, and US electric grid performance. Together, the traceability, rigor, and comprehensiveness of STPA serve as useful tools for improving R&D strategy and development discussions. In conclusion, leveraging STPA as well as related systems engineering techniques can be helpful in early R&D planning and strategy development to better triangulate deeper theoretical meaning or evaluate empirical results to better inform systems engineering solutions.

42 ENGINEERING↗

DOE OSTI2024

Metal Oxide vs Organic Semiconductor Charge Extraction Layers for Halide Perovskite Indoor Photovoltaics

Halide perovskite indoor photovoltaics (PVs) are highly promising to autonomously power the billions of microelectronic sensors in the emerging and disruptive technology of the Internet of Things (IoT). However, how the wide range of different types of hole extraction layers (HELs) impacts the indoor light harvesting of perovskite solar cells is still elusive, which hinders the material selection and industrial–scale fabrication of indoor perovskite photovoltaics. In the present study, new insights are provided regarding the judicial selection of HELs at the buried interface of halide perovskite indoor photovoltaics. This study unravels the detrimental and severe light–soaking effect of metal oxide transport layer–based PV devices under the indoor lighting effect for the first time, which then necessitates the interface passivation/engineering for their reliant performance. This is not a stringent criterion under 1 sun illumination. By systematically investigating the charge carrier dynamics and sequence of measurements from dark, light–soaked, interlayer–passivated device, the bulk and interface defects are decoupled and reveal the gradual defect passivation from shallow to deep level traps. Thus, the present study puts forward a useful design strategy to overcome the deleterious effect of metal oxide HELs and employ them in halide perovskite indoor PVs.

14 SOLAR ENERGY↗

DOE OSTI2020

An in-situ crosslinking binder for binder jet additive manufacturing

Additive Manufacturing (AM) of metals is a potentially disruptive technology that could significantly change the industrial supply chain. There are a limited number of AM methods capable of creating metal parts, and one method showing significant potential is Binder Jet AM (Binder Jetting). Binder Jetting utilizes an inkjet print head to deposit a binder fluid onto a powder bed and bind together powder particles into a desired geometry. This study investigates a new binder system consisting of a difunctional monomer, triethylene glycol dimethacrylate (TEG-DMA). TEG-DMA exhibits excellent printability with an Ohnesorge’s number of .258 making the Z number 3.876. During the thermal curing process, the difunctional monomer polymerizes and crosslinks at the onset temperature of 138 °C, becoming a solid dimethacrylate network. When the binder is utilized within the stainless-steel powder bed at 200 °C, it forms a network incorporating the stainless-steel particles, binding the powder into any specified geometry. Crosslinking the monomer within the stainless-steel 420 powder bed imparts a flexural strength of 1.0–3.3 MPa to the green part depending on the volume of monomer in the part. After sintering, the final stainless-steel parts results in a void fraction close to 60 % and carbon content below 0.4 %.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Defects and anomalies in powder bed fusion metal additive manufacturing

Metal additive manufacturing is a disruptive technology that is revolutionizing the manufacturing industry. Despite its unrivaled capability for directly fabricating metal parts with complex geometries, the wide realization of the technology is currently limited by microstructural defects and anomalies, which could significantly degrade the structural integrity and service performance of the product. Accurate detection, characterization, and prediction of these defects and anomalies have an important and immediate impact in manufacturing fully-dense and defect-free builds. As such, this review seeks to elucidate common defects/anomalies and their formation mechanisms in powder bed fusion additive manufacturing processes. They could arise from raw materials, processing conditions, and post-processing. While defects/anomalies in laser welding have been studied extensively, their formation and evolution remain unclear. Additionally, the existence of powder in powder bed fusion techniques may generate new types of defects, e.g., porosity transferring from powder to builds. Practical strategies to mitigate defects are also addressed through fundamental understanding of their formation. Such explorations enable the validation and calibration of models and ease the process qualification without costly trial-and-error experimentation.

42 ENGINEERING↗

DOE OSTI2024

Generation and control of nonlocal chiral currents in graphene superlattices by orbital Hall effect

Graphene-based superlattices offer a unique materials playground to exploit and control a higher number of electronic degrees of freedom, such as charge, spin, or valley for disruptive technologies. Recently, orbital effects, emerging in multivalley band structures lacking inversion symmetry, have been discussed as possible mechanisms for developing . Here, we report nonlocal transport measurements in small gap hBN/graphene/hBN moiré superlattices which reveal very strong magnetic field-induced chiral response which is stable up to sizable temperatures. The measured sign dependence of the nonlocal signal with respect to the magnetic field orientation clearly indicates the manifestation of emerging orbital magnetic moments. The interpretation of experimental data is well supported by numerical simulations, and the reported phenomenon stands as a formidable way of manipulation of the transverse flow of orbital information that could enable the design of orbitronic devices. Published by the American Physical Society 2024

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2025

Crash–and–dash: a new era in tree genome editing

In less than a decade since the first demonstrations of CRISPR genome editing of agronomic genes in several tree species (Zhou et al., 2015; Jia et al., 2016; Ren et al., 2016), this disruptive technology has been deployed for a growing number of traits in both basic and applied research. The precision and efficiency of CRISPR editing allow for the recovery of null mutants in the first generation (Zhou et al., 2015; Elorriaga et al., 2018; Muhr et al., 2018), which is a significant benefit for perennial trees with long generation times. The stability of editing outcomes over multiple years or clonal propagation cycles (Bewg et al., 2022; Chen et al., 2023; Goralogia et al., 2024) is another key advantage since most woody perennials are vegetatively propagated in commercial operations. However, in many countries, gene-edited trees with stably integrated T-DNA face the same regulatory hurdles as traditional transgenics, slowing field trial characterization and the integration of transgenesis with conventional breeding (Boerjan & Strauss, 2024). In an article recently published in New Phytologist, Hoengenaert et al. (2025; doi: 10.1111/nph.20415) demonstrate transgene-free editing in poplar (Populus tremula × alba) that shows promise for wide adoption. The CRISPR-edited, transgene-free canker-resistant citrus (Citrus sinensis) trees (Su et al., 2023) have recently been approved by USDA-APHIS and are exempt from regulation by the US Environmental Protection Agency (EPA) for commercial production. The work by Hoengenaert et al. (2025) suggests a similar path could be followed for purpose-grown plantations for bioenergy, bioproducts, and biomaterials.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

IoT Devices and Applications for Wire-Based Hybrid Manufacturing Machine Tools

Hybrid manufacturing machine tools have the potential to be a disruptive technology as they can leverage the benefits of both additive and subtractive manufacturing by incorporating both processes on the same machine while limiting the downsides of the individual processes. Since these machines use two very disparate manufacturing processes and hybrid manufacturing is an emerging technology, it will be useful to monitor data coming from the machine and apply it to improve the manufacturing process, the operation of the machine, and to integrate the machine into the larger digital framework of Industrial Internet of Things (IoT). The present work discusses IoT devices that would be beneficial to add to a hybrid machine tool as well as applications for those devices. The proposed methods discussed in this work have not been experimentally implemented on a hybrid machine tool and so there are no performance data available yet. The hybrid machine tool used as a basis to generate these IoT applications is the Mazak VC-500A/5x AM Hot Wire Deposition, which is a 5-axis machine tool incorporated with a wire feedstock 4kW laser deposition system. Methodologies and applications will be outlined for machine health and process monitoring. Other areas covered include process benchmarking, secure networking options for the proposed IoT framework, and hybrid process improvement. Limitations of these methods and future work for new sensor devices and application areas is also discussed.

Thien, Austen↗

DOE OSTI2025

Establishing model credibility for process-microstructure-property relationships in additive manufacturing using exascale computing

Additive Manufacturing (AM) of alloys holds significant promise as a disruptive technology in various industries, yet its adoption is often hindered by challenges in achieving consistent part quality. These issues are primarily due to the complex process-microstructure-property (PSP) relationships inherent to AM. Computational models can greatly aid in understanding these relationships, but their widespread impact and adoption has been limited by a lack of validated, open-source, and computationally efficient PSP modeling frameworks and hardware limitations. Here, this study leverages the ExaAM software suite and data from the AMBench-2018 series of laser powder bed fusion (LPBF) benchmark experiments to perform a comprehensive model assessment, including verification, validation, sensitivity analysis, and uncertainty quantification. The RADICAL-EnTK workflow manager was used to perform an ensemble of heat transport, solidification, and mechanical response simulations on the exascale computer Frontier, considering uncertainties in critical model inputs such as laser spot size and nucleation parameters, and consisting of 125 explicit grain structure simulations and 7875 crystal plasticity simulations. For a selected location within the Inconel 625 AMBench-2018 test artifact, sensitivity analysis and uncertainty quantification were performed using the predicted distributions of grain structure and mechanical properties. Qualitative agreement was found between the predicted grain size and texture and the observed AMBench-2018 microstructure, the mean predicted yield stress was within 5% of the experimental measurement mean, and the mean predicted engineering stress at 5% strain was within 10% of the experimental measurement mean. The insights gained from development and validation of the ExaAM PSP modeling framework will help guide future directions for enhancing the credibility and reliability of PSP models in AM, thereby accelerating the adoption of AM technologies in various industries.

Additive manufacturing↗

DOE OSTI2021

Advancing lightweight mirror design: a paradigm shift in mirror preforms by utilizing design for additive manufacturing

Additive manufacturing is a disruptive technology that can be leveraged by the redesign of components in most engineering fields. Fundamental engineering resources for lightweight mirrors were developed more than 30 years ago with a main design limitation, state of the art manufacturing. In this study, we present two design methodologies for the design of lightweight mirrors. The first method utilizes analytical expressions to design a traditional isogrid mirror, which provided the foundation for most lightweight mirrors to date. The second method employs a combination of topology optimization, lattice infill, and analytical estimation to develop an advanced lightweight mirror designed for additive manufacturing. The advanced mirror design outperforms the traditional design for each functional requirement, including a 94% reduction in predicted surface quilting and a higher specific stiffness. The manufacturing of the advanced mirror is only possible with an additive manufacturing process.

36 MATERIALS SCIENCE↗

DOE OSTI2020

The Automated Mobility District Implementation Catalog: Insights from Ten Early-Stage Deployments

Major disruptive technologies are set to redefine the way in which people view travel, particularly in dense urban areas. Already, ride-hailing services have redefined mobility expectations of a new generation of urban dwellers in some places around the country. Over the next few decades, the proliferation of autonomous vehicles, which are generally referred to in the industry as “automated vehicles (AVs),” will be enhanced by the next generation of shared mobility. This combination of AV operations with on-demand service will provide convenience of mobility similar to that being exhibited in today’s transportation networking companies (TNCs). Shared, automated, public mobility resulting from the cross-hybridization of AVs with on-demand mobility service will bring economic and system efficiencies. Economic efficiencies may be realized by less vehicle ownership and more vehicle “usership.” Many companies are already exploring avenues for shared automated mobility through fleet operations as the wave of the future.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Situational Awareness of Grid Anomalies (SAGA) for Visual Analytics—Near-Real-Time Cyber-Physical Resiliency Through Machine Learning

The Situational Awareness of Grid Anomalies (SAGA) project built upon foundational power system tools developed at the National Renewable Energy Laboratory (NREL) integrated with an ever-increasing set of Gridmetrics data extracted from the cable television (CATV) broadband network infrastructure while assimilating other time-series geospatial data and information, such as weather and cyber-physical phenomena, to demonstrate a disruptive technology for power system data analytics relying on existing infrastructure. Three research thrusts supported (1) visual analytics, (2) cyber-physical power system simulation, and (3) anomaly detection. SAGA created technology that leverages, couples, and fortifies two vastly different realms - power and broadband - to increase the resiliency of the power grid in the face of increasing cyberattacks and operational challenges related to integrating DERs. The exploration of potential synergies of broadband-enabled grids resulted in identifying a mutually beneficial symbiosis that can increase the resiliency of both power and broadband services. Broadband networks perform better with reliable power and are good at providing real-time measurements that identify where the grid is under attack, is failing, or is weak. Likewise, sensor-starved distribution grids perform better and can be more reliable when their operation is buttressed with observations of broadband-detected anomalies. Future research can explore broadband's contribution to continuing to improve grid resiliency, reliability, and cost-effective operation.

24 POWER TRANSMISSION AND DISTRIBUTION↗