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NASA NTRS2009

Performance Testing of Yardney Li-Ion Cells and Batteries in Support of Future NASA Missions

NASA requires lightweight rechargeable batteries for future missions to Mars and the outer planets that are capable of operating over a wide range of temperatures, with high specific energy and energy densities. Due to the attractive performance characteristics, Li-ion batteries have been identified as the battery chemistry of choice for a number of future applications. For example, JPL is planning to launch another unmanned rover mission to the planet Mars. This mission, referred to as the Mars Science Laboratory (MSL), will involve the use of a rover that is much larger than the previously developed Spirit and Opportunity Rovers for the 2003 Mars Exploration Rover (MER) mission, that are currently still in operation on the surface of the planet after more than five years. Part of the reason that the MER rovers have operated so successfully, far exceeding the required mission duration of 90 sols, is that they possess robust Li-ion batteries, manufactured by Yardney Technical Products, which have demonstrated excellent life characteristics. Given the excellent performance characteristics displayed, similar Li-ion batteries have been projected to successfully meet the mission requirements of the up-coming MSL mission. In addition to future missions to Mars, Li-ion technology is attractive for a number of other future NASA applications which require high specific energy, rechargeable batteries. To ascertain the viability of using Li-ion batteries for these applications, a number of performance validation tests have been performed on both Yardney cells and batteries of various sizes. These tests include mission simulation tests, charge and discharge rate characterization testing, cycle life testing under various conditions, and storage testing.

Smart, M. C.↗

NASA NTRS1999

Lithium-Ion Batteries for Aerospace Applications

This presentation reviews: (1) the goals and objectives, (2) the NASA and Airforce requirements, (3) the potential near term missions, (4) management approach, (5) the technical approach and (6) the program road map. The objectives of the program include: (1) develop high specific energy and long life lithium ion cells and smart batteries for aerospace and defense applications, (2) establish domestic production sources, and to demonstrate technological readiness for various missions. The management approach is to encourage the teaming of universities, R&D organizations, and battery manufacturing companies, to build on existing commercial and government technology, and to develop two sources for manufacturing cells and batteries. The technological approach includes: (1) develop advanced electrode materials and electrolytes to achieve improved low temperature performance and long cycle life, (2) optimize cell design to improve specific energy, cycle life and safety, (3) establish manufacturing processes to ensure predictable performance, (4) establish manufacturing processes to ensure predictable performance, (5) develop aerospace lithium ion cells in various AH sizes and voltages, (6) develop electronics for smart battery management, (7) develop a performance database required for various applications, and (8) demonstrate technology readiness for the various missions. Charts which review the requirements for the Li-ion battery development program are presented.

Surampudi, S.↗

DOE OSTI2025

2020 Budget Request for the DOE Computational Science Graduate Fellowship (CSGF) Grant

The Department of Energy Computational Science Graduate Fellowship (DOE CSGF) is essential for addressing the increasingly complex national workforce demands stemming from the growth of computational science and engineering challenges. Computational science and engineering (CSE) takes a multidisciplinary approach that utilizes scientific computing to tackle practical problems and provide technical tools across the spectrum of scientific discovery. The DOE CSGF specifically highlights high-performance computing (HPC) as a critical enabling technology in CSE, driving advancements in science and engineering that are vital to both the DOE and the broader economy. Over the past half-century, HPC has been an essential tool for DOE’s success. During this period, important missions, such as nuclear stockpile stewardship, have turned to HPC as an essential technology. Entire science disciplines have been transformed through the augmentation of scientific observation via HPC. At government laboratories, academic institutions, and in industry, DOE CSGF alumni are helping push traditional HPC boundaries while contributing to discoveries in high-energy physics, quantum information systems, fusion-reactor design, machine learning, additive manufacturing, nano materials for next-generation batteries and transistors, and advanced nuclear reactor modeling. In addition, HPC is used to address national health needs that will eventually point to cures both by helping cancer researchers manage and analyze huge troves of data, by simulating biological mechanisms, and by accelerating drug development. A 2023 report from the ASCAC Subcommittee on American Competitiveness and Innovation to the ASCR office, “Can the United States Maintain Its Leadership in High-Performance Computing?” says of the Program, “The CSGF program provides a barometer for disciplines that will be of interest to future DOE computing. Computational biology, machine learning, and quantum computing are among the subjects that began to swell in the ranks of CSGF applicants before the labs were hiring as high a percentage of employees in these categories.” The explosion of scientific and technological data has heightened the demand for advanced high-performance computing (HPC) to transform these data into meaningful scientific insights. As access to vast amounts of data increases, the fields of Machine Learning and Artificial Intelligence are experiencing a resurgence, enhancing the established practices of computational modeling and simulation. In its September 2020 subcommittee report on "AI/ML, Data Intensive Science, and High-Performance Computing," the DOE Advanced Scientific Computing Advisory Committee (ASCAC) specifically called for a fellowship program to train computational and data scientists to address exascale and data-intensive computing challenges. This integration of empirical and theoretical modeling will increasingly guide federal policymakers in making decisions that impact American society and future generations. It demands a workforce of highly skilled and intellectually agile computational scientists capable of navigating the rapid advancements in scientific computing within the DOE National Laboratory research environment. The DOE CSGF program has consistently addressed this critical need.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

LAMP Technical Readiness Evaluation Report

An internal preliminary evaluation of Critical Technology Elements (CTEs) for the LANSCE Modernization Project (LAMP) was completed in 2023. This included determining corresponding Technical Readiness Levels (TRLs) for all subsystems using the criteria of DOE G 413.3-4A, Technical Readiness Assessment Guide. This revised report includes a summary of the recent design modifications required to meet the project Key Performance Requirements (KPPs), some of which may reduce technical risk to the project. These recent design modifications include: • Further optimization of the low-energy and medium-energy beam transport regions (LEBT and MEBT, respectively), including relocation of various functional elements (ie choppers, kickers, and bunchers). • An additional H - ion source to separate ion-source function based on beam delivery requirements. • A high-repetition-rate pulsed kicker magnet to select/merge the two H ion beams into a common low-energy beam transport. • Modification and further optimization to a more conventional RFQ design. Performance of the RFQ has been optimized to deliver the required three types of beams while meeting the project KPPs. • The addition of a second chopper in the medium-energy beam transport (MEBT) line to reduce the required pulser voltages. The scope of the evaluation was limited to the project Work Breakdown Structure (WBS) elements as defined for the RFQ Injector and Drift Tube Linac (DTL) systems only. Integration of Instrumentation and Controls (I&C) and Safety Systems was not considered, although specific technologies as related to the RFQ and DTL systems were included. Other elements of the project such as Shielding, System Design, Technical Management, and additional facility integration needed to enable off-line testing and pre-installation commissioning were also not evaluated. Each technical subsystem element was evaluated for technical readiness, however, not all were found to meet the criteria for a CTE. Three subsystem elements were determined to meet the CTE criteria. Their associated TRLs are summarized in the table below. These subsystem elements of the project have the lowest technical readiness due to either being new, novel or modified, requiring additional R&D before being capable of meeting the project Key Performance Parameters (KPPs) and subsystem requirements, or present technology exists but has not yet been demonstrated in a relevant environment. All other subsystems were determined to have a TRL of 8, indicating that actual operating systems exist having similar performance requirements as needed for LAMP. Details of the technical readiness evaluation for each subsystem is given in the following sections of this report.

43 PARTICLE ACCELERATORS↗

NASA NTRS2015

The NASA Advanced Space Power Systems Project

The goal of the NASA Advanced Space Power Systems Project is to develop advanced, game changing technologies that will provide future NASA space exploration missions with safe, reliable, light weight and compact power generation and energy storage systems. The development effort is focused on maturing the technologies from a technology readiness level of approximately 23 to approximately 56 as defined in the NASA Procedural Requirement 7123.1B. Currently, the project is working on two critical technology areas: High specific energy batteries, and regenerative fuel cell systems with passive fluid management. Examples of target applications for these technologies are: extending the duration of extravehicular activities (EVA) with high specific energy and energy density batteries; providing reliable, long-life power for rovers with passive fuel cell and regenerative fuel cell systems that enable reduced system complexity. Recent results from the high energy battery and regenerative fuel cell technology development efforts will be presented. The technical approach, the key performance parameters and the technical results achieved to date in each of these new elements will be included. The Advanced Space Power Systems Project is part of the Game Changing Development Program under NASAs Space Technology Mission Directorate.

batteries↗

DOE OSTI2025

Systems Analysis of Biomass and Coal Co-firing Power Plants with Deep Carbon Capture Toward Net-zero Emissions

Achieving a net-zero emission economy in the United States requires integrating diverse low-carbon and negative-emission technologies into the existing fossil fuel-dominant power fleet. Potential technologies from the low-carbon portfolio include renewable power, fossil power with carbon capture and storage (CCS), bioenergy with CCS (BECCS), and direct air capture (DAC). Renewable power is a clean energy source but has to pair with costly battery storage to provide dispatchable electricity. Fossil power with CCS offers dispatchable electricity yet still relies on DAC to offset residual emissions, even when deploying deep CCS with more than 90% CO2 capture. Coal-biomass co-firing with CCS, a subset of BECCS, is a reliable energy production technology that can be retrofitted from existing electricity generation units (EGUs). Power plant retrofit maximizes the use of the current U.S. coal power fleet without the need for large-scale deployment of new renewable power, battery storage, or DAC. Retrofitting coal-biomass co-firing with deep CCS in EGUs is a promising option, but not a universal solution. Biomass co-firing at a power plant introduces economic challenges and indirectly poses pressure on land and water resources. Meanwhile, retrofitting deep CCS affects plant efficiency and raises electricity generation costs. Overall, the technical feasibility and economic viability of plant retrofits vary across EGUs, as they are contingent upon the regional availability of biomass, unit-specific characteristics, site-specific fuel supply costs, and adjacent CO2 storage potential. Government incentives like 45Q can improve the retrofit viability, though the impact requires further quantification. A comprehensive analysis at the unit level is essential to address the question regarding the fate of the U.S. coal-fired electricity generation fleet toward the net-zero emission goal. This study conducts a systematic techno-economic-environmental assessment of EGUs to identify the viability of biomass co-firing and deep CCS retrofits in the U.S. coal-fired power fleet. Specifically, it characterizes the techno-economic performance of deep carbon capture, estimates life cycle greenhouse gas (GHG) emissions, and conducts a fleet-level assessment on retrofit viability. The key objectives are (1) to estimate the unit-specific performance and retrofitted cost under various biomass co-firing levels and CO2 capture rates; (2) to determine the possibility of reaching net-zero emission at the fleet level; (3) to quantify the cumulative capacities that are suitable for plant retrofits under current and future biomass supply scenarios; and (4) to improve the understanding of policy impacts on such retrofits to help the power sector’s transition to a net-zero economy. Techno-economic Model of Deep Carbon Capture. This study develops the performance and economic models for Monoethanolamine-based post-combustion CO2 capture at 95–99% capture rates. The process is simulated in Aspen Plus, analyzing the performance of carbon capture technology by varying the plant sizes, solvent lean loading, CO2 concentrations, and flue gas inlet temperature. Based on the key inputs and output parameters of CO2 capture, a reduced-order performance model of deep carbon capture is formulated. In addition, an engineering-economic model integrating the performance metrics is developed to estimate the capital as well as operation and maintenance (O&M) costs. Capital cost estimations follow the framework of the Integrated Environmental Control Model (IECM) and incorporate data regressions from three technical reports by IECM, the National Energy Technology Laboratory (NETL), and the National Renewable Energy Laboratory. The O&M cost estimation utilizes the actual inventory consumption rate and labor requirements. Both performance and cost models are embedded into IECM v13.0-beta, a fossil-fuel power plant modeling tool. Life Cycle Assessment of Power Plants. This study estimates the GHG emissions of power plants through life cycle assessment (LCA). The LCA scope includes fuel supply, combustion-based power generation, and CO2 transport and storage. The fuel-based life cycle module is designed following the framework of the NETL Unit Process Library and CO2U LCA Guidance Toolkit. The module is then incorporated into IECM v13.0-beta. The process-based LCA is applied to estimate the GHG emissions of coal and biomass supply, coal- and coal-biomass co-firing power plant operation, as well as CO2 pipeline transport and geographical sequestration. An uncertainty analysis is conducted to quantify the variability and uncertainty associated with the LCA using the Latin Hypercube Sampling (LHS) method. Fleet-level Assessment. This study evaluates the technical and economic feasibility of selected coal-fired EGUs, examines the role of tax credits in retrofit viability, and assesses the competitiveness of retrofitted units against other low-carbon options. Unit screening identifies EGUs for the study, focusing on new, efficient baseload units with air pollution controls. The power plant databases are then established to organize unit-specific information on performance and operating conditions from the relevant public databases. Biomass for co-firing retrofits is selected based on home and neighboring county availability, ensuring sustained operation with at least a 5% co-firing level. The CO2 storage site is determined by state-level storage potential, with ArcGIS Pro and NETL CO2 Saline Storage Cost Model used to identify the optimal balance between the nearest transport distances and affordable storage costs. The latest IECM v13.0-beta is then employed to configure and evaluate the eligible EGUs with or without the deployment of deep CCS and biomass co-firing. A supply curve is established to illustrate the cumulative installed capacity suitable for retrofits at different cost levels. A sensitivity analysis on tax credits for carbon sequestration is performed. Finally, a unit-level cost comparison is conducted among retrofitted plants, renewable power with battery storage, and abated fossil fuels with DAC. Expected Results. This study evaluates the technical, economic, and environmental metrics of each EGU across an array of CO2 capture rates and biomass co-firing level scenarios. Unit-level comparisons will identify critical factors influencing technical performance. The supply curves with and without tax incentives will provide insights into the impact of tax credits on biomass co-firing and CCS deployment. The cost comparisons with renewables and DAC-retrofit will assess the competitiveness of the retrofitted units. Life cycle emissions from each unit will be assessed to identify the scenarios under which net-zero emissions can be achieved. These analyses are expected to determine the total coal-fired capacity suitable for serving as a low-carbon energy source with or without tax incentives. The study results are novel in identifying optimal unit-specific strategies for producing carbon-neutral power, whether through retrofitting EGUs with deep CCS, biomass co-firing, DAC, or installing renewable power with battery. The findings will provide insight into nationwide efforts to ensure reliable, affordable, and low-carbon electricity. It also will inform investment decisions and policies in the deployment of deep carbon capture and negative emission technologies for a net-zero energy future.

Biomass Co-firing↗

DOE OSTI2025

Hierarchical Resilience Planning for Networked Microgrids: A Case Study of Puerto Rico

Microgrids can be designed to enhance the energy resilience of communities and critical infrastructures, such as hospitals, data centers, and communication networks, which are vulnerable to frequent weather-related disruption. Coordinating multiple microgrids in a network can leverage the geographical diversity of load and generation resources while enabling resilient and cost-effective planning of the distribution system. Designing a networked microgrid is complex, involving intricate technical assessment, cost-benefit analysis, site-specific requirements, and the evaluation of existing resources. Therefore, this paper proposes a hierarchical resilience planning framework and performs an extensive techno-economic analysis for the design of a networked microgrid. Hierarchical resilience planning involves technology sizing at an individual community level to meet the critical load and satisfy resilience criteria, and resource optimization at networked microgrid level to provide a higher level of resilience and energy adequacy. A real-world case of Puerto Rico's cooperative microgrid “Microrred de la Montaña” is investigated considering localized electricity tariffs, site-specific demand profiles, solar generation, and existing hydro resources. Multiple optimization scenarios are developed based on the resiliency requirement to estimate the capacity of solar photovoltaic and battery energy storage (BES) to be installed at each substation. The results provide the optimal sizing for individual community and networked microgrid to withstand 1day and 3-day outages along with the criteria for critical load.

13 - HYDRO ENERGY↗

NASA NTRS1982

Economics of wind energy for utilities

Utility acceptance of this technology will be contingent upon the establishment of both its technical and economic feasibility. This paper presents preliminary results from a study currently underway to establish the economic value of central station wind energy to certain utility systems. The results for the various utilities are compared specifically in terms of three parameters which have a major influence on the economic value: (1) wind resource, (2) mix of conventional generation sources, and (3) specific utility financial parameters including projected fuel costs. The wind energy is derived from modeling either MOD-2 or MOD-0A wind turbines in wind resources determined by a year of data obtained from the DOE supported meteorological towers with a two-minute sampling frequency. In this paper, preliminary results for six of the utilities studied are presented and compared.

Mccabe, T. F.↗

DOE OSTI2024

Review of Feasibility and Cost Drivers for Floating Offshore Wind Energy in Washington State

The state of Washington must double its clean electricity supply by 2050 to meet its clean energy goals and comply with the Clean Energy Transformation Act. With more than 6.6 GW of technical resource potential in federal waters where Bureau of Ocean Energy Management has leasing authority, offshore wind energy could play an important role in diversifying Washington State's clean energy mix, reducing dependence on out-of-state energy sources, and helping meet state decarbonization goals. Decision makers need technology-specific information to assist with long-term energy system planning, so the Bureau of Ocean Energy Management requested that the National Renewable Energy Laboratory provide an overview of several drivers of offshore wind energy feasibility and cost in Washington. This study summarizes some of the existing engagement efforts and perspectives on offshore wind energy in the region and quantifies the offshore wind resources in Washington as well as technology costs and performance of potential projects. Furthermore, this report reviews existing grid and port infrastructure and discusses infrastructure needs along with information gaps. This study also explores opportunities and barriers to Washington entities supporting the broader floating offshore wind energy supply chain along the U.S. West Coast. Note that this study is not part of a formal project planning process or official engagement effort, nor does it assess environmental or economic impacts from potential offshore wind energy development.

17 WIND ENERGY↗

NASA NTRS2012

Beamed-Energy Propulsion (BEP) Study

The scope of this study was to (1) review and analyze the state-of-art in beamed-energy propulsion (BEP) by identifying potential game-changing applications, (2) formulate a roadmap of technology development, and (3) identify key near-term technology demonstrations to rapidly advance elements of BEP technology to Technology Readiness Level (TRL) 6. The two major areas of interest were launching payloads and space propulsion. More generally, the study was requested and structured to address basic mission feasibility. The attraction of beamed-energy propulsion (BEP) is the potential for high specific impulse while removing the power-generation mass. The rapid advancements in high-energy beamed-power systems and optics over the past 20 years warranted a fresh look at the technology. For launching payloads, the study concluded that using BEP to propel vehicles into space is technically feasible if a commitment to develop new technologies and large investments can be made over long periods of time. From a commercial competitive standpoint, if an advantage of beamed energy for Earth-to-orbit (ETO) is to be found, it will rest with smaller, frequently launched payloads. For space propulsion, the study concluded that using beamed energy to propel vehicles from low Earth orbit to geosynchronous Earth orbit (LEO-GEO) and into deep space is definitely feasible and showed distinct advantages and greater potential over current propulsion technologies. However, this conclusion also assumes that upfront infrastructure investments and commitments to critical technologies will be made over long periods of time. The chief issue, similar to that for payloads, is high infrastructure costs.

Patrick George↗

DOE OSTI2026

Developing a Deep Learning-Computer Vision Framework to Monitor Avian Interactions with Solar Energy Facility Infrastructure (Final Technical Report)

The project addressed an inability to monitor avian interactions with photovoltaic (PV) solar energy facilities necessary for understanding PV solar impacts on birds. In the project, machine-vision technology that continuously monitors avian activities at PV solar facilities was developed. The technology includes four machine-learning (ML) models, each of which accomplishes a specific task in detecting birds and classifying their activities in live or recorded videos—detecting and tracking moving objects, differentiating birds from other objects, detecting bird collisions with solar panels, and classifying non-collision bird activities around PV facilities. Major project outcomes include adoption by two of DOE SETO’s SolWEB projects, providing novel observational data on birds to promote co-location of PV solar development and habitat conservation, known as ecovoltaics.

14 SOLAR ENERGY↗

DOE OSTI2025

Comparative evaluation and selection of heat exchangers using multicriteria decision-making

Here, this study presents a well-structured method for comparing and selecting Heat Exchanger (HE) technologies for Integrated Energy Systems (IES). The decision to select a HE for a particular IES configuration can vary greatly depending not only on engineering requirements but also on customer’s specific demand. In other words, the HE selection for IES requires a multicriteria decision-making approach, taking into account diverse technical, economic, and safety aspects, as well as the relative priorities considered by energy users. This study employs a HE evaluation approach combining multicriteria decision-making techniques widely used in various industries: quality function deployment (QFD) and analytic hierarchy process (AHP) techniques. Of particular interest is the use of the proposed method to select a high-temperature HEs that couples advanced nuclear reactors and industrial processes. To build a practical basis for comparing HEs within the proposed framework, efforts were made to identify the various HEs requirements for IES purposes. In addition, leveraging the insights obtained from the literature review and the market survey of commercial HE suppliers, a knowledge base was built to facilitate the comparison of each requirement across various HE designs. Also, evaluation metrics were identified for HE requirements with robust rational to enhance the quality of decisions made throughout the proposed evaluation process. The evaluation procedure and knowledge base described in this study can provide a useful basis for those interested in screening the appropriate HE designs for various IES scenarios.

Analytic Hierarchy Process (AHP)↗

DOE OSTI2025

ResStock Technical Reference Documentation (V.3.3.0)

ResStock™ is the best-in-class building stock energy model for simulating and publishing energy use, utility bills, and greenhouse gas emissions from the residential sector of the U.S. ResStock answers two primary questions: (1) How is energy used in the U.S. residential building stock? and (2) What is the timeseries aggregate impact of energy technologies? Specifically, ResStock quantifies energy use across geographical locations, demographic groups, building types, fuels, end uses, and time of day. Additionally, it details the impact of efficiency or electrification measures: total changes in the amount of energy used by measure; where or in what use cases efficiency or electrification upgrade measures save energy; when or at what times of day savings occur; and which building stock or demographic segments have the biggest savings potential. This model, and the datasets it produces, are foundational to identifying pathways to affordable and equitable decarbonization of the U.S. residential buildings sector.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Envelope-driven comfort risk in residential demand response

Residential demand response (DR) is a valuable resource for grid reliability, but remains challenging because the highly heterogeneous residential building stock leads to widely varying and hard-to-predict load and comfort responses during DR events. Although prior research has estimated the technical potential of DR-capable technologies for achieving energy demand savings, little is known about how they affect thermal comfort. In particular, it remains unclear how indoor thermal conditions due to DR depend on the thermal envelope characteristics of the housing stock. To address this gap, this study provides a systematic, location-specific assessment of indoor thermal performance during DR-events across the US housing stock using both typical DR weather data and detailed building metadata. We evaluate how envelope characteristics influence indoor temperatures during realistic simulated summer and winter DR events across 37 US locations, applying both temperature threshold and rate of temperature change criteria to estimate region-level probabilities of discomfort. Additionally, we show the impact of distinct weather patterns that intensify or abate thermal stress on comfort outcomes. Results show a near-universal overheating risk in summer DR events, where comfort outcomes are strongly influenced by rapid risk of comfort violations. In contrast, overall winter DR discomfort risk is lower, risk escalation is more gradual and shows greater sensitivity to event duration. These findings offer a data-driven quantification of comfort risk across diverse climates and building envelopes, demonstrating the need for region-specific DR scheduling and discomfort mitigation strategies tailored to local weather patterns and the performance of existing residential buildings.

Demand response↗

NASA NTRS1995

Proceedings of the 4th International Conference and Exhibition: World Congress on Superconductivity, volume 1

The papers presented at the 4th International Conference Exhibition: World Congress on Superconductivity held at the Marriott Orlando World Center, Orlando, Florida, are contained in this document and encompass the research, technology, applications, funding, political, and social aspects of superconductivity. Specifically, the areas covered included: high-temperature materials; thin films; C-60 based superconductors; persistent magnetic fields and shielding; fabrication methodology; space applications; physical applications; performance characterization; device applications; weak link effects and flux motion; accelerator technology; superconductivity energy; storage; future research and development directions; medical applications; granular superconductors; wire fabrication technology; computer applications; technical and commercial challenges, and power and energy applications.

Krishen, Kumar↗

DOE OSTI2024

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

The aerospace, construction/architecture, and transportation manufacturing industries rely heavily on the mass production of near-net shape metallic and composite extrusions. While the production of raw extrusions is a relatively fast process, adding functional features such as holes and slots require additional time, cost, and energy to produce. To compensate for the inherent flexibility of extrusions, conventional machining requires rigid purpose-built fixtures for operations such as trimming, drilling and thinning. This approach requires that the machine tools be as large or larger than the parts themselves. This results in the need for excess shop floor space, energy for auxiliary equipment and motion systems, and significant capital expenditure. Considerable engineering expense and time involved in the designing, building, and proving out of part-specific fixtures for holding the components in specific configurations while machining add to the overall manufacturing cost. The primary objective of the technical collaboration between Oak Ridge National Laboratory and Fairmount Technologies (FT) is to improve the XM-3, a fixtureless CNC milling machine designed by FT. The machine was developed to trim, drill, and thin extrusions without part specific fixturing to make the manufacturing process more efficient and flexible. Dynamic measurements of the existing structure were collected, and modeling efforts were made to evaluate optimal machining parameters for the current system. Areas of improvement to increase the system stiffness, manufacturability, and machining efficiency were evaluated and highlighted for the next generation design. The impact of this effort may enable agile manufacturing across the commercial and defense aerospace industries, and other industries where extrusions are utilized like in the construction, architecture, and transportation industries.

42 ENGINEERING↗

DOE OSTI2025

Design and Development of a Fixtureless, Pass-through Machine Tool for Extrusion Machining

42 ENGINEERING↗

NASA NTRS1980

Energy from wood waste - A case study

A joint study has been conducted by NASA and Army installations collocated in a dense forest in southwestern Mississippi in order to determine the technical and economic feasibility of using wood waste as a renewable energy source. The study has shown that, with proper forest management, the timber on government lands could eventually support the total energy requirements of 832 billion Btu/yr. Analysis of the current conversion technologies indicates that the direct combustion spreader stoker approach is the best demonstrated technology for this specific application. The economics of the individual powerplants reveal them as attractive alternatives to fossil fueled plants. Environmental aspects are also discussed.

Scola, R.↗