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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 379 records · Page 21

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NASA NTRS2020

Development of a Display Tool to Quality Control Weather Balloon Data for Space Launch Vehicles Using Python

Continuous atmospheric data analysis is an important factor for space launch vehicle design and operations. The balloon quality control tool was developed by NASA’s Marshall Space Flight Center (MSFC) Natural Environments Branch (NEB) for monitoring quality control processes and verifying the automated flags created on the balloon data sets analyzed. The data sets currently analyzed are comprised of high-resolution and low-resolution balloon data from NASA Kennedy Space Center (KSC), co-located on the United States Air Force’s Eastern range (ER) at the Cape Canaveral Air Force Station. The NEB was tasked to perform a quality assessment of these data sets and needed a tool to confirm the quality control (QC) flags produced from an automated process and add additional QC flags if necessary. This Graphical User Interface (GUI) was developed to visualize all of the data from these balloon sets, display any flags from the automated QC process, and add additional flags to variables if necessary. The GUI was developed in Python 3.6 utilizing different packages available such as pandas for data analysis and manipulation, NumPy for high-performance multidimensional array and tools to compute with and manipulate arrays, Matplotlib for plotting data and Tkinter to build the GUI.

Jessica K Headley↗

NASA NTRS2020

Development of a Display Tool to Quality Control Weather Balloon Data for Space Launch Vehicles

Jessica K Headley↗

DOE OSTI2025

An Additively Manufactured Fe-3Si Stator for a High-Performance Electrical Motor

Additive manufacturing (AM) has the potential to produce novel high-performance electrical machines, enabling the direct printing of complex shapes and the simultaneous processing of multiple feedstocks in a single build. We examined the properties and functional performance of Fe-3 wt.% Si materials that were printed via selective laser melting, machined down to thin laminates, and stacked to form a stator core of a prototype brushless permanent-magnet electrical motor. Big Area Additive Manufacturing of Nd2Fe14B (NdFeB)–polyphenylene sulfide (PPS) bonded magnets was performed, with them then being magnetized and used for the rotor. The magnetic, mechanical, and electrical properties of the as-printed and various heat-treated thin laminates and the back electromotive force (EMF) of the electrical motors at different rotational speeds were measured. The thin laminates exhibit a maximum relative permeability of 7494 at an applied field of 0.8 Oe and a core loss of about 20 W/lb at 60 Hz with the maximum induction of 15 kg. In addition to the demonstration of AM printing, motor assembly, and complete characterization of printed Fe-3 wt.% Si, this report highlights the areas of improvement needed in printing technologies to achieve AM built electrical motors and the need for isotropic microstructure refinements to make the laminates appropriate for high-mechanical-strength and low-loss rotational electrical devices.

36 MATERIALS SCIENCE↗

NASA NTRS2015

The CHARIS IFS for high contrast imaging at Subaru

The Coronagraphic High Angular Resolution Imaging Spectrograph (CHARIS) is an integral field spectrograph (IFS) being built for the Subaru telescope. CHARIS will take spectra of brown dwarfs and hot Jovian planets in the coronagraphic image provided by the Subaru Coronagraphic Extreme Adaptive Optics (SCExAO) and AO188 adaptive optics systems. The system is designed to detect objects five orders of magnitude dimmer than their parent star down to an 80 milliarcsecond inner working angle. For characterization, CHARIS has a high-resolution prism providing an average spectral resolution of R82, R69, and R82 in J, H, and K bands respectively. The so-called discovery mode uses a second low-resolution prism with an average spectral resolution of R19 spanning 1.15-2.37 microns (J+H+K bands). This is unique compared to other high contrast IFS designs. It augments low inner working angle performance by reducing the separation at which we can rely on spectral differential imaging. The principal challenge for a high-contrast IFS is quasi-static speckles, which cause undue levels of spectral crosstalk. CHARIS has addressed this through several key design aspects that should constrain crosstalk between adjacent spectral features to be below 1%. Sitting on the Nasmyth platform, the alignment between the lenslet array, prism, and detector will be highly stable, key for the performance of the data pipeline. Nearly every component has arrived and the project is entering its final build phase. Here we review the science case, the resulting design, status of final construction, and lessons learned that are directly applicable to future exoplanet instruments.

Subaru Coronagraphic Extreme Adaptive Optics (SCEx↗

DOE OSTI2023

Multi-Model Future Typical Meteorological (fTMY) Weather Files for nearly every US County

Exploring climate-induced impacts on building energy consumption can provide valuable insights for sustainable energy planning and environmental management in the face of a changing climate. By utilizing future weather data statistically downscaled from the Intergovernmental Panel on Climate Change (IPCC) General Circulation Models (GCMs) from 2020-2100, this paper presents a broadening industry-consensus approach for generating future Typical Meteorological Year (fTMY) weather files through a combination of statistical downscaling and high-performance computing that generalizes across decades, multiple locations for a region, and varying climate models. Furthermore, these fTMY files have been generated for 3,128 US counties for capturing potential weather on a 20-year basis.

Building↗

DOE OSTI2023

Adopting occupancy-based HVAC controls in commercial building energy codes: Analysis of cost-effectiveness and decarbonization potential

Recent research has shown the energy-saving potential of occupancy-based HVAC controls (OBCs) in commercial buildings. However, building energy codes have not fully adopted this technology. This study aims to evaluate the cost-effectiveness and decarbonization benefits of OBCs and provide guidance for integrating occupancy sensors into building energy code development. To this end, a parametric simulation using EnergyPlus and a nationwide cost-effectiveness analysis are carried out considering three building types and 40 representative cities in the U.S. Here, the findings reveal that the current cost-effectiveness performance of OBCs is limited due to the high cost of occupancy sensors. However, incorporating the societal cost of carbon factor in future energy and environmental policy could greatly enhance the actual cost-effectiveness performance. Besides, a reduction in the cost of occupancy sensors to approximately 60% of the current price level could also greatly shorten the discounted payback period of OBCs. Additionally, OBCs demonstrate significant potential in building decarbonization, with potential CO 2 emissions savings of more than 5.56 million metric tons across the three building types and 40 selected cities. Finally, policy implications are provided to guide the incorporation of occupancy-based HVAC controls in future energy codes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Transferring Liquid Metal to form a Hybrid Solid Electrolyte via a Wettability-Tuning Technology for Lithium-Metal Anodes

Integrating solid-state electrolyte (SSE) into Li-metal anodes has demonstrated great promise to unleash the high energy density of rechargeable Li-metal batteries. However, fabricating a highly cyclable SSE/Li-metal anode remains a major challenge because the densification of the SSE is usually incompatible with the reactive Li metal. Here, a liquid-metal-derived hybrid solid electrolyte (HSE) is proposed, and a facile transfer technology to construct an artificial HSE on the Li metal is reported. By tuning the wettability of the transfer substrates, electron- and ion-conductive liquid metal is sandwiched between electron-insulating and ion-conductive LiF and oxides to form the HSE. The transfer technology renders the HSE continuous, dense, and uniform. The HSE, having high ion transport, electron shut-off, and mechanical strength, makes the composite anode deliver excellent cyclability for over 4000 h at 0.5 mA cm(-2) and 1 mAh cm(-2) in a symmetrical cell. When pairing with LiFePO4 and sulfur cathodes, the HSE-coated Li metal dramatically enhances the performance of full cells. Therefore, this work demonstrates that tuning the interfacial wetting properties provides an alternate approach to build a robust solid electrolyte, which enables highly efficient Li-metal anodes.

li-metal anodes↗

DOE OSTI2025

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

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

36 MATERIALS SCIENCE↗

DOE OSTI2022

Design, Construction, and Field Validation of a Blown-In Fiberglass Wall System in a Cold, Wet, and Windy Climate

In the Native Village of Tununak, located on Nelson Island in Southwest Alaska,buildings are exposed to wind-driven rain and snow throughout the year. The Cold Climate Housing Research Center (CCHRC) and Knauf Insulation partnered with the community in 2018 to design a residence for a public safety officer. Construction began in fall 2021 and is scheduled to conclude in summer 2022. The house will use integrated trusses with floor, attic, and wall cavities filled with blown-in fiberglass insulation. Hygrothermal models of the building envelope system demonstrate that the high ambient moisture load will wet the outer edges of the insulation annually regardless of the extent and integrity of exterior weather sealing measures; blown-in fiberglass is expected to be more resilient to this wetting than blown-in cellulose. To verify this, researchers will embed temperature, relative humidity, and moisture sensors in the two windward walls of the house to monitor the ability of the blown-in fiberglass insulation to dry out after wetting events that may have occurred during the transport of the insulation to the building site, storage of the insulation on site, construction process, or after installation in the wall. Sensors will remain in place for two years,documenting the wall's performance over time and verifying the design's potential for use in buildings located in climates where the chance for moisture damage is high. Here, we describe the wall system , design criteria, and the results from the hygrothermal modeling. We share details on the monitoring system's components and the planned management and analysis of data. Finally, we explain how the experiences and data from this project will inform future builds in similar locations.

building design↗

DOE OSTI2023

Development of dual phase soft magnetic laminate for advanced electric machines

The development of dual phase soft magnetic laminate for advanced electric machines at General Electric is summarized, including alloy development, properties, manufacturing trials, prototype experience, potential applications, and future material development. Dual phase soft magnetic laminates provide the flexibility to tune magnetic/non-magnetic state at the desired locations, using solution nitriding treatment with protective mask/coating. This enabling material technology benefits electric machine performance by reducing flux leakage in the laminates. It also decouples the electromagnetic and mechanical design, which opens up the design space for advanced electric machines. Magnetic and mechanical properties of dual phase laminates were compared to commercial FeSi and FeCo soft magnetic laminates. Driven by the market needs for high power density and high-speed electric machines, a synchronous reluctance (SynRel) machine without PMs using dual phase soft magnetic laminates was assessed in machine electromagnetic performance as well as rotor stress analysis by finite element simulation. Successful prototype build and testing further retired manufacturing risks and advanced the technology maturity level. Future material development with higher mechanical strength, higher saturation magnetization, higher permeability, and lower loss are highly desired for ground and air transportation electrification.

Rallabandi, Vandana↗

DOE OSTI2026

Africa Battery Energy Storage Systems (BESS) Capacity Building Li-Ion Battery Degradation and Performance [Slides]

This presentation is intended for power system engineers, operators, and planners who work on isolated power systems that have (or may soon have) high levels of power generation coming from wind turbines, solar farms, and battery energy storage, which are collectively referred to as inverter-based resources. It describes the basics of lithium-ion battery energy storage systems and lithium-ion battery degradation. Battery degradation at the cell-level is explained, and then the structure and degradation of battery energy storage systems is also explained. This is intended to help power system engineers, operators, and planners to understand and effectively utilize battery energy storage systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Machine learning-led semi-automated medium optimization reveals salt as key for flaviolin production in Pseudomonas putida

Although synthetic biology can produce valuable chemicals in a renewable manner, its progress is still hindered by a lack of predictive capabilities. Media optimization is a critical, and often overlooked, process which is essential to obtain the titers, rates and yields needed for commercial viability. Here, we present a molecule- and host-agnostic active learning process for media optimization that is enabled by a fast and highly repeatable semi-automated pipeline. Its application yielded 60% and 70% increases in titer, and 350% increase in process yield in three different campaigns for flaviolin production in Pseudomonas putida KT2440. Explainable Artificial Intelligence techniques pinpointed that, surprisingly, common salt (NaCl) is the most important component influencing production. The optimal salt concentration is very high, comparable to seawater and close to the limits that P. putida can tolerate. The availability of fast Design-Build-Test-Learn (DBTL) cycles allowed us to show that performance improvements for active learning are rarely monotonous. This work illustrates how machine learning and automation can change the paradigm of current synthetic biology research to make it more effective and informative, and suggests a cost-effective and underexploited strategy to facilitate the high titers, rates and yields essential for commercial viability.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

Review of in situ process monitoring for metal hybrid directed energy deposition

Hybrid manufacturing, or the combination of additive and subtractive manufacturing within a single build volume is transforming the way products are being fabricated. Additive manufacturing confers unprecedented freedom of design and reduced material usage while enabling serial customization. Subtractive manufacturing provides superior surface finish and improved dimensional accuracies. Interwoven, these two digital manufacturing paradigms are enabling the rapid manufacturing of complex, highly accurate, and customized geometries in a diversity of high-performance alloys. In situ monitoring, heavily relied upon in either additive or subtractive, becomes even more crucial with the interplay of the two processes in a single combined build sequence. Moreover, challenges that do not exist in either process alone can now have a dramatic impact on final part quality: (1) a large amount of heat is generated during additive manufacturing deposition, which is primarily dissipated into the machine tooling and impacts accuracy by deforming the material and causing misaligned machining; (2) microstructure, mechanical properties, and residual stresses are the result of the complex thermal histories generated by additive manufacturing and can impact subsequent cutting performance. This comprehensive review considers previous research in monitoring and providing closed-loop control in both additive and subtractive manufacturing separately and then considers the implications of the effectiveness of these monitoring techniques when additive and subtractive processes are integrated together.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Dynamic Modelling and Performance Evaluation of a Chemisorption Heat Pump for Cold Climate

Space heating is a significant contributor to the energy consumption in residential buildings, especially in cold climates where electric-driven heat pumps lose the advantage of high efficiency and conventional gas-combustion furnaces have limited efficiency. Chemical adsorption (chemisorption) heat pumps (CSHP) have the potential for producing heating with high energy efficiency under cold operating conditions. A CSHP operates intermittently between desorption and adsorption modes, and their performance is affected by system design and transient system control. This study developed a dynamic model and used it to evaluate the daily system performance under different designs and controls, particularly the buffer tank size and the controlled minimum heating power. The simulation results revealed the effects of these parameters on the system performance and helped identify the optimal design and control for the highest coefficient of performance and heating capacity.

Yang, Zhiyao↗

DOE OSTI2020

Reconstruction of Charged Particle Tracks in Realistic Detector Geometry Using a Vectorized and Parallelized Kalman Filter Algorithm

One of the most computationally challenging problems expected for the High-Luminosity Large Hadron Collider (HL-LHC) is finding and fitting particle tracks during event reconstruction. Algorithms used at the LHC today rely on Kalman filtering, which builds physical trajectories incrementally while incorporating material e ects and error estimation. Recognizing the need for faster computational throughput, we have adapted Kalman-filterbased methods for highly parallel, many-core SIMD and SIMT architectures that are now prevalent in high-performance hardware. Previously we observed significant parallel speedups, with physics performance comparable to CMS standard tracking, on Intel Xeon, Intel Xeon Phi, and (to a limited extent) NVIDIA GPUs. While early tests were based on artificial events occurring inside an idealized barrel detector, we showed subsequently that our mkFit software builds tracks successfully from complex simulated events (including detector pileup) occurring inside a geometrically accurate representation of the CMS-2017 tracker. Here, we report on advances in both the computational and physics performance of mkFit, as well as progress toward integration with CMS production software. Recently we have improved the overall eciency of the algorithm by preserving short track candidates at a relatively early stage rather than attempting to extend them over many layers. Moreover, mkFit formerly produced an excess of duplicate tracks; these are now explicitly removed in an additional processing step. We demonstrate that with these enhancements, mkFit becomes a suitable choice for the first iteration of CMS tracking, and eventually for later iterations as well. We plan to test this capability in the CMS High Level Trigger during Run 3 of the LHC, with an ultimate goal of using it in both the CMS HLT and oine reconstruction for the HL-LHC CMS tracker.

Cerati, Giuseppe↗

DOE OSTI2026

Data mining the missing ordered phases of Li/Na metal oxides

Data-driven discovery of Li-ion and Na-ion battery materials has been pioneered by generic materials data platforms such as the Materials Project. After decades of progress, it is timely to ask whether there remain underexplored compositional spaces. Here, in this work, we present a systematic data-mining effort to uncover missing ordered binary, ternary and quaternary Li/Na-containing metal oxides using high-throughput density functional theory (DFT). Building on 19,120 stable and metastable oxides entries from the Materials Project, we performed 13,245 additional calculations through isovalent substitutions of known ground states, experimentally reported compounds, and specific prototype structures. Our study identifies 36 new ground states within the GGA/GGA + U convex hull and 45 within the r 2 SCAN convex hull. Additionally, we identified 840 metastable compounds from GGA/GGA + U and 979 from r 2 SCAN that are absent in the present Materials Project databases. Moreover, we have tripled the metastable materials in compositional spaces with a molar ratio of cation/anion >1, highlighting the overlooked opportunities in this compositional space.

25 ENERGY STORAGE↗

DOE OSTI2025

Promotional Effect of ZnO and ZrO 2 in K-Doped Fe Catalysts for CO 2 Hydrogenation to Light Olefins

Promoters play a critical role in tuning the activity and selectivity of Fe catalysts in CO 2 hydrogenation to produce light olefins, which are key building blocks in the petrochemical industry. Herein, by a combined experimental and theoretical approach, we show that high and stable performance of Fe catalysts could be achieved by taking advantage of the promotional effect of both Zn and Zr. Structural characterization indicates that ZnO could improve the dispersion and reducibility of Fe oxides and facilitate the formation of active Fe carbide species, whereas ZrO 2 could stabilize the structure and catalytic performance, especially the selectivity of hydrocarbon products. In situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) experiments suggest that carbonate, bicarbonate, formate, and methoxy are essential intermediates in the CO 2 hydrogenation to hydrocarbon products, including paraffins and olefins. The conversion kinetics of each intermediate species are dependent on the type of promoters as well as the phase structure of the active Fe species. DFT calculations revealed a strong correlation between the formation energy of surface oxygen vacancies and that of Fe carbide species in promoted Fe oxides, in accordance with experimental results. Moreover, the calculated energy profiles of CO 2 hydrogenation over different catalysts indicate that Zn could promote the activation of CO 2 and its transformation to the oxygenate intermediates, while Zr could facilitate the conversion of oxygenates to hydrocarbon precursors. Finally, the discrepancies in the evolution trend of various intermediate species on promoted Fe catalysts in the transient DRIFTS experiments can be rationalized by the differences in energy barriers of elementary or rate limiting steps.

CO2 conversion↗

DOE OSTI2026

Ecosystems for Scientific Computing in the Age of AI

Scientific computing is at an inflection point. Artificial intelligence (AI) is reshaping how scientific software is developed, how teams collaborate, how projects are governed, and how the next generation is trained. Drawing on insights from a 2025 workshop report, this article argues that the future of discovery will depend on agile, robust ecosystems built through socio-technical co-design—the intentional integration of technical and human systems. This perspective is essential for ensuring that future scientific computing remains trustworthy, sustainable, and scalable. It combines advances in AI, high-performance computing, and software with new models for cross-disciplinary collaboration, education, and workforce development. Key recommendations include building modular, trustworthy AI-enabled software ecosystems; enabling teams to integrate AI into scientific workflows while preserving human creativity, integrity, and rigor; and developing adaptive training pathways that keep pace with rapid technological change. By sharing these perspectives, we hope to stimulate broader community dialogue and encourage coordinated action.

AI↗