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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 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Process-based cost estimation framework for assessing economic viability of environmentally and socially sustainable rare earth element feedstocks

Rare Earth Elements (REEs) are critical raw material inputs that are required to enable the energy transition. Constraints on the U.S. supply of conventional REE feedstocks and the desire to diversify U.S. reliance on foreign supply chains have motivated the pursuit of REE recovery from unconventional feedstocks including waste products. Recovery of REEs from unconventional sources is also motivated by environmental and social considerations, including the potential to offset new mining activity and subsidize the remediation of REE-containing wastes from coal, natural gas, and other mineral extraction activities. Sourcing REEs from unconventional feedstocks would reduce supply chain constraints and minimize the environmental impacts of REE extraction, but current processes to exploit these feedstocks have uncertain technical and economic performance and the processes have not been demonstrated at scale. This work aims to reduce uncertainty in evaluating the performance of new REE production pathways. A database of operating and capital expenses for REE recovery and establish consistent process unit costs for common stages in the conventional supply chain are developed. Market prices are used to develop well-defined methods for determining product values for a diverse set of products that can be generated (e.g. oxalates, alloys, end-use products such as magnets) but are not typically considered in technoeconomic analyses. Finally, to provide insight on the effects of economies of scale and feedstock purity on capital and operating costs, process unit level cost functions relating total costs per kilogram of REE produced are reported. These tools can be applied to assess and facilitate scale-up of REE production from diverse sources of REEs.

Fritz, Alison↗
DOE OSTI2022

Frequency Domain Detection and Precoding for Massive MIMO With Single Carrier Modulation

Single carrier modulation (SCM) schemes are attractive for uplink (UL) transmissions due to improved power efficiency at the user equipment (UE) transmitter compared with multi-carrier modulation schemes. In a massive MIMO scenario with SCM, the UL detection must mitigate the effects of inter-symbol interference and multiuser interference. This processing is effectively performed in the frequency domain (FD) using a minimum mean squared error (MMSE) detector when the transmission is framed with a cyclic prefix. This paper presents a MMSEbased detector that is compatible with distributed processing in a time-division duplex (TDD) system. The matrix inverses computed for the UL detection are then reused to perform multi-user precoding for the downlink (DL). We find that this scheme yields a tremendous savings in computational complexity compared to commonly used zero-forcing (ZF) precoding without sacrificing any performance. Since MMSE processing introduces a bias to the estimates, we then derive the scalar coefficients necessary to cancel the MMSE bias. The impact of channel estimation errors are analyzed for both the UL and DL cases in conjunction with a power-efficient approach to SCM channel estimation. Moreover, extensive simulations are performed to confirm our theoretical findings.

42 ENGINEERING↗
DOE OSTI2026

Speeding Up Hartree–Fock in JuliaChem with Density Fitting

In this work, the density fitting (DF) approximation is added to the restricted Hartree–Fock (RHF) implementation in the JuliaChem computational chemistry code. Utilizing a DF algorithm that uses symmetry and integral screening, a significant reduction in time to compute the Fock matrix is achieved. The symmetry and screening DF-RHF techniques were adapted to be performed on graphics processing units (GPUs), which are well suited to perform the matrix multiplications that comprise the bulk of the Fock build time in DF-RHF. The JuliaChem DF-RHF GPU algorithm employs a novel approach that automatically switches between two DF-RHF algorithms depending on the number of basis functions in the calculation. The JuliaChem GPU DF-RHF implementation demonstrates up to 2× speedup for Fock build times compared to the existing best-in-class GPU DF-RHF implementation by operating directly on screened intermediate matrices. Due to the high portability of the Julia language code, the JuliaChem CPU and GPU DF-RHF implementations could be benchmarked on a variety of CPU and GPU architectures from multiple hardware vendors.

Hayes, John J. [Ames Laboratory, and Iowa State Un↗
DOE OSTI2020

Metal-assisted etch combined with regularizing etch

In an aspect of the disclosure, a process for forming nanostructuring on a silicon-containing substrate is provided. The process comprises (a) performing metal-assisted chemical etching on the substrate, (b) performing a clean, including partial or total removal of the metal used to assist the chemical etch, and (c) performing an isotropic or substantially isotropic chemical etch subsequently to the metal-assisted chemical etch of step (a). In an alternative aspect of the disclosure, the process comprises (a) performing metal-assisted chemical etching on the substrate, (b) cleaning the substrate, including removal of some or all of the assisting metal, and (c) performing a chemical etch which results in regularized openings in the silicon substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A single-component water-lean post-combustion CO 2 capture solvent with exceptionally low operational heat and total costs of capture – comprehensive experimental and theoretical evaluation

A comprehensive evaluation of a recently developed water-lean amine-based solvent, namely N-(2-ethoxyethyl)-3-morpholinopropan-1-amine (2-EEMPA), has been performed to analyze its post-combustion CO 2 capture performance. This evaluation comprises (1) fundamental characterization of the solvent–CO 2 interaction using vapor–liquid equilibria, kinetics and viscosity measurements; (2) process characterization of the CO 2 capture performance as measured in a laboratory scale continuous flow system and via Aspen Plus® simulation using a flue gas simulant; as well as (3) a full techno economic analysis of the capture process at industrial scale with corresponding projections of critical metrics. This paper summarizes the many parts of this comprehensive evaluation and shows how the various parts come together to empower validated conclusions about its process performance. Notably, it is projected that this solvent can operate at a regeneration heat rate of 2.0 GJ per tonne CO 2 for post-combustion capture, and at a total cost of capture of $50.6/tonne CO 2 . Overall, with further process optimization significant reductions in the capture cost are predicted.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Model-based, in-situ, non-destructive qualification and certification of parts made by autonomous additive manufacturing

To address the significant productivity challenges associated with the qualification and certification (Q&C) tasks of additively manufactured (AM) parts, which have traditionally relied on rigorous post‐build inspection and testing, we propose an integrated framework that combines model‐based qualification and certification (MBQ&C) with autonomous additive manufacturing (AAM). MBQ&C employs high‐fidelity predictive models, developed within the Integrated Computational Materials Engineering (ICME) paradigm, to simulate process–structure–property–performance relationships for assessing a part’s fitness for use. Since predictive models are commonly machine learning (ML)-based or reduced-order surrogates of validated physics models, they run efficiently, enabling timely inference. In parallel, the self-driving AAM utilises ML-based adaptive, closed‐loop control strategies to avoid, mitigate, or repair defects and anomalies during fabrication, thereby increasing the likelihood of producing acceptable parts. A key feature of the combined AAM-MBQ&C framework is that predictive models explicitly incorporate defects or anomalies that persist after the build, using instance-specific data captured via in-situ sensing. This customisation enables a build‐specific assessment of fitness for use, rather than relying on nominal or generic parameters. Such individualised evaluation provides a robust basis for Q&C-related acceptance decisions relating to each build. Additionally, the rapid solution capabilities of ML or reduced-order models enable the determination of a part’s suitability for service shortly after build completion. As the framework matures, it has the potential to substantially reduce reliance on conventional point‐design approaches—such as time‐consuming post‐build computed tomography scanning and costly destructive testing. Thus, the AAM-MBQ&C framework represents a transformative, scalable strategy for quality assurance of AM components, as parts produced within a stable, validated, and certified envelope can be certified with reduced testing. Key benefits include: (1) significant gains in Q&C productivity through efficient, model-centric assessment; (2) performance-based classification of defects into critical and non-critical categories; (3) the ability to predict potential deviations in the performance of parts affected by real-time, adaptive process control interventions relative to those produced under a certified process, and (4) the enabling of virtual Q&C for service environments that are difficult, hazardous, or impractical to access or reproduce experimentally. Collectively, these capabilities strengthen the business case for AM, particularly for high‐consequence and mission‐critical applications. Finally, although this work focuses on powder-based AM, the proposed techniques could be extended to AM processes employing alternative feedstock forms.

Gunasegaram, Dayalan↗
DOE OSTI2024

A Methodology for Simulating Supercritical CO2 Heat Transfer Experiments Using Machine Learning Models

To support the growth of supercritical carbon dioxide (sCO2) power cycles in the energy industry, this study seeks to train a machine learning model to mirror experimental data to predict new heat transfer data. To do this experimental data was amassed, one preliminary set comprised of 16 test results, and an expanded version comprised of 38 test results. With the goal of predicting experimental apparatus temperatures and pressures, several iterations of models were tested investigating the impact of model hyper-parameters, data inclusion, and data pre-processing on model performance. A total of 15 variations cumulatively of Gaussian Process Regressors, Gradient Boosting Regressors, and Multi-Layer Perceptrons were trained and validated on the preliminary set, and the best algorithm of each class was re-trained on the expanded set. These were compared based on test/train R^2 , test/train mean absolute error (MAE), and validation MAE, to identify the successfulness of these models. It was shown temperatures could be predicted within just a few degrees, showing the potential of this approach. Future research has been identified with approaches to improve pressure and temperature predictions going forward.

Grabowski, Owen↗
DOE OSTI2026

Fabrication of thin-walled tubes from alloy 602 CA using shear assisted processing and extrusion

Thin-walled tube is usually produced seamlessly via an expensive multi-step process or via welding of thin sheets but at reduced performance. To overcome the current process and performance inefficiencies, advanced manufacturing methods need to be investigated. In this investigation, shear assisted processing and extrusion (ShAPE) was used to fabricate thin-walled Inconel 602 tube in a single-step. Tubes measuring 0.83 m length with a 12 mm outer diameter and 1 mm wall thickness were fabricated with an average surface roughness, Ra of 1.6 µm and Rz of 15 µm. Tensile testing of tubes in the as-fabricated condition showed strength increases of 4-35% over current offerings while maintaining or improving elongation. Electron microscopy analysis revealed the recrystallized microstructure with refined inter- and intra-granular carbides. Preliminary results obtained in this investigation shows the feasibility of producing thin-wall high temperature tube in single-step via ShAPE. This achievement marks a significant step towards manufacturing larger diameter nickel alloy tubes for the U.S. Department of Energy’s Waste Treatment and Immobilization Plant.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Final SeaQuest Results on the Flavor Asymmetry of the Proton Light-Quark Sea with Proton-Induced Drell-Yan Process

The Fermilab E906/SeaQuest collaboration performed measurements of the Drell-Yan process using 120 GeV proton beams bombarding liquid hydrogen and liquid deuterium targets. A combined analysis of all collected data was performed to obtain the final results for the 𝜎 𝑝⁢𝑑 /2⁢𝜎 𝑝⁢𝑝 Drell-Yan cross section ratio covering the kinematic region of 0.13 < 𝑥 <0.45. The 𝑥 dependencies of $\bar{d}$(𝑥)/$\bar{𝑢}$⁡(𝑥) and $\bar{d}$(𝑥) $-$ $\bar{𝑢}$⁡(𝑥) are extracted from these cross section ratios. It is found that $\bar{d}$(𝑥) is greater than $\bar{𝑢}$⁡(𝑥) over the entire measured 𝑥 range, with improved statistical accuracy compared to previous measurements. The new results on $\bar{d}$(𝑥)/$\bar{𝑢}$⁡(𝑥) and $\bar{d}$(𝑥) $-$ $\bar{𝑢}$⁡(𝑥) are compared to various parton distribution functions and theoretical calculations.

Leung, C. H. [University of Illinois at Urbana-Cha↗
DOE OSTI2023

System and method to fuse multiple sources of optical data to generate a high-resolution, frequent and cloud-/gap-free surface reflectance product

Aspects of the subject disclosure may include, for example, performing, by a processing system, image fusion using two or more groups of images to generate predicted images, wherein each group of the two or more groups has one of a different resolution, a different frequency temporal pattern or a combination thereof than another of the two or more groups. Gap filling can be performed by the processing system to correct images of the two or more groups. Additional embodiments are disclosed.

Guan, Kaiyu↗
DOE OSTI2025

Cold-Sprayed NMC622 Composite as a Cathode for Lithium-Ion Batteries

The growing demand for high-energy, low-cost lithium-ion batteries (LIBs) to power electric vehicles (EVs) necessitates advances in both materials and manufacturing processes. Conventional cathode fabrication methods, such as slurry casting and drying, are energy-intensive and pose challenges for scalability and environmental compliance. In this study, we propose cold-spray (CS) deposition as a solvent-free approach for fabricating LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) composite cathodes. Powder blends of NMC622, poly(vinylidene fluoride) (PVDF), and carbon black (CB) are directly deposited onto stainless steel and Inconel substrates under varied gas temperatures, pressures (and thus velocities), and standoff distances. The effects of temperature on the deposit morphology, coating density, and volume are systematically investigated. Computational fluid dynamics simulations reveal that increasing the gas temperature enhances the particle velocity, narrows the spray angle, and reduces the mass concentration radially at the nozzle outlet. CS deposition results in a dense cathode microstructure, accompanied by fracture in polycrystalline NMC622 particles. X-ray diffraction analysis further verifies that there are no phase changes during the deposition process. The electrochemical performance of the cold-sprayed cathodes reveals an initial capacity of approximately 96 mAh g –1 for single-crystal NMC622 and 167 mAh g –1 for polycrystalline NMC622. While these values are modest compared to state-of-the-art slurry-cast cathodes, which typically exhibit 180–200 mAh g –1 under optimized conditions. The results demonstrate a competitive performance given the solvent-free nature of the CS process and compare favorably with tape-cast samples made from identical feedstock. In conclusion, he CS process enables the formation of dense, binder-integrated cathode coatings without the need for solvent processing, offering a promising pathway for scalable, energy-efficient dry electrode manufacturing of next-generation LIBs.

Batteries↗
DOE OSTI2021

The PAU Survey: narrow-band photometric redshifts using Gaussian processes

Here, we study the performance of the hybrid template machine learning photometric redshift (photo- z ) algorithm delight , which uses Gaussian processes, on a subset of the early data release of the Physics of the Accelerating Universe Survey (PAUS). We calibrate the fluxes of the 40 PAUS narrow bands with six broad-band fluxes ( uBVriz ) in the Cosmic Evolution Survey (COSMOS) field using three different methods, including a new method that utilizes the correlation between the apparent size and overall flux of the galaxy. We use a rich set of empirically derived galaxy spectral templates as guides to train the Gaussian process, and we show that our results are competitive with other standard photometric redshift algorithms. delight achieves a photo- z 68th percentile error of σ 68 = 0.0081(1 + z ) without any quality cut for galaxies with i auto < 22.5 as compared to 0.0089(1 + z ) and 0.0202(1 + z ) for the bpz and annz 2 codes, respectively. delight is also shown to produce more accurate probability distribution functions for individual redshift estimates than bpz and annz 2. Common photo- z outliers of delight and bcnz 2 (previously applied to PAUS) are found to be primarily caused by outliers in the narrow-band fluxes, with a small number of cases potentially indicating spectroscopic redshift failures in the reference sample. In the process, we introduce performance metrics derived from the results of bcnz 2 and delight , allowing us to achieve a photo- z quality of σ 68 < 0.0035(1 + z ) at a magnitude of i auto < 22.5 while keeping 50 per cent objects of the galaxy sample.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Effects of Photonic Curing Processing Conditions on MAPbI 3 Film Properties and Solar Cell Performance

Thermal annealing is the most used postdeposition materials processing method in laboratory research, but due to its slow speed and high energy cost, it is not compatible with the upscaling and commercialization of perovskite solar cell (PSC) manufacturing. Here, we adapt photonic curing (PC), which uses millisecond light pulses to deliver energy to the sample, to replace thermal annealing for crystallization of methylammonium lead iodide (MAPbI 3 ) films and rapid fabrication of PSCs. We study how PC conditions affect the outcome of MAPbI 3 conversion from the precursor to the crystalline perovskite phase by evaluating the films’ optical, crystalline, and morphological properties, as well as PSC performance. The results are understood using simulated film temperature profiles. We show that MAPbI 3 is readily converted under a wide range of PC conditions. While previous reports all used short pulses (<3 ms), we find that longer pulses produce more dense films and higher-performing PSCs. We achieve a champion power conversion efficiency in a PC-processed MAPbI 3 PSC of 11.26% under forward scan and 10.34% under reverse scan, with the processing time for the MAPbI 3 layer reduced by 30,000-fold, from 10 min to 20 ms. Using a 6 in. lamp, spatial uniformity tests show a cross-web efficiency variation of 5%. Our results indicate that using longer pulse lengths, >10 ms, is the best PC strategy for perovskite conversion, and PC is a promising annealing method for large-area, high-throughput PSC manufacturing.

14 SOLAR ENERGY↗
DOE OSTI2025

Assessing the coating implications of slurry formulations in NCMA and LFMP blend cathodes for lithium-ion batteries

This paper investigates the implications of slurry formulations and electrode processing on the performance of lithium-ion battery (LIB) cathodes, focusing on Nickel Cobalt Manganese Aluminum (NCMA) and Lithium Ferro Manganese Phosphate (LFMP) blends. Through a comprehensive examination of electrode processing steps, from material selection to coating application, we elucidate the critical role of processing parameters in shaping electrode morphology and electrochemical behavior. Rheological studies reveal the influence of slurry composition on viscosity and flow behavior, highlighting the importance of achieving optimal rheological properties for uniform coating deposition. Electrochemical characterization, including cyclic voltammetry and rate capability tests, unveils the electrochemical behavior of NCMA, LFMP, and their blend, showcasing the synergistic effects of material blending on battery performance. In conclusion, our findings underscore the intricate relationship between slurry formulation, electrode processing, and LIB performance, offering valuable insights for the design and optimization of high-performance electrode materials for next-generation batteries.

25 ENERGY STORAGE↗
DOE OSTI2025

Ancilla-assisted process tomography of a deployed fiber link

We perform ancilla-assisted process tomography over a deployed 1.6 km fiber-optic link using Bayesian inference, confirming a stable, high-fidelity polarization channel. Overall, our approach should offer value for in situ analyses of entanglement networks.

Rahman, Arefur [Arizona State University]↗
DOE OSTI2020

Improving Performance of M-to-N Processing and Data Redistribution in In Transit Analysis and Visualization

In an in transit setting, a parallel data producer, such as a numerical simulation, runs on one set of ranks M, while a data consumer, such as a parallel visualization application, runs on a different set of ranks N. One of the central challenges in this in transit setting is to determine the mapping of data from the set of M producer ranks to the set of N consumer ranks. This is a challenging problem for several reasons, such as the producer and consumer codes potentially having different scaling characteristics and different data models. The resulting mapping from M to N ranks can have a significant impact on aggregate application performance. In this work, we present an approach for performing this M-to-N mapping in a way that has broad applicability across a diversity of data producer and consumer applications. We evaluate its design and performance with a study that runs at high concurrency on a modern HPC platform. By leveraging design characteristics, which facilitate an “intelligent” mapping from M-to-N, we observe significant performance gains are possible in terms of several different metrics, including time-to-solution and amount of data moved.

Loring, Burlen↗
DOE OSTI2020

Improving Performance of M-to-N Processing and Data Redistribution in In Transit Analysis and Visualization

In an in transit setting, a parallel data producer, such as a numerical simulation, runs on one set of ranks M, while a data consumer, such as a parallel visualization application, runs on a different set of ranks N: One of the central challenges in this in transit setting is to determine the mapping of data from the set of M producer ranks to the set of N consumer ranks. This is a challenging problem for several reasons, such as the producer and consumer codes potentially having different scaling characteristics and different data models. The resulting mapping from M to N ranks can have a significant impact on aggregate application performance. In this work, we present an approach for performing this M-to-N mapping in a way that has broad applicability across a diversity of data producer and consumer applications. We evaluate its design and performance with a study that runs at high concurrency on a modern HPC platform. By leveraging design characteristics, which facilitate an ''intelligent'' mapping from M-to-N, we observe significant performance gains are possible in terms of several different metrics, including time-to-solution and amount of data moved.

Loring, Burlen↗
DOE OSTI2021

Data processing pipeline for Tianlai experiment

The Tianlai project is a 21cm intensity mapping experiment for detecting dark energy by measuring the baryon acoustic oscillation (BAO) features in the large scale structure power spectrum. This experiment provides an opportunity to test the data processing methods for cosmological 21cm signal extraction, which is still a great challenge in current radio astronomy research. The 21cm signal is much weaker than the foregrounds and easily aected by the imperfections in the instrumental responses. Furthermore, processing the large volumes of interferometer data poses a practical challenge. We have developed a data processing pipeline called tlpipe to process the drift scan survey data from the Tianlai experiment. It performs oine data processing tasks such as radio frequency interference (RFI) agging, array calibration, binning, and map-making, etc. It also includes utility functions needed for the data analysis, such as data selection, transformation, visualization and others. A number of new algorithms are implemented, for example the eigenvector decomposition method for array calibration and the Tikhnov regularization for m-mode analysis. In this paper we describe the design and implementation of the pipeline and illustrate its functions with some analysis of real data. Finally, we outline directions for future development of this publicly code.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗