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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Mechanical Design of the PIP-II ORBUMP Pulsed Dipole Magnet

The Proton Improvement Plan-II (PIP-II) is a vital upgrade to Fermilab's accelerator complex. The upgrade is designed to power the world s most intense high-energy neutrino beam in future experiments. The magnet pulse repetition rate of the PIP-II injection system is being upgraded from 15 Hz to 20 Hz and requires a roughly 30% increase in the magnetic field of the new Orbital Bump (ORBUMP) magnets in the Booster. The magnet is secured in a vacuum box and the core is made up of 0.127 mm thick, low carbon steel laminations with a C-5 inorganic coating. The core is clamped using external tie bars welded to the core end plates. ANSYS Finite Element Analysis (FEA) was used to evaluate the clamping design to minimize the deflection of the core post welding of the tie bars. The water-cooled single turn coil is electrically isolated from the core using virgin PEEK insulating material in the gap. An investigation into the high voltage performance of the virgin PEEK insulator was conducted. The design of the coil which shapes the magnetic field by acting as the pole tips is critical for the integrated field homogeneity. The coil manufacturing tolerances and fabrication techniques were evaluated to ensure the magnetic properties of the magnet could be obtained. The ORBUMP magnet mechanical design is presented in this paper.

Karas, Dino [Fermilab] (ORCID:0000000304340670)↗
DOE OSTI2025

High average current HVDC electron gun for EIC hadron cooling

A critical R&D initiative for the Electron Ion Collider (EIC) involves the design of an electron gun capable of gen erating a high average current and high-brightness electron beam for the hadron cooler. This is essential to preserve hadron beam quality and achieve the collider’s luminosity target of 1 × 10 34 s −1 cm −2 . For an energy recovery linac (ERL)-based hadron cooler, the gun must deliver a high average current of 98.5 mA, a normalized transverse emittance of less than 2 mm−mrad, and a bunch charge of up to 2.5 nC. This proceeding outlines the high-voltage design of a DC gun operating at 500 kV, with conditioning capability up to 600 kV. The design incorporates several unique fea tures, including the use of inverted ceramic at this voltage level, active cooling for the cathode, and large single-crystal multi-alkali cathodes grown on a silicon carbide substrate. High-brightness electron sources are also pivotal for other ad vanced applications, such as high-intensity gamma sources, future 𝑒 + 𝑒 − colliders, and ultra-deep UV sources for the semiconductor industry. Additionally, this paper provides an overview of the hadron cooling approaches planned or proposed for the EIC.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Developing tools and process controls to manufacture energy-efficient powders for additive manufacturing feedstocks

Traditionally, metal powders have been produced through methods such as grinding, atomization, and electrolysis. In contrast to these techniques, Metal Powder Works, Inc. has pioneered a methodology based on metal cutting. This innovative approach utilizes a vibrating cutting tool to machine metal particles, in the form of chips, from a workpiece. This technique allows for control of powder particle size, morphology, and avoids any thermally induced material changes. This collaboration aims to elucidate metal cutting characteristics and assess performance on tough materials like Inconel alloys. Computational models, using FEA and SPH techniques, will be developed initially, focusing on aluminum alloy (Al 7075- T6) for studying mesh sensitivity, cutting forces, and chip morphology.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development of a High-Rate Lithium-Air Battery Using a Gaseous CO 2 Reactant

Li-air batteries are considered a potential alternative to Li-ion batteries for transportation applications due to their high theoretical specific energy. Most works in this area focus on use of O 2 as the reactant. However, newer concepts for using gaseous reactants (such as CO 2 , which has a theoretical specific energy density of 1,876 Wh/kg) provide opportunities for further exploration. The main objective of this project was the development of a novel strategy that enables operation of Li-CO 2 batteries at high-capacity and high-rate, with a long-cycle-life. The team was able to: (1) Synthesize two novel transition metal chalcogenide (TMC) catalysts that work in synergy with ionic liquid-based electrolytes to enhance the efficiency of reactions during discharge and charge processes; (2) Fabricate high-porosity cathode electrodes with 3D printing to increase electrode surface area and gas permeability; (3) Develop a multiscale modeling framework that integrates Density Functional Theory (DFT), Ab-Initio Molecular Dynamics (AIMD), classical Molecular Dynamics (MD), and Finite Element Analysis (FEA) to investigate atomic and cell-level properties of Li-CO 2 batteries; (4) Assemble a stackable Li-CO 2 pouch-cell able to deliver a capacity of >200 mAh. These achievements were realized through an integrated approach based on materials synthesis, testing, characterization, analysis, and computation. This project produced a thorough understanding of key chemical, electronic, and kinetic parameters that govern the operation of Li- CO 2 batteries in realistic conditions. The methodologies employed, and the insight generated, will be valuable beyond advancing the field of Li-CO 2 batteries

25 ENERGY STORAGE↗
DOE OSTI2025

Novel Design and Fabrication of a High Frequency Transient Heat Flux Sensor for Use in an RDE

Rotating detonation engine (RDE) combustion systems have been a topic of interest in the pressure gain combustion community for their benefits over traditional gas turbine engine combustors. However, cooling requirements for these engines are significantly higher and less predictable than non-detonating engines. To understand the high-speed heat transfer dynamics inside an RDE, a novel, high-frequency heat flux gage is presented. This study aims to design a robust, single-sided sensor that can withstand the high temperature and harsh environment of an RDE for extended durations. Sensor bench testing is performed using a hot plate as a heat source, and the sensor response is compared to a finite-element analysis (FEA) model. The sensor response is then tested inside a water-cooled RDE and the wall heat flux is compared to calorimetry data.

rotating detonation engines↗
DOE OSTI2025

Characterization and Damping Control of Mechanical Connections to Improve Performance of Horn Stripline

Magnetic focusing horns are critical components for creating a stable beam of neutrinos for neutrino facilities, such as the Long Baseline Neutrino Facility (LBNF) and the Neutrinos and Main Injector (NuMI) beam lines at Fermilab. The pulsed magnetic horns are powered by high current electricity through long striplines, which must survive in a harsh radiation environment for the operational life of the component. Each stripline assembly consists of four layers of Al 6101-T6. As an electro-mechanical system, the stripline layers are bolted together with ceramic isolators for electrical insulation and to facilitate passive cooling and mechanical stability. The striplines experience vibrational force in addition to clamping force, repetitive thermal and electro-magnetic loading. The holes of stripline plates for ceramic joints represent one of the weak links for potential failure. Damping can be achieved by adding damp material to the joint. By characterizing behavior of the joint and optimizing their damping properties through FEA and EMA, the stripline performance and longevity can be improved. Appropriate damp materials are the key.

Liu, Zunping [Fermilab]↗
DOE OSTI2025

Integral Field Probe for Mapping of Curved Magnets

The Single Stretched Wire (SSW) method allows highly precise integral field measurements by recording voltage across a tensioned wire mounted to 2-axis linear stages at either end of the magnet aperture. However, traditional SSW probes are not well suited for curved accelerator magnets, which are essential for steering charged particles along arced trajectories in storage rings or beamlines. The tension required to eliminate sag demands a purely straight path, making them incompatible with non-linear magnet geometries. To address this limitation for curved magnets, a modified approach was developed using a segmented, 3D-printed support structure that incorporates a pre-shaped anti-sag curve. Under its own weight and that of the wire bundle, the structure deforms to lie flat while conforming to the curvature of the magnet in the horizontal plane. The optimal geometry of the probe was derived using an iterative process combining FEA simulations in Ansys Mechanical with testing of various carbon fiber-reinforced filaments. The printed and assembled probe was successfully used to measure the SDD-059 magnet at Fermilab, yielding promising results.

Jakopin, Alexander [Northern Illinois U.]↗
DOE OSTI2026

High-Speed Layup and Forming of Automotive Composite Components

This Project is focused on the design and manufacture of automotive components that meet functional and environmental requirements of an existing automotive application at a cost of ≤ $\$$11.00 per kilogram weight reduction. This project fosters the development of composite material technologies suitable for high volume automotive processes and run rates as well as industry workforce development with these technologies. Current automotive manufacturing involves utilizing steel or aluminum in sheet form which is rapidly stamped into components at rates up to 3600 per hour. The metallic sheets are available in many different thicknesses, strength levels, and manufacturing rates are reasonable independent of part size. While composite materials are available for use in automotive applications, the material cost, labor to manufacture and the processing of the waste far exceed the cost compared to metallic designs. Typical composite layer by layer layup procedures don’t meet the desired 60 second layup time that current automotive processes require and are also restricted by part size. Due to these factors, composites have not yet made advances into today’s high volume automotive applications. Industry partners DURA, BASF, Ford, and IACMI core innovation partner MSU collaborated to develop a manufacturing process technology that is capable of manufacturing composite blanks at high volume and independent of part size. IACMI core innovation partner Purdue provided FEA analysis and cost modelling. The objective of this project was to demonstrate a composite sheet layup and consolidation process that can be commercialized for high volume requirements, identify potential layup equipment suppliers, and develop a process of 60 second layup, forming, and trimming of a continuous fiber automotive component for the mainstream market.

42 ENGINEERING↗
DOE OSTI2026

Design and Development of the PIP-II Stripline Beam Position Monitor

• Designed a stripline Beam Position Monitor (BPM) for the PIP-II accelerator to ensure precise proton beam alignment under ultra-high vacuum (UHV) conditions • Developed a mechanically robust and manufacturable assembly, including a cylindrical housing, electrodes, flange interfaces, and internal supports • Achieved high safety margins under pressure loading, using finite element analysis (FEA), while

Avalos Angel, Alejandro [Northern Illinois U.]↗
DOE OSTI2026

Determining Stability Margins in Adiabatic Superconducting Magnets with 3-D Finite Element Analysis

Superconducting magnets play a key role in the development of experiments at Fermilab; understanding the operating stability of these can allow us to utilize more potent magnets for future experiments (like the proposed Muon Collider), optimize the design of magnets in more immediate experiments (like Mu2e), and research the future use of more exotic materials (like high-temperature superconductors). This summer, I developed a 3-D parametric FEA program in ANSYS Mechanical APDL that simulates quench in superconducting magnets, and I also developed a parametric MATLAB program that predicts thermal behavior in magnet quench using the MIITS method. These programs can provide useful quenching parameters (like minimum quench energy and normal zone propagation velocity) for different cases of quench, leading to the previously mentioned objective of magnet design optimization. To test the programs, preliminary cases were run and the data produced was compared and analyzed. The results of these analyses, as well as the program operating methods, are discussed in this project.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2026

Cooperative Education

Los Alamos National Laboratory (LANL) is a multidisciplinary national laboratory that conducts research and development in national security, engineering, materials science, computational modeling, and advanced manufacturing. The laboratory develops innovative technologies to address complex scientific and engineering challenges. This project focuses on the development and evaluation of high-performance absorbing structures through computational design, simulation, and engineering analysis. Absorbing structures are used in applications where damage mitigation, structural protection, and material efficiency are critical performance requirements. The increasing demand for lightweight, high-strength, and highly efficient structural systems has created a need for improved design methodologies capable of maximizing absorption while minimizing weight and material usage. The project utilizes advanced engineering software, including 3D CAD software and FEA, to generate and optimize structural concepts. Computational simulations are performed to evaluate structural behavior under loading conditions, while mathematical analyses are conducted using Python-based tools as well as established analytical equations from material and structural mechanics. The project benefits LANL by supporting the development of advanced design methodologies and improving the understanding of material and structural performance. During the internship term, a significant portion of the design development, simulation, and data analysis activities will be completed. Success of the project depends on collaboration among engineering mentors and technical staff members. Work will be conducted at Los Alamos National Laboratory using laboratory computing resources and engineering software.

42 ENGINEERING↗
DOE OSTI2025

Effects of Central Cut Width on the Dynamical Characteristics of Box Assembly Structure

An investigation into the Box Assembly with Removable Component (BARC) structure is conducted by utilizing computational simulations and experimental structural testing in order to determine the complex dynamical responses instigated by the central cut of the system. Because the dynamics of the BARC system is complex, this study focuses primarily on analyzing the behavior of the box assembly (BA) system. The investigation explores the dynamics of the BA system by varying the central cut widths, ranging from a cut as wide as 0.5” cut to a 0.25” cut system, as well as a 0.1” cut and a system with no cut at all. Experimental testing is performed on each system including a free vibration test using an impact hammer to excite and identify the dominant frequencies of each structure. This testing is followed by pseudo-random vibration tests and swept sinusoidal excitation tests to determine the nonlinear aspects of these systems, such as the possible existence of nonlinear softening, hardening, and/or damping. The results show that nonlinear softening and nonlinear damping are present in each system. The no-cut system demonstrated the highest peak frequencies throughout all the tests, being the most rigid structure. The 0.25” cut system was shown to have the highest peak frequencies among all the cut systems in both the finite elemenet analysis (FEA) and impact testing. This trend did not continue, though, in the random and harmonic testing, possibly due to the added stiffness of the test setup with the slip table and stinger. The results show the importance of accurately measuring the central cut width and how possible geometric uncertainties change the overall dynamical behaviors of complex systems, such as natural characteristics, nonlinear responses, coupling of modes, and oscillating amplitudes.

Padilla, Christopher (ORCID:000900033446732X)↗
DOE OSTI2024

Optimal Geometry for Focused Ion Beam-Milled Samples for Direct-Pull Micro-Tensile Testing Performed In Situ in a Scanning Electron Microscope

A thorough procedure was developed to efficiently manufacture dogbone samples using focused ion beam (FIB) milling for micro-tensile testing. A Bruker PI 89 PicoIndenter, Billerica, MA, USA, was used as a case study, although the analysis and results are applicable to other micro-mechanical testing systems capable of mounting a standard, Ø12.7 mm × Ø3.2 mm pin, scanning electron microscopy (SEM) pin stub (Ted Pella, Redding, CA, USA). Nine dogbones were made from an Fe-45Cu alloy additively manufactured using powder-fed laser-directed energy deposition (DED-LB). Testing showed that fracture was confined to the gauge section for all dogbones and that the fracture mode, ductile vs. brittle, was entirely dependent on the grain orientation relative to the loading direction. The analysis showed that the measured plastic strain to failure can vary from >11% (optimal geometry) to <1% (non-optimal geometry) in micro-tensile testing of high-tensile-strength (>1 GPa) metallic materials. Subsequently, a finite element analysis (FEA) was conducted to identify the improved dogbone geometries. A total of ten thousand dogbone geometries were tested, and their dimensions were defined by a set of four adjustable parameters (corner radius, load surface angle, load surface length, and dogbone head length). The gauge width and gauge length were fixed to 4 µm and 10 µm, respectively. Three-dimensional surface plots of the stress concentration as a function of two parameters were used to identify the optimal ranges of parameter values. The addition of maximum width and length constraints, measuring 25 µm and 30 µm, respectively, allowed us to identify an optimal geometry at load surface angles of 30° and 45°. Their respective dimensions (corner radius, load surface length, and dogbone head length) are, in µm, 12, 6, and 7 and 10, 7, and 7. Testing these two optimal geometries with a range of gauge lengths from 4 to 20 µm showed that smaller gauge lengths only slightly reduced the detrimental stress concentration outside the gauge section. However, smaller gauge lengths will notably improve the FIB surface polishing step as tapering is reduced with smaller dogbone lengths.

Chemistry↗
DOE OSTI2025

Failure Strain and Related Triaxiality of Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 Metals, Part I: Experimental Investigation

The objective of this study is to develop failure-limit material models for Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 metals, based on parameters of plastic equivalent strain (failure strain) and stress triaxiality. The research is conducted in two parts. This paper presents Part One of the study. In Part One, custom-designed test specimens undergo controlled uniaxial tension and compression testing at ambient temperature. These tests are performed at quasi-static speeds using Universal Testing Machines (UTMs) in accordance with ASTM E8 and ASTM E9 standards. Experimental data, specifically engineering stress–strain and force–displacement curves, are recorded from the onset of loading until specimen fracture, or in the case of compression tests, until the capacity of the testing machine is reached. In Part Two, the emphasis shifts to the calibration of Finite Element Analysis (FEA) models of the custom-designed test specimens. Plastic equivalent strain and the corresponding stress triaxiality values at failure are extracted from each test specimen for the given metal. These values are then systematically plotted onto a single graph to construct the failure-limit curve, which delineates the boundary conditions for material failure. This approach will facilitate the development of a comprehensive material property definition that correlates plastic equivalent strain with stress triaxiality at failure for Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 metals.

Harwell, Ron↗
DOE OSTI2023

Electrothermally Driven Reconfiguration of Microrobotic Beam Structures for the ChipSail System

Solar sailing enables efficient propellant-free attitude adjustment and orbital maneuvers of solar sail spacecraft with high area-to-mass ratios. However, the heavy supporting mass for large solar sails inevitably leads to low area-to-mass ratios. Inspired by chip-scale satellites, a chip-scale solar sail system named ChipSail, consisting of microrobotic solar sails and a chip-scale satellite, was proposed in this work. The structural design and reconfigurable mechanisms of an electrothermally driven microrobotic solar sail made of Al\Ni 50 Ti 50 bilayer beams were introduced, and the theoretical model of its electro-thermo-mechanical behaviors was established. The analytical solutions to the out-of-plane deformation of the solar sail structure appeared to be in good agreement with the finite element analysis (FEA) results. A representative prototype of such solar sail structures was fabricated on silicon wafers using surface and bulk microfabrication, followed by an in-situ experiment of its reconfigurable property under controlled electrothermal actuation. The experimental results demonstrated significant electro-thermo-mechanical deformation of such microrobotic bilayer solar sails, showing great potential in the development of the ChipSail system. Analytical solutions to the electro-thermo-mechanical model, as well as the fabrication process and characterization techniques, provided a rapid performance evaluation and optimization of such microrobotic bilayer solar sails for the ChipSail.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2024

On the mechanisms of J c increment and degradation in high- J c Ba122 tapes made by different processing methods

We compared the grain and grain boundary (GB) nanostructures in two Ba122 tapes with similarly high J c . The Ag-sheathed tape made by hot pressing has larger, more plate-like grains with better c-axis alignment but has more GBs blocked by FeAs and Ba–O. In contrast, the tape made by cold pressing with an Ag-Sn/stainless steel sheath possesses fewer plate-like grains and weaker grain alignment but has more continuous current paths with clean physically well-connected GBs. Our nanostructural comparison emphasizes the strong need to achieve both good grain alignment and clean GBs for further J c improvement of Ba122 tapes.

Kametani, F.↗
DOE OSTI2021

Impact of Materials Properties on Higher-Temperature Engine Operation

Here, we examine the effects on materials temperatures and engine efficiency via simulations of engines operating at temperatures which exceed the thermal limits of today’s materials. Potential focus areas include high-speed, high-load operation (in the fuel-enrichment zone) as well as conditions of selective cooling at lower speeds and loads. We focus on a light-duty DISI and a heavy-duty CI engine using GT-Power. Temperature distributions within the head, block, piston, and valves were obtained from 3D FEA simulations coupled with 1D GT-Power representations of the engine’s gas flow and combustion regions. We use experimentally measured thermal properties of current commercial alloys for specific engine components, as well as candidate developmental alloys with improved temperature tolerance, to gauge the effects of materials properties on engine performance, particularly focusing on operating areas where materials which can withstand higher temperatures can enable intensified combustion conditions and increased specific output. The outcome of this work is guidance on materials selection targets and benefits as OEMs meet engine-performance needs in the coming decades, to include Class 8 line-haul freight vehicles with reduced emissions, as well as design of future near net zero-carbon light-duty range extenders for more rapid electrification of medium- and heavy-duty vehicles.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Multi‐scale simulation of rock compaction through breakage models with microstructure evolution

Abstract. Regional subsidence due to fluid depletion includes the interaction among multiple physical processes. Specifically, rock compaction is governed by coupled hydro-mechanical feedbacks involving fluid flow, effective stress change and pore collapse. Although poroelastic models are often used to explain the delay between depletion and subsidence, recent evidence indicates that inelastic effects could alter the rock microstructure, thus exacerbating coupling effects. Here, a constitutive law built within the framework of Breakage Mechanics is proposed to account for the inherent connection between rock microstructure, hydraulic conductivity, and pore compaction. Furthermore, it is embedded into a 1-D hydromechanical coupled finite element analysis (FEA) to explore the effects of micro-structure rearrangement on the development of reservoir compaction. Numerical examples with the proposed model are compared with simulations under constant hydraulic conductivity to illustrate the model capability to capture the non-linear processes of reservoir compaction induced by fluid depletion.

Buscarnera, Giuseppe↗