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DOE OSTI2024

Tierra del Fuego Case Study Capacity Expansion Analysis

This case study, developed by Net Zero World Initiative and the Government of Argentina, examines least-cost decarbonization pathways for Tierra del Fuego, Argentina, utilizing renewable energy, energy storage, hydrogen, and other decarbonization technologies. Being the second largest natural gas producing province in Argentina, Tierra del Fuego has historically relied on natural gas for their energy sector needs. As they look at possible decarbonization pathways, they face challenges due to extreme weather conditions, isolation from the mainland, and low population density. The study utilizes the Engage web application for capacity expansion modeling, addressing both business-as-usual (BAU) and accelerated decarbonization scenarios, with varying degrees of electrification and carbon emission constraints. Key findings reveal that an interconnection with the mainland, high contribution of wind energy development on Tierra del Fuego, energy storage, and hydrogen, coupled with energy-efficient electrification technologies (such as heat pumps and electric vehicles), emerge as the most cost-effective solutions to decarbonize, significantly reducing carbon emissions and total system energy costs. The study explores self-generation and interconnection alternatives, demonstrating the economic advantage of an interconnection of Tierra del Fuego with the mainland, as an alternative to 100% local generation. Sensitivity analyses on wind data sources and temporal resolutions, as well as projected natural gas prices, highlight the influence of external factors on the feasibility of decarbonization pathways. Challenges identified include the practicality of phasing out natural gas, economic uncertainty, cost implications of long-term storage technologies as wind energy increases, and geographical limitations for wind generation. The case study concludes that while substantial emissions reductions can be achieved by 2050, and be competitive with conventional pathways, achieving a full 100% decarbonization by 2050 would entail higher costs, particularly due to the significant reliance on storage solutions with higher contribution of wind energy. The analysis offers valuable insights for policymakers and stakeholders in Argentina's energy sector, emphasizing the importance of strategic planning, investment in renewable energy and storage technologies, and careful consideration of local conditions in the transition towards Net Zero targets.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1983

Stirling cycle cryogenic cooler

A long lifetime Stirling cycle cryogenic cooler particularly adapted for space applications is described. It consists of a compressor section centrally aligned end to end with an expansion section, and respectively includes a reciprocating compressor piston and displacer radially suspended in interconnecting cylindrical housings by active magnetic bearings and has adjacent reduced clearance regions so as to be in noncontacting relationship therewith and wherein one or more of these regions operate as clearance seals. The piston and displacer are reciprocated in their housings by linear drive motors to vary the volume of respectively adjacent compression and expansion spaces which contain a gaseous working fluid and a thermal regenerator to effect Stirling cycle cryogenic cooling.

Gasser, M. G.↗

NASA NTRS1989

Explicit modeling and computational load distribution for concurrent processing simulation of the space station

Two important aspects of concurrent processing under development at TRW are discussed. These are: (1) the derivation of explicit mathematical models of multibody dynamic systems, and (2) a balanced computational load distribution (BCLD) among loosely coupled computational units (processors) of a concurrent processing system. The developed methodologies are demonstrated by way of an application to the Phase 1 of the Space Station - a task being performed by TRW under NASA/JSC contract NAS9-17778. The mathematical model of the Space Station consists of three interconnected flexible bodies capable of undergoing large, rigid-body motion with respect to each other. Body 1 is the main central body and contains the pressurized modules inboard of the two Alpha gimbals. Bodies 2 and 3 are the starboard and port bodies connected to Body 1 at the Alpha gimbals and include all components on the transverse booms outboard of the Alpha gimbals (including the solar arrays). The control systems in the model maintain Body 1 in a prescribed 3-axis attitude control mode, while producing large-angle rotations of the flexible solar arrays to position them normal to the sun-line.

Gluck, R.↗

NASA NTRS2012

Iridium Interfacial Stack - IrIS

Iridium Interfacial Stack (IrIS) is the sputter deposition of high-purity tantalum silicide (TaSi2-400 nm)/platinum (Pt-200 nm)/iridium (Ir-200 nm)/platinum (Pt-200 nm) in an ultra-high vacuum system followed by a 600 C anneal in nitrogen for 30 minutes. IrIS simultaneously acts as both a bond metal and a diffusion barrier. This bondable metallization that also acts as a diffusion barrier can prevent oxygen from air and gold from the wire-bond from infiltrating silicon carbide (SiC) monolithically integrated circuits (ICs) operating above 500 C in air for over 1,000 hours. This TaSi2/Pt/Ir/Pt metallization is easily bonded for electrical connection to off-chip circuitry and does not require extra anneals or masking steps. There are two ways that IrIS can be used in SiC ICs for applications above 500 C: it can be put directly on a SiC ohmic contact metal, such as Ti, or be used as a bond metal residing on top of an interconnect metal. For simplicity, only the use as a bond metal is discussed. The layer thickness ratio of TaSi2 to the first Pt layer deposited thereon should be 2:1. This will allow Si from the TaSi2 to react with the Pt to form Pt2Si during the 600 C anneal carried out after all layers have been deposited. The Ir layer does not readily form a silicide at 600 C, and thereby prevents the Si from migrating into the top-most Pt layer during future anneals and high-temperature IC operation. The second (i.e., top-most) deposited Pt layer needs to be about 200 nm to enable easy wire bonding. The thickness of 200 nm for Ir was chosen for initial experiments; further optimization of the Ir layer thickness may be possible via further experimentation. Ir itself is not easily wire-bonded because of its hardness and much higher melting point than Pt. Below the iridium layer, the TaSi2 and Pt react and form desired Pt2Si during the post-deposition anneal while above the iridium layer remains pure Pt as desired to facilitate easy and strong wire-bonding to the SiC chip circuitry.

Spry, David↗

NASA NTRS2014

SpaceCube v2.0 Space Flight Hybrid Reconfigurable Data Processing System

This paper details the design architecture, design methodology, and the advantages of the SpaceCube v2.0 high performance data processing system for space applications. The purpose in building the SpaceCube v2.0 system is to create a superior high performance, reconfigurable, hybrid data processing system that can be used in a multitude of applications including those that require a radiation hardened and reliable solution. The SpaceCube v2.0 system leverages seven years of board design, avionics systems design, and space flight application experiences. This paper shows how SpaceCube v2.0 solves the increasing computing demands of space data processing applications that cannot be attained with a standalone processor approach.The main objective during the design stage is to find a good system balance between power, size, reliability, cost, and data processing capability. These design variables directly impact each other, and it is important to understand how to achieve a suitable balance. This paper will detail how these critical design factors were managed including the construction of an Engineering Model for an experiment on the International Space Station to test out design concepts. We will describe the designs for the processor card, power card, backplane, and a mission unique interface card. The mechanical design for the box will also be detailed since it is critical in meeting the stringent thermal and structural requirements imposed by the processing system. In addition, the mechanical design uses advanced thermal conduction techniques to solve the internal thermal challenges.The SpaceCube v2.0 processing system is based on an extended version of the 3U cPCI standard form factor where each card is 190mm x 100mm in size The typical power draw of the processor card is 8 to 10W and scales with application complexity. The SpaceCube v2.0 data processing card features two Xilinx Virtex-5 QV Field Programmable Gate Arrays (FPGA), eight memory modules, a monitor FPGA with analog monitoring, Ethernet, configurable interconnect to the Xilinx FPGAs including gigabit transceivers, and the necessary voltage regulation. The processor board uses a back-to-back design methodology for common parts that maximizes the board real estate available. This paper will show how to meet the IPC 6012B Class 3A standard with a 22-layer board that has two column grid array devices with 1.0mm pitch. All layout trades such as stack-up options, via selection, and FPGA signal breakout will be discussed with feature size results. The overall board design process will be discussed including parts selection, circuit design, proper signal termination, layout placement and route planning, signal integrity design and verification, and power integrity results. The radiation mitigation techniques will also be detailed including configuration scrubbing options, Xilinx circuit mitigation and FPGA functional monitoring, and memory protection.Finally, this paper will describe how this system is being used to solve the extreme challenges of a robotic satellite servicing mission where typical space-rated processors are not sufficient enough to meet the intensive data processing requirements. The SpaceCube v2.0 is the main payload control computer and is required to control critical subsystems such as autonomous rendezvous and docking using a suite of vision sensors and object avoidance when controlling two robotic arms.

Xilinx FPGA↗

NASA NTRSDate not supplied

Press-fit Connectors in Spaceflight Applications - Drivers and Challenges

Starting from the 1970s when press-fit technology was nascent and confined within the telecommunications industry, this technology has matured as its adoption has increased within high reliability applications such as medical devices and avionics. Press-fit connectors are strongly preferred in today’s designs because the smaller press-fit pins require smaller diameter holes which require smaller pads and allows more routing real-estate without taking exceptions to specs. The lack of solder for a press-fit connection makes the conductive path more predictable for high-speed digital design and impedance discontinuities can be minimized as the signal moves from the printed circuit board to the connector. Touch-up during manufacturing is also reduced and streamlines the assembly process. This presentation at the 2022 NEPP ETW will introduce the audience to press-fit connectors and its contact physics followed by a deeper dive into specific press-fit applications for space flight environments, including information on qualification, testing, and screening.

pressfit↗

DOE OSTI2022

Time-resolved 3D characterisation of early-age microstructural development of Portland cement

Abstract Time-resolved in-situ synchrotron X-ray microtomography reveals new levels of detail about the chemical and physical processes that take place as Portland cement hardens. The conversion of a fluid paste into a hardened product can be monitored on a sub-minute time-scale, and with sample movement/settlement corrections applied to enable individual particles to be tracked as they react, hydrate, and become interconnected into a single strong monolith. The growth of the strength-giving hydrate phases surrounding cement grains, and of the fluid-filled pore network that surrounds them, is able to be directly viewed at the level of individual cement particles through the application of this tracking protocol. When cement is brought into contact with water, a layer which differs in density from the bulk of the cement grains becomes observable on the grain surfaces during the induction period (during which time the heat evolution from the paste is relatively low). As hydration continues, reaction products grow both from particle surfaces into the initially fluid-filled region, and also into the space originally occupied by the cement particles, forming a density gradient within the microstructure. As the reaction accelerates and larger volumes of solid phases precipitate, the newly-formed solid structure percolates via interconnection of agglomerated low-density outer hydrates, which then densify as hydration continues. This eventually leads to solidification of the structure into a hardened porous matrix. Graphical abstract

36 MATERIALS SCIENCE↗

NASA NTRS1997

System-Level Integrated Circuit (SLIC) Technology Development for Phased Array Antenna Applications

This report documents the efforts and progress in developing a 'system-level' integrated circuit, or SLIC, for application in advanced phased array antenna systems. The SLIC combines radio-frequency (RF) microelectronics, digital and analog support circuitry, and photonic interfaces into a single micro-hybrid assembly. Together, these technologies provide not only the amplitude and phase control necessary for electronic beam steering in the phased array, but also add thermally-compensated automatic gain control, health and status feedback, bias regulation, and reduced interconnect complexity. All circuitry is integrated into a compact, multilayer structure configured for use as a two-by-four element phased array module, operating at 20 Gigahertz, using a Microwave High-Density Interconnect (MHDI) process. The resultant hardware is constructed without conventional wirebonds, maintains tight inter-element spacing, and leads toward low-cost mass production. The measured performances and development issues associated with both the two-by-four element module and the constituent elements are presented. Additionally, a section of the report describes alternative architectures and applications supported by the SLIC electronics. Test results show excellent yield and performance of RF circuitry and full automatic gain control for multiple, independent channels. Digital control function, while suffering from lower manufacturing yield, also proved successful.

Windyka, John A.↗

DOE OSTI2024

Cognitive Grid Optimization

This project laid the foundation to include a security constrained economic dispatch (SCED) within one of the leading simulators which is used to train system operators who keep the lights on for over 150 million people in USA. The SCED is designed to handle very high penetrations of renewable generation as well as battery storage. As a follow on the this project, a Trusted Source Model of the North American Electric Interconnections will be built from public GIS data. The various North American Markets will be emulated. This Trusted Source Model will grow the software developers for the next generation of power applications that are needed to transition to all green generation while everything is electrified.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Digital Twin Applications in the Water Sector: A Review

As cities develop and resource demands rise, the water sector faces crucial challenges to deliver reliable, sustainable, and efficient services. Digital Twins (DTs), virtual replicas of physical systems, offer a promising tool to transform how we manage water infrastructure. Originally developed in the aerospace industry, DTs are now gaining traction in the water sector, enabling real-time monitoring, simulation, and predictive control of water and wastewater treatment, collection and distribution networks, and water reclamation and reuse systems. While still emerging in the water sector, DTs have shown potential to enhance operational efficiency, reduce environmental impacts, and support smarter, more resilient water management. This review study provides a comprehensive overview of current DT applications in the water sector, highlighting successful case studies, technical challenges, and knowledge gaps. It also explores how DTs can help bridge the water–energy nexus by optimizing resources utilized across interconnected systems. By synthesizing recent advances and identifying future research directions, this paper illustrates how DTs can play a central role in building sustainable, adaptive, and digitally-enabled water infrastructure.

digital twin↗

NASA NTRS1973

Remote sensing program

Research projects concerning the development and application of remote sensors are discussed. Some of the research projects conducted are as follows: (1) aerial photographic inventory of natural resources, (2) detection of buried river channels, (3) delineation of interconnected waterways, (4) plant indicators of atmospheric pollution, and (5) techniques for data transfer from photographs to base maps. On-going projects involving earth resources analyses are described.

Liang, T.↗

NASA NTRS2003

Functionally Graded Nanophase Beryllium/Carbon Composites

Beryllium, beryllium alloys, beryllium carbide, and carbon are the ingredients of a class of nanophase Be/Be2C/C composite materials that can be formulated and functionally graded to suit a variety of applications. In a typical case, such a composite consists of a first layer of either pure beryllium or a beryllium alloy, a second layer of B2C, and a third layer of nanophase sintered carbon derived from fullerenes and nanotubes. The three layers are interconnected through interpenetrating spongelike structures. These Be/Be2C/C composite materials are similar to Co/WC/diamond functionally graded composite materials, except that (1) W and Co are replaced by Be and alloys thereof and (2) diamond is replaced by sintered carbon derived from fullerenes and nanotubes. (Optionally, one could form a Be/Be2C/diamond composite.) Because Be is lighter than W and Co, the present Be/Be2C/C composites weigh less than do the corresponding Co/WC/diamond composites. The nanophase carbon is almost as hard as diamond. WC/Co is the toughest material. It is widely used for drilling, digging, and machining. However, the fact that W is a heavy element (that is, has high atomic mass and mass density) makes W unattractive for applications in which weight is a severe disadvantage. Be is the lightest tough element, but its toughness is less than that of WC/Co alloy. Be strengthened by nanophase carbon is much tougher than pure or alloy Be. The nanophase carbon has an unsurpassed strength-to-weight ratio. The Be/Be2C/C composite materials are especially attractive for terrestrial and aerospace applications in which there are requirements for light weight along with the high strength and toughness of the denser Co/WC/diamond materials. These materials could be incorporated into diverse components, including cutting tools, bearings, rocket nozzles, and shields. Moreover, because Be and C are effective as neutron moderators, Be/Be2C/C composites could be attractive for some nuclear applications.

Voronov, Oleg A.↗

NASA NTRS2003

Functionally Graded Nanophase Beryllium/Carbon Composites

Choi, Michael K.↗

NASA NTRS1974

Balancing of high speed interconnect shafting for operation above multiple bending critical speeds

The present work first reviews the key elements of rotating system dynamics which are crucial to the control of lateral vibration levels for supercritical shafting of the type which is considered for use in advanced aircraft applications. Then the results of an analytical investigation of procedures for balancing flexible shafts designed for critical operation are discussed. Some of the conclusions made were: (1) even in undamped configuration, reasonably low vibration levels can be achieved through a sequential multiplane-multispeed balancing process; and (2) combination of analytical response and balancing prediction procedures yields a powerful tool for the dynamic analysis and design of advanced shaft-bearing systems.

Badgley, R. H.↗

DOE OSTI2022

Performance of stainless steel interconnects with (Mn,Co) 3 O 4 -Based coating for solid oxide electrolysis

Mixed transition-metal oxide coatings are commonly applied to stainless steel interconnects for solid oxide cell stacks. Such coatings reduce oxidation and Cr evaporation rates, leading to improved degradation rate and stack lifetime. Here, the ChromLok™ MCO-based composition (Mn,Co) 3 O 4 is applied to Crofer 22 APU stainless steel and evaluated specifically for application in solid oxide electrolyzer stacks operating around 800 °C and utilizing oxygen-ion-conducting solid oxide cells. The MCO coating is found to decrease the stainless steel oxidation rate by about one order of magnitude, and decrease the Cr evaporation rate by fourfold. Furthermore, the coating also dramatically lowers the rate of area-specific resistance increase for stainless steel coupons oxidized for 500 h with constant current applied, from 33 mΩ*cm 2 kh -1 for an uncoated coupon to less than 4 mΩ*cm2 kh -1 for coated coupons. The coating is demonstrated on full-scale interconnects for single-cells, where the coating dramatically reduces degradation rate, and for a stack, which displays stable operation for 700 h.

08 HYDROGEN↗

DOE OSTI2022

A quantitative and holistic circular economy assessment framework at the micro level

Circular Economy (CE) aims to solve resource, waste, and emission challenges by creating a production-to-consumption supply chain that is restorative and environmentally benign. A variety of metrics has been developed with the focus mainly on the macro and meso levels. This work introduces a micro level CE assessment framework that provides i) a set of indicators and metrics with sector-specific dimensions, ii) quantitative and holistic CE overall and category-based metrics, iii) media for data visualization and analysis of CE indicators, and iv) an analytical tool to assess multi-national businesses and the multi-scale and interconnected CE supply chains. Using this quantitative tool, companies are able to track their transition towards CE, conduct temporal analysis, and benchmark their performance against their peers and industry’s standards. The applicability and the capabilities of the developed CE assessment framework is demonstrated through three case studies, with the results demonstrating a clear trend towards circularity.

42 ENGINEERING↗

DOE OSTI2021

Side chain engineering control of mixed conduction in oligoethylene glycol-substituted polythiophenes

A major limitation for polymeric mixed ionic/electronic conductors (MIECs) is the trade-off between ionic and electronic conductivity; changes made that improve one typically hinder the other. In order to address this fundamental problem, this work provides insight into ways that we could improve one type of conduction without hindering the other. Here, we investigated a common oligoethylene glycol side chain polymer by adjusting the oxygen atom content and position, providing structural insights for materials that better balanced the two conduction pathways. The investigated polymer series showed the prototypical conflict between ionic and electronic conduction for oxygen atom content, with increasing oxygen atom content increasing ionic conductivity, but decreasing electronic conductivity; however, by increasing the oxygen atom distance from the polymer backbone, both ionic and electronic conductivity could be improved. Following these rules, we show that poly(3-(methoxyethoxybutyl)thiophene), when blended with lithium bistrifluoromethanesulfonimide (LiTFSI), matches the ionic conductivity of a comparable MIEC [poly(3-(methoxyethoxyethoxymethyl)thiophene)], while simultaneously showing higher electronic conductivity, highlighting the potential of this design strategy. We also provide strategies for tuning the MIEC performance to fit a desired application, depending on if electronic, ionic, or balanced conduction is most important. These results have implications beyond just polythiophene-based MIECs, as these strategies for balancing backbone crystallization and coordinating group interconnectivity apply for all semicrystalline conjugated polymers.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Southeast Regional CO 2 Utilization and Storage Acceleration Partnership (SECARB-USA): Data Quality Methodology (4.2.1)

SECARB-USA Deliverable 4.2.1 utilizes the outputs from the Needs Assessment (Subtask 2.1) to develop a data quality methodology. Many types of data are needed to evaluate a site for technical and financial viability. Several inventories of data types have been produced (for example NETL, 2010). The objective here is to organize the data types so that the needs met are specified. From this cross index (Table 1 in the Appendix), it will be possible in future tasks to (1) determine, on a site-specific basis, how much of each data type is required at each stage of a project to meet the need, and conversely (2) to further specify and define the data collection methods applied such that the data are tailored to fit that need. Derivative tables can then be developed to semi-quantitively evaluate the extent to which need is critical for early go/no decision points, or if it is more important than average, requiring faster or larger capitalization and spend to meet the need. In an additional step, the current availability of data for a site can be semi-quantitively assessed. From the table of data criticality and the table of data availability, site-specific cost for meeting the data needs can be determined, and allow a pre-permit spend estimated for a portfolio of projects. All of the data needs to evaluate a site are somewhat interconnected. We used criterion (2) above to determine if the data collection design would have to be modified to meet the need; if this was commonly true a linkage was shown. The application of this cross index to sites in the subsequent tasks will demonstrate that the demand for data types varies site-to-site and project-to-project. Examples of factors to be considered are the complexity of the geology, the injection goals such as rate and duration of the injection, and the types of risk and risk tolerance of key stakeholders. In future tasks the team will compare the demand for data with existing data availability. This will, in turn, determine when data needs to be acquired to support project development. For example, in a project area with complex structure, 3-D seismic data may be needed earlier and more urgently than in an area with simple rock body geometries. In some locations, a 3-D seismic survey has already been collected and can be purchased. In other locations the project developer will need to collect these data. For another example, a project near an urban area or near to a park may generate earlier and more substantive public concern than a site that is developed in mined lands. A calculation using the derivative from table 1 will show the different investment needs. Project cost will vary corresponding to data criticality and data availability.

42 ENGINEERING↗