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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Pulse duration dependent effects of ultrafast laser induced damage on a 1030 nm multi-layer dielectric mirror for high repetition rate, high average power laser systems

High repetition rate, high peak, and average power laser systems are crucial for next-generation particle accelerators, inertial confinement fusion, and secondary particle sources. These applications demand durable laser optics, particularly interference coatings on optics lasting millions of shots at high fluence. This study focuses on designing, testing, and simulating multi-layer dielectric (MLD) mirrors for pulse durations of 260 fs, 77 fs, and 25 fs at 1030 nm wavelength and 45-degree incidence angle with p -polarization. S-on-1 laser-induced damage thresholds (LIDT) for varying pulse numbers were determined, with single-shot LIDT values of 0.98 Jcm -2 , 1.63 Jcm -2 , and 2.3 Jcm -2 for 25 fs, 77 fs, and 260 fs respectively. A strong correlation between blister shape and local fluence was observed, implying that the layer expansion in a blister depends on local fluence. We have also examined mechanisms responsible for laser-induced stress generation and energy release rates in blister formation. Damage mechanisms are further explored by finite-difference time-domain (FDTD) simulations, incorporating Keldysh strong field ionization, whose predictions were in excellent agreement with the onset of damage determined experimentally. These findings offer insights for enhancing MLD coating technology, promising more efficient and resilient laser systems for diverse scientific and industrial applications.

Noor, Mohamed Yaseen (ORCID:000000021036644X)↗
DOE OSTI2020

High-power few-cycle Cr:ZnSe mid-infrared source for attosecond soft x-ray physics

The development of mid-infrared, high-energy pulses of extremely short pulse duration is of great importance to the strong-field physics community, as it enables extension of the high-harmonic cutoff towards the keV range of photon energies. Here we demonstrate a C r 2 + : Z n S e laser amplifier delivering 7 mJ, 100 fs pulses at 1 kHz repetition rate and 2.4 µm central wavelength with excellent energy stability and beam quality. These pulses are post-compressed to 39 fs, 6.2 mJ, and 115 GW peak power in a novel nonlinear compression scheme. The laser system was used to generate coherent soft x-ray radiation up to 0.6 keV covering the entire water window, which is of high importance for bio-relevant applications. The obtained results open a wide range of applications in nonlinear optics, attosecond and strong-field physics, and remote sensing.

Leshchenko, Vyacheslav E. (ORCID:0000000199708559)↗
DOE OSTI2020

High-dimensional and high-resolution x-ray tomography for energy materials science

At the forefront of developments in synchrotron x-ray microscopy, we report nanoscale-resolution high-dimensional spectrotomography under controlled sample environments has been demonstrated. Such cutting-edge experimental capability has been broadly applied to scientific studies in the field of energy materials science, where the dynamically evolving structural and chemical defects play a vital role in the functionality. In this article, we review novel developments of this technique from both experimental and data/information mining perspectives. Using studies on lithium-ion battery electrode materials as examples, we highlight the rich information in the high-dimensional and high-resolution x-ray tomographic data, which can be used to interpret the complicated thermal-electro-chemo-mechanical interplay that occurs under the operating conditions and collectively determines battery performance. We also discuss the frontier challenges in this field and our perspectives of the future directions in the context of projected major developments in the landscape of largescale x-ray facilities across the globe.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Highly-Accessible Catalysts for Durable High-Power Performance (Final Technical Report)

Reduction of costly Pt usage in proton exchange membrane fuel cell (PEMFC) electrodes is one of the major challenges towards development and commercialization of fuel cell electric vehicles (FCEV). However, reducing the Pt loading results in increasing local mass transport fluxes, and eventual performance loss, especially at high power. In this project, a team of 4 universities, 2 companies, and a national lab came together to develop fuel cell catalysts and electrodes with high performance and durability. The were several key concepts addressed in this project. The first concept is to develop a carbon support that possess internal porosity which are believed to enhance kinetic activity of the catalysts, and yet the pore morphology allows for good reactant transport. The second concept is to improve the Pt-electrolyte interface in hope to reduce the local transport resistance. This was done by using new ionomers and ionic liquids. The last concept involves improving the catalyst stability by introducing Pt alloy catalyst with ordered intermetallic phase. The collaborative platform provided by DOE funding enabled development of a highly active and durable catalyst with performance that exceeds previous catalysts and meets the DOE targets for light duty vehicle application.

08 HYDROGEN↗
DOE OSTI2020

Advanced High-Performance Computational Modeling of the Seismic Response of High-Hazard and/or Nuclear Facilities and Critical Infrastructure at the NNSS

New methods for predicting the amplitude and variability of ground shaking from earthquakes (and explosions) are needed for seismic hazard analysis for buildings, nuclear power plants, and critical infrastructure at the NNSS. We are comparing existing 1-D and new 3-D geophysical methods for estimating the shear-wave velocity structure in the upper 30 meters of the ground surface (Vs30), which plays a major role in ground motion amplification and seismic response of buildings. We evaluate the performance of these methodologies at the U1a Complex at the NNSS and develop simple 1-D and high-resolution 3-D Vs30 models. We then emplace these high-resolution models into a background seismic velocity model. We will collaborate with Lawrence Livermore National Laboratory (LLNL) to conduct numerical modeling of the ground shaking at the NNSS using their high-performance computing technology and state-of-the-art ground motion simulation methodology. The primary work that was completed in FY 2019 was to acquire the seismic systems and familiarize staff at the NNSS with their use. We also worked on developing a collection plan with the Device Assembly Facility (DAF) at the NNSS, but due to time constraints and other ongoing projects at the DAF, we had to use U1a as a backup. We were able to coordinate the seismic survey, and we will complete the collection of seismic data in FY 2020. Additionally, during FY 2019, we completed the geologic framework model (GFM) for the U1a Complex and modeled the Yucca fault. LLNL worked with us through FY 2019 to prepare the data files for their modeling software and tested the software for reliability. In FY 2020 we will develop the end-to-end capability so that any facility could easily be modeled and the expected shaking from a local earthquake understood. The work in FY 2020 will include building fault models from the GFM and finalizing the velocity model analysis. The final simulations will be run for multiple rupture models, and final assessments will demonstrate the seismic hazard at the U1a Complex.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

High Energy Physics Network Requirements Review (Final Report, July-October 2020)

Throughout 2020, ESnet and the Office of High Energy Physics (HEP) of the DOE SC organized an ESnet requirements review of HEP-supported activities. Preparation for this event included identification of key stakeholders: program and facility management, research groups, technology providers, and a number of external observers. These individuals were asked to prepare formal case study documents about their relationship to the HEP program to build a complete understanding of the current, near-term, and long-term status, expectations, and processes that will support the science going forward. A series of pre-planning meetings better prepared case study authors for this task, along with guidance on how the review would proceed in a virtual fashion.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

A High-Voltage High-Reliability Scalable Architecture for Electric Vehicle Power Electronics (Final Report)

This project developed and demonstrated new composite converter technologies that lead to high power density (> 20 kW/L) at power levels of 10s of kW, 100s of kW, or possibly higher, with fundamental advances in converter efficiency and Q that lead to substantial increases in mean time to failure (MTTF). These advantages were realized through development of new composite converter topologies that perform buck, boost, or other conversion functions and that are scalable to higher voltage and power levels through sharing of voltage and current stresses among multiple dissimilar partial-power converter modules. The project led to experimental demonstration of a125 kW multifunction electric vehicle power conversion system having in-creased dc bus voltage (950 V nominal, 1200 V peak) that interfaces a 200 V to 400 V battery pack, and that includes integrated level 2 wired charging and wireless charging functions. The project incorporated SiC MOSFET modules having switching frequencies in excess of 100 kHz, planar magnetics, a hierarchical control architecture that enables scaling to higher voltages and powers with additional converter modules, and a high-power density in excess of 20 kW/L. The research demonstrated how a more complex converter approach can increase mean-time-to-failure, even though the number of elements is increased. This is achieved through significant reduction of temperature rise through fundamentally superior converter circuit topologies. The research also demonstrated new high power planar magnetics that increase power density. The technology is appropriate to a variety of applications including EV power trains, EV charging, PV inverters, battery storage, and similar areas. These systems potentially can be manufactured in the U.S.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Framework for Characterizing the Performance of High-Early Strength, High-Volume Fly Ash (HVFA) Concrete Structures

This presentation will highlight the development of a comprehensive framework to characterize the performance of high-volume fly ash (HVFA) concretes at early ages and discuss the resulting implications for concrete structures built using such materials. Achieving high-early compressive and/or flexural strength is often of particular importance for precast and/or prestressed concrete components – due to early age loading demands resulting from lifting, handling, or application of initial prestress – or other types of concrete structures that can significantly benefit from rapid strength development - such as for bridge deck repairs. The framework first includes a methodology for optimizing the strength of HVFA cementitious binders before subsequently scaling up the technology to evaluation of fresh and hardened HVFA concrete performance. A series of trial mix designs will be presented to demonstrate the effectiveness of the framework to achieve not only the desired high-early strength targets but also satisfactory workability, often in the form of self-consolidating concrete. Mechanical performance was evaluated at several age-dependent milestones and, in conjunction with estimating concrete strength using the maturity method, was ultimately used to facilitate the development of novel strength development history curves. By way of these datasets, concrete mechanical properties were utilized in the design of prototype structural components, such as beams and wall panels, for subjection to larger-scale experimental testing. Implications for other pertinent HVFA concrete performance attributes, such as shrinkage or creep, will also be discussed. The framework also includes a comprehensive methodology for evaluating the environmental life-cycle performance of HVFA concrete structures focused on mitigating any unwarranted environmental consequences resulting from beneficial HVFA reuse in concrete. Strategies for more widespread implementation of HVFA concrete materials into construction practice will also be presented. Lastly, the role of the HVFA concrete framework towards the development of new provisions for building codes and/or design standards, and recommendations for future research needs will also be discussed.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

High-Fidelity and High-Performance Computational Simulations for Rapid Design Optimization of Sulfur Thermal Energy Storage (CRADA Report)

NREL and Element 16 collaborated on sulfur thermal energy storage modeling using NREL’s high performance computing (HPC) resources to assist its application in industrial processes. Industrial process heat (IPH) accounts for ~70% of US manufacturing energy use and is primarily produced by fossil fuel combustion. Approximately, 1500 TWht (~60% Terawatt hour thermal) of IPH demand is in the temperature range of 100-300°C. Industrial applications in this temperature range include drying, hydrothermal processing, thermal enhanced oil recovery, food and beverage, bioethanol production, etc. Cost-effective thermal energy storage (TES) that increases the utilization of waste and renewable heat (solar, geothermal, etc.) could provide significant energy savings and reliable heat sources, decrease emissions, and increase US manufacturing competitiveness through reductions in fuel consumption. This HPC4EI project facilitated Element 16’s development of low-cost and high-impact molten sulfur TES for dispatchable IPH. The development of a high-fidelity model validated by experimental data and HPC simulations enabled the successful resolution of the complex interplay between fluid dynamics and heat transfer processes during transient operation of sulfur TES, overcoming the numerical challenges posed by the non-linear temperature-dependent physical properties of sulfur. The project helped accelerate Element 16’s molten sulfur TES product design and support its broad applications.

25 ENERGY STORAGE↗
DOE OSTI2024

Microscopic 3D Graphene for High-Performance Supercapacitors with Ultra-High Areal Capacitance

Despite graphene being considered as an ideal supercapacitor electrode material, its use in commercial devices is limited because few methods exist to produce high-quality graphene at large scale and low-cost. We report a simple method to synthesize 3D graphene by graphenization of coal tar pitch with a K2CO3 catalyst. This produces 3D graphenes with high specific surface areas up to 2113 m2 g-1 and exceptional crystallinity (Raman ID/IG as low as ~ 0.15). The material has an outstanding specific capacitance of 182.6 F g-1 at a current density of 1.0 A g-1. This occurs at mass loading of 30 mg cm-2 which is 3 times higher than commercial requirements, yielding an ultra-high areal capacitance of 5.48 F cm-2. Moreover, the K2CO3 is recycled and reused over 10 cycles. The synthesis method and resulting electrocapacitive performance properties create new opportunities for using 3D graphene more broadly in practical supercapacitor devices.

Pham, Viet Hung↗
DOE OSTI2023

High Density Thermal Energy Storage by Highly Stable Glauber’s Salt Composites with Low Supercooling for Building-Scale Application

Phase change materials (PCM) are a promising candidate for thermal energy storage in building infrastructure, enabling grid-integrated peak load shaving by utilizing energy production in off-peak hours. Glauber’s salt (Na2SO4.10H2O, Sodium sulfate hydrate) are highly attractive due to their high energy storage capacity and low cost but Glauber’s salt suffers from long-standing challenges including high supercooling ( > 15oC) and low thermal cyclic stability, which is a major setback for practical building-scale energy storage applications. Here, we developed a unique ionic molecular nucleating agent for Glauber’s salt which reduced the supercooling temperature to less than 5oC. By combining this nucleated SSD with a polymer, phase segregation of salt hydrate for over 100 thermal cycles without degradation was achieved. Key was that the polymer confined the SSD crystals, preventing phase separation. In addition, we applied our stable Glauber’s salt composite in a miniatured building model and demonstrate that our PCM composite can be utilized for real-world building infrastructure.

additives↗
DOE OSTI2025

High-Speed and High-Quality Field Welding Repair Based on Advanced Non-Destructive Evaluation and Numerical Modeling

Creep strength-enhanced ferritic (CSEF) steels such as Grade 91 (9Cr-1Mo-V) and Grade 92 (Fe-9Cr-2W-0.5Mo) steels are widely used in the fossil-fuel-fired and nuclear power plants. The weld integrity of these steels is crucial for power plants' safe and reliable operations. Due to harsh service conditions, the steel weld can become susceptible to environmental degradation. Field welding repair is used to restore the degraded weld’s performance where a controlled temper-bead welding technique is commonly used to temper the freshly formed martensite during welding. However, knowledge of weld repairability is limited and experimental trial and error optimization to achieve desired microstructure and joint properties is expensive and time-consuming. Many existing computational models, e.g., finite element models, are limited to solving heat conduction equation and ignoring convective heat transfer due to molten metal flow. These models can result in over-prediction of peak temperatures of weld pool and heat-affected zone (HAZ), which in turn can affect the accuracy of tempering prediction. Moreover, these finite element models require an input of the deposit profiles in advance and thus limits the usability of these models. Here, a molten pool-based, multi-pass multi-layer model has been developed based on computational fluid dynamics (CFD) approach with the Volume of Fluid (VOF) method. The model calculates the bead formation, thereby eliminating the need for pre-determined bead profiles required by finite element models. For computational efficiency, a coordinate system attached to the moving heat source is utilized. A subroutine is developed to convert the temperature profiles in the reference frame stationary to the heat source to that stationary to the workpiece. The converted thermal cycles are then imported into a microstructure model to compute the tempering kinetics and resultant hardness using a Johnson-Mehl-Avrami-Kolmogorov (JMAK), and modified Grange-Baughman parameter. The modeling approach is first developed and validated on single- and multi-pass deposition of stainless steel filler metal onto a SA-533 high strength steel substrate. The models are then applied to a multi-pass V-groove repair weld of Grade 91 steel plate as well as directed energy deposition of Grade 92 steel. Non-destructive characterization of microstructures was performed on Grade 91 and 92 steel welds. Two welding processes, cold metal transfer (CMT) and flux-cored arc welding (FCAW), were investigated for the Grade 91 steel weld samples. For the Grade 92 weld samples, three different heat inputs (low, medium, and high) of gas tungsten arc welding (GTAW) were utilized to replicate traditional field welding processes. The non-destructive evaluation (NDE) method used for this research was immersion ultrasonic testing (UT) using a micro-resolution ultrasonic imaging methodology specifically designed to operate in the through-transmission configuration operating at 20 MHz of frequency. The system used a focused ultrasonic beam spot size diameter between 250-300 μm, and a 6 μm laser vibrometer spot size for detection, to produce highly defined images with longitudinal and mode-converted shear waves. From the micro-resolution ultrasonic C-scan images, three microstructural regions, i.e., weld metal (WM), HAZ, and base metal (BM), were clearly identifiable. Various levels of ultrasonic amplitudes distributed over the three regions were correlated with electron beam backscattered diffraction (EBSD) images using grain size, grain boundaries, and dislocation densities. The results showed that areas with relatively higher ultrasonic amplitude levels were associated with smaller grains and higher dislocation densities, while areas with lower amplitude levels were associated with larger grains and lower dislocation densities. In addition, ultrasonic velocity data obtained across the three different weld microstructural regions of Grade 91 test samples were correlated with optical metallographic images and hardness measurements. The results showed distinctive decreases in ultrasonic velocity and hardness over the HAZ region, where weld failures often occur during service.

36 MATERIALS SCIENCE↗
DOE OSTI2025

High Flux Isotope Reactor Low-Enriched Uranium High Density Silicide Fuel Preliminary Design Update: System Transient Analysis

As a part of conversion efforts from highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel under direction of the National Nuclear Security Administration of the U.S. Department of Energy, multiple proposed designs of the High Flux Isotope Reactor (HFIR) have been created and assessed regarding reactor physics performance metrics, including designs utilizing uranium silicide dispersion fuel (U3Si2-Al). This report updates the previous analyses that evaluated the nuclear safety performance of LEU fuel designs with respect to selected accident events from the HFIR Safety Analysis Report (SAR). Both the Low Density (LD) and High Density (HD) Optimized designs’ reactivity initiated accident fuel performance improved relative to the HEU fuel, attributed to greater 238 U negative Doppler feedback. However, the thermal margins for primary coolant system accidents were reduced with some acceptance criteria unable to be met. The need to resolve reduced thermal margin, open modeling items, and unresolved assumptions was identified.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

High waste loading glass formulation development for High-Mn HLW

One of the primary objectives of the work described herein was to develop and identify HLW glass compositions and glass forming additive blends that achieve high waste loadings and processing rates for high manganese HLW streams while maintaining acceptable glass properties. Another objective was to determine the effect of the form of manganese (MnO, MnO2, MnCO3) on feed processing properties, glass production rates, and product quality while vitrifying a high manganese HLW stream. This was accomplished through a combination of crucible-scale tests, vertical gradient furnace tests, and confirmation tests on a DM100 melter system.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Low-Cost Highly Recyclable Structural Composites Utilizing Vitrimers and Natural Fibers (Basalt) Manufactured via a Novel Pultrusion Method for High-Volume Applications

The project’s overall goal is to explore and demonstrate as proof-of-concept that a highly recyclable and repairable composite material system, that is reinforced with natural fibers, can be used to produce lightweight structural components using a low-cost manufacturing process for high-volume automotive applications. More specifically, the project’s objectives will focus on vitrimer resins (which are a hybrid polymeric system of thermoplastics and thermosets) reinforced with basalt fibers and manufactured using pultrusion technologies. Pultrusion, as a method, is well-known to be one of the lowest-cost manufacturing processes for high-volume applications. However, to date, the validity and viability of such attractive objectives have not been demonstrated in support of the automotive industry.

36 MATERIALS SCIENCE↗
DOE OSTI2020

CLUE: A Fast Parallel Clustering Algorithm for High Granularity Calorimeters in High-Energy Physics

One of the challenges of high granularity calorimeters, such as that to be built to cover the endcap region in the CMS Phase-2 Upgrade for HL-LHC, is that the large number of channels causes a surge in the computing load when clustering numerous digitized energy deposits (hits) in the reconstruction stage. In this article, we propose a fast and fully parallelizable density-based clustering algorithm, optimized for high-occupancy scenarios, where the number of clusters is much larger than the average number of hits in a cluster. The algorithm uses a grid spatial index for fast querying of neighbors and its timing scales linearly with the number of hits within the range considered. We also show a comparison of the performance on CPU and GPU implementations, demonstrating the power of algorithmic parallelization in the coming era of heterogeneous computing in high-energy physics.

Rovere, Marco↗
DOE OSTI2023

High-brightness electron injectors for high-duty cycle X-ray free electron lasers

The successful development in the last two decades of X-ray free electron lasers (FELs) with their revolutionary brightness performance has been tightly dependent on the parallel development of electron guns and injectors capable of providing the high-brightness electron beams required by FELs lasing at these short wavelengths. The ultimate brightness delivered by a linear accelerator (linac) is already set at its injector and the remaining part of the accelerator can be only designed to preserve the injector performance. The technology to be used for the accelerator part of an X-Ray FEL strongly depends on the duty-cycle at which the FEL operates. Normal-conducting, room-temperature, copper-based radio frequency (RF) technology is typically used for low duty-cycles of up to approximately 10 −3 . For higher duty-cycles and up to continuous wave (CW) operation, the linac must rely on superconductive RF technology because, with the higher duty-cycle, the increasingly higher power dissipated in normal conducting RF structures becomes excessive for the warm technology. The situation changes in the lower energy part of the accelerator, where injector schemes, based on direct current, normal-conducting, and superconducting RF electron guns, are demonstrating the beam quality performance required by high-duty-cycle X-ray FELs. In this paper we start with a description of the requirements for such injectors, followed by an overview of the pursued technologies and schemes, and by a discussion on the main differences in terms of beam dynamics between low and high duty-cycle injectors.

Sannibale, Fernando↗
DOE OSTI2022

LiNi 0.8 Fe 0.1 Al 0.1 O 2 as a Cobalt-Free Cathode Material with High Capacity and High Capability for Lithium-Ion Batteries

Obtaining cathode materials with high capacity and cycle stability is one of the main challenges regarding the success of electric vehicle technologies. However, most of the widely used materials with these properties involve the use of toxic and expensive cobalt as the active material. To overcome this challenge, this work proposes a novel cobalt-free cathode material, synthesized for the first time using a solid-state reaction, whose general formula is LiNi 0.8 Fe 0.1 Al 0.1 O 2 (NFA). This class of materials offers high capacity and reduces the battery costs by removing cobalt, without jeopardizing the structural stability and safety of the NFAs. The morphology and the structural properties of the obtained NFA cathode material were characterized using different techniques, e.g., scanning electronic microscopy, X-ray diffraction, X-ray fluorescence, and infrared and Raman spectroscopies. The electrochemical activity and diffusivity of the Li-ion during lithium removal and its insertion into the bulk of the NFA cathode demonstrated high-yield specific capacities of ≈180 mAh g –1 at 0.1C, along with a reasonable rate capability and cycling stability, with a capacity retention of ≈99.6% after 100 charge/discharge cycles at a rate of C/2, and whose operando X-ray diffraction experiments have been used to study the crystallographic transitions during the lithiation–delithiation reaction.

25 ENERGY STORAGE↗