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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 OSTI2024

High Temperature Copper Metallization: Demand, Hurdles and Reliability

As newer cells structures come online, the pressing need to replace silver in the metallization pastes has renewed interest in alternative technologies employing base metals. Copper typically leads the charge with its abundance and lower cost but has faced numerous obstacles from relatively higher oxidation and diffusion rates which can damage the lifetime of the devices. In this study, a low-cost alternative to silver metallization pastes has been shown on PERC cells. The screen printable copper paste can be fired in air at temperatures >500 degrees C, and the impact of processing conditions and equipment on the performance and reliability of 274 cm2 cells have been evaluated. Through damp heat testing of micro-modules using 16 cm2 cells, routes that can lead to both the failure and success of durable contacts have been demonstrated.

copper↗
DOE OSTI2022

Snapshots of a light-induced metastable hidden phase driven by the collapse of charge order

Nonequilibrium hidden states provide a unique window into thermally inaccessible regimes of strong coupling between microscopic degrees of freedom in quantum materials. Understanding the origin of these states allows the exploration of far-from-equilibrium thermodynamics and the development of optoelectronic devices with on-demand photoresponses. However, mapping the ultrafast formation of a long-lived hidden phase remains a longstanding challenge since the initial state is not recovered rapidly. Here, using state-of-the-art single-shot spectroscopy techniques, we present a direct ultrafast visualization of the photoinduced phase transition to both transient and long-lived hidden states in an electronic crystal, 1T-TaS 2 , and demonstrate a commonality in their microscopic pathways, driven by the collapse of charge order. We present a theory of fluctuation-dominated process that helps explain the nature of the metastable state. Our results shed light on the origin of this elusive state and pave the way for the discovery of other exotic phases of matter.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2025

Emergent Dimer-Model Topological Order and Quasiparticle Excitations in Liquid Crystals: Combinatorial Vortex Lattices

Liquid crystals have proven to provide a versatile experimental and theoretical platform for studying topological objects such as vortices, skyrmions, and hopfions. In parallel, in hard condensed matter physics, the concept of topological phases and topological order has been introduced in the context of spin liquids to investigate emergent phenomena like quantum Hall effects and high-temperature superconductivity. Here, we bridge these two seemingly disparate perspectives on topology in physics. Combining experiments and simulations, we show how topological defects in liquid crystals can be used as versatile building blocks to create complex, highly degenerate topological phases, which we refer to as “combinatorial vortex lattices” (CVLs). CVLs exhibit extensive residual entropy and support locally stable quasiparticle excitations in the form of charge-conserving topological monopoles, which can act as mobile information carriers and be linked via Dirac strings. CVLs can be rewritten and reconfigured on demand, endowed with various symmetries, and modified through laser-induced topological surgery—an essential capability for information storage and retrieval. We demonstrate experimentally the realization, stability, and precise optical manipulation of CVLs, thus opening new avenues for understanding and technologically exploiting higher-hierarchy topology in liquid crystals and other ordered media.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A 75 kVA Intelligent Power Stages (IPS) Unit Design for Future Grid-interface Application

The demand for grid-interface converter with flexible dc bus is driven by the fast development of energy storage system (ESS), electric vehicle (EV) charging system, and versatile residential load. This paper first proposes a two-stage intelligent power stage (IPS) unit for future grid-interface applications. To achieve zero common-mode (CM) voltage emissions, step-up and step-down voltage gain, a 3-level four-switch buck-boost (3-L FSBB) dc-dc converter is adopted with fully zero voltage switching (ZVS). In one IPS unit, an advanced fiberoptic communication with sub-nanosecond synchronization is developed for different enhanced gate drivers. Moreover, an enhanced gate driver integrated current and voltage sensors is designed for monitoring and diagnostics. To achieve a whole low-profile design, three 12 oz heavy copper planar ac inductors are designed and implemented. Finally, a 75 kVA IPS unit was built to verify both the thermal and electrical design.

Cao, Yuliang↗
DOE OSTI2022

Breakdown of Electric Vehicle Supply Equipment Installation Costs

The plug-in electric vehicles (PEVs) market is receiving help from the current political climate, incentives at the federal and state levels, excessive cost of petroleum fuel, growing focus on climate solutions, increasing investment and direction by automobile manufacturers and increased awareness through media reports and advertising. Increasingly, the transportation industry, in both the United States and many other countries, is aimed at electric motive energy where practical. Increased investment in research and development have led to increasing vehicle range and lower battery costs; both of which have been deterrents in the past. The increasing demand for PEVs (consisting of the battery electric vehicle [BEV] and plug-in hybrid electric vehicle [PHEV], is challenged by the need for charging infrastructure to support these vehicles. The BEV relies totally on the on-board battery to supply the motive energy while the PHEV utilizes its battery and an installed internal combustion engine (ICE). The maximum benefit is achieved by using the battery power as much as possible. This arrangement requires the use of battery charging equipment, known as electric vehicle supply equipment (EVSE).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Multilayer Electrodes with Metalized Polymer Current Collector for High-Energy Lithium-Ion Batteries with Extreme-Fast-Charging Capability

The pursuit of batteries capable of extreme fast charging (XFC), that also satisfy high energy and safety criteria, poses a significant challenge to current lithium-ion battery technologies. Additionally, the increasing demand for aluminum (Al) and copper (Cu) in electrification, and vehicle lightweighting is driving these metals towards near-critical status in the medium term. This study introduced metalized polymer films by depositing an Al or Cu thin layer onto two sides of a polyethylene terephthalate (PET) film – named mPET/Al and mPET/Cu, as lightweight, cost-effective alternatives to traditional metal current collectors in LIBs.

25 ENERGY STORAGE↗
DOE OSTI2021

A Contrast Calibration Protocol for X-ray Speckle Visibility Spectroscopy

X-ray free electron lasers, with their ultrashort highly coherent pulses, opened up the opportunity of probing ultrafast nano- and atomic-scale dynamics in amorphous and disordered material systems via speckle visibility spectroscopy. However, the anticipated count rate in a typical experiment is usually low. Therefore, visibility needs to be extracted via photon statistics analysis, i.e., by estimating the probabilities of multiple photons per pixel events using pixelated detectors. Considering the realistic X-ray detector responses including charge cloud sharing between pixels, pixel readout noise, and gain non-uniformity, speckle visibility extraction relying on photon assignment algorithms are often computationally demanding and suffer from systematic errors. In this paper, we present a systematic study of the commonly-used algorithms by applying them to an experimental data set containing small-angle coherent scattering with visibility levels ranging from below 1% to ∼60%. We also propose a contrast calibration protocol and show that a computationally lightweight algorithm can be implemented for high-speed correlation evaluation.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Development and Demonstration of Medium-Heavy Duty PHEV Work Trucks

The heavy-duty vehicle market (Class 6-8) has been a difficult segment for the introduction of plug-in vehicles due to the large energy storage requirement (with corresponding cost), challenging duty cycles, and the diversity of vehicle configurations. The Work Truck market represents a significant opportunity for Heavy-Duty PHEV adoption. (1) The usage cycle includes driving and stationary/worksite power requirements, ensuring full daily usage of the grid-charged battery (battery size: 15-30kWhr). Though daily driving can often be short (an average of 26 miles per day), worksite power includes substantial demand (hydraulics, exportable 110/220V power, 12V support, HVAC). (2) Worksite power demands for conventional vehicles require continuous loaded engine operation, resulting in significant emissions, fuel consumption and noise impacts. (3) These trucks serve an industry that is highly diverse in final vehicle duty cycle, configuration, and jobsite power demands resulting in the need for a modular, configurable hybrid solution. Through this program, Odyne has developed and demonstrated a medium/heavy duty plug-in hybrid solution capable of meeting the needs of the work truck market while delivering fuel and emissions reductions of 50% or greater when evaluated against the full-day work truck duty cycle. The Odyne system developed in this project was released for commercial sale as the G2V7 Odyne Plug-in Hybrid and ePTO systems. The testing and field demonstration proved that the Odyne hybrid system is capable of reducing work truck fuel use and emissions by over 50% while subsequent commercial sales demonstrate the flexibility of the modular design and the capability to support electric systems of 12 – 30 kW and hydraulic based systems of 60 kW (80 HP) or greater. Odyne is continuing to work with suppliers on reducing component costs and working with supporting agencies to initiate projects to increase the driving and full day fuel and emissions savings in order to continue to improve the customer value and return on investment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Pueblo of Laguna Village Community Solar

The project was to install approximately 11.44 kilowatts (kW) rooftop solar photovoltaic (PV) system on the Mesita Village Community Center, an approximately 9.24 kW rooftop solar PV system on the Paguate Village Community Center, an approximately 21.56 kW rooftop solar PV system on the Paraje Village Community Center, and an approximately 11.00 kW rooftop solar PV system on the Seama Community Center, for a total of about 53.24 kW on four village community centers. The systems were expected to generate approximately 93,329 kWh annually. Installing solar PV systems on the four village community centers would have helped achieve the Pueblo of Laguna’s six energy objectives: community development (decreased utility bills, funds for other needs), economic development (training and participation in the renewable energy economy), energy reliability (future storage), community resilience (alternative sources), relationship to people and the natural world (reducing fossil fuel use), and energy sovereignty (Pueblo decision-making). Installing solar PV systems would have also met specific project goals to offset not less than 85% of each selected building’s annual electricity use, ranging from 87% to 103% of demand; save a minimum of 70% of the cost of utility bills per year for each building, ranging from 75% to 77% percent (including service charges); and would have had payback periods shorter than the estimated useful life of the project

14 SOLAR ENERGY↗
DOE OSTI2024

Electric Vehicle Charging for Residential and Commercial Energy Codes: Technical Brief

Numerous studies show that sales of electric vehicles (EVs) have grown consistently over recent years in the U.S. The U.S. Energy Information Administration (EIA) estimated 3 million EVs were on the road in 2022, and the Edison Electric Institute (EEI) forecasts a total of 26.4 million EVs on the road by 2030. Based on this forecast, EEI projects the need for an additional 12.9 million EV charge ports by 2030. If EV charging infrastructure fails to keep pace with sales of EVs it could result in consumers stranded without options to power their vehicles. EVs are capable of providing substantial benefits to the consumers. EVs are less expensive to operate than conventional internal combustion engine vehicles, have lower maintenance costs, and have the convenience of fueling (charging) at home or work. Studies conducted in California show that costs associated with installing EV charging infrastructure can be substantially more expensive for retrofit scenarios compared to new construction, making inclusion of EV infrastructure in new construction codes a cost-effective policy option to increase infrastructure to meet growing demands. PNNL tracks adoption of mandatory EV provisions across the U.S. As of December 20, 2024, 12 states (California, Oregon, Washington, Colorado, New Mexico, Illinois, Maryland, Delaware, New Jersey, Rhode Island, Massachusetts and Vermont) and 53 local governments have added EV provisions to their building codes, local ordinances and zoning requirements. Originally published in 2022, this tech brief has been revised to align with recent model energy code committee discussions and published EV infrastructure code language. This technical brief summarizes market trends, costs and benefits, and provides sample code language for EV charging infrastructure for consideration to be included in model codes, such as the International Energy Conservation Code (IECC) and ANSI/ASHRAE/IES Standard 90.1, as well as directly by states and local governments in their building codes. The technical brief summarizes related efforts undertaken by states and local governments, and builds upon language considered during the 2021 and 2024 IECC development cycles.

2021 IECC↗
DOE OSTI2020

Balancing Ionic and Electronic Conduction for High‐Performance Organic Electrochemical Transistors

Abstract Conjugated polymers that support mixed (electronic and ionic) conduction are in demand for applications spanning from bioelectronics to energy harvesting and storage. To design polymer mixed conductors for high‐performance electrochemical devices, relationships between the chemical structure, charge transport, and morphology must be established. A polymer series bearing the same p‐type conjugated backbone with increasing percentage of hydrophilic, ethylene glycol side chains is synthesized, and their performance in aqueous electrolyte gated organic electrochemical transistors (OECTs) is studied. By using device physics principles and electrochemical analyses, a direct relationship is found between the OECT performance and the balanced mixed conduction. While hydrophilic side chains are required to facilitate ion transport—thus enabling OECT operation—swelling of the polymer is not de facto beneficial for balancing mixed conduction. It is shown that heterogeneous water uptake disrupts the electronic conductivity of the film, leading to OECTs with lower transconductance and slower response times. The combination of in situ electrochemical and structural techniques shown here contributes to the establishment of the structure–property relations necessary to improve the performance of polymer mixed conductors and subsequently of OECTs.

Savva, Achilleas↗
DOE OSTI2025

Elucidating the impact of fiber source on polypropylene/hemp composite performance for the automotive industry

Given their high strength-to-weight ratio, there is an ever-increasing volume of plastics being used in the automotive industry as plastics aid in the charge to lightweight vehicles for improved fuel efficiency. However, these plastics are often landfilled at their end-of-life, which has given rise to the demand for sustainable materials and waste management alternatives compared to purely synthetic systems. Natural fiber composites have been explored as a viable material option to reduce the environmental impact of plastic use in automobiles while simultaneously ensuring the part performance is not sacrificed. Herein, we explored the use of hemp/polypropylene (PP) composites in which US-sourced hemp is compared to internationally sourced and industrially available hemp. There appears to be a minimal impact on the composite properties regardless of fiber sourcing, and the addition of a natural filler to the PP matrix results in up to a 367% increase in Young's modulus, 126% increase in heat deflection temperature, and comparable water uptake performance. It should be noted that the natural filler addition does increase density by up to 13% due to the higher density of natural fibers compared to the low-density PP matrix. A modified rule of mixtures calculation revealed that the composite materials produced in this study demonstrated good agreement with analytical modeling. Finally, a screening analysis was performed exploring the transportation of hemp fibers, and the results build a strong case for regionalized manufacturing of automotive parts.

Hubbard, Amber M. [Oak Ridge National Laboratory (↗
DOE OSTI2024

Techno-Economic Analysis and Market Potential of Geological Thermal Energy Storage (GeoTES) Charged With Solar Thermal and Heat Pumps

In this project, we developed a techno-economic analysis (TEA) model that can be used to evaluate the viability of a proposed Geological Thermal Energy Storage (GeoTES) design. This MATLAB-based model integrates distinct subsystem models for the reservoir, wells, power cycle, and solar field to capture their distinct characteristics. It applies this approach in simulating GeoTES storage and dispatch operations for durations ranging from hourly to seasonal. Using cases studies based on GeoTES designs provided by industry partners - Premier Resource Management (PRM) and EarthBridge Energy - we validated the TEA model estimations of system performance and costs (such as thermal and electrical power/energy inflow and outflow, capital costs, and levelized costs of energy and storage) for both concentrating solar thermal (CST) and Carnot Battery (CB) pairings with GeoTES (CST-GeoTES and CB-GeoTES). For the CST-GeoTES case, the model was validated against the proposed system designed by PRM. It showed good agreement with PRM's estimations when well and pump costs derived from PRM's estimations were used. When GETEM-based costs were used, there was a slight overprediction due to GETEM's project/site agnostic assumption of these costs. From a sensitivity analysis perspective, the levelized cost of electricity (LCOE) of the CST-GeoTES case was most sensitive to well flow rate and the charging temperature. An optimal design scenario resulted in an LCOE of 0.11 $\$$/kWhe. CST-GeoTES can also provide a source of heat to meet seasonal demands. With 12-hour and 24-hour levelized cost of heat (LCOH) of 0.018 $\$$/kWhth and 0.022 $\$$/kWhth, respectively, CST-GeoTES could be competitive in the California market with an average industrial price of natural gas in California between 0.041-0.047 $\$$/kWhth. The levelized cost of storage (LCOS) for CST-GeoTES depends on the energy storage duration. Although the LCOS is relatively higher for shorter durations (e.g., ~0.50 $\$$/kWhe for 1 hour of storage), it is an order of magnitude lower (0.06 $\$$/kWhe) for longer storage durations and competitive with lithium-ion batteries (beyond 12 hours of storage) and molten-salt thermal energy storage (beyond 32 hours). Energy. Three options were explored and applied to the EarthBridge case study: (1) A Carnot Battery design using R125 working fluid with both hot and cold storage; (2) A Carnot Battery design using R125 working fluid with only hot storage; (3) A Carnot Battery using a commercially available heat pump with carbon dioxide (CO2) working fluid and hot storage only. The CB-GeoTES with cold storage only had a slight (round-trip) efficiency advantage over the system without (43.4% vs. 42.8%). This is because the cold storage is limited by the freezing point of water, so the cold storage is not much colder than the environment. The system using commercially available technologies was the least efficient - partly because different cycles were used in the heat pump (CO2) and heat engine (binary cycle) which leads to some inefficiencies. Using the commercially available design, the levelized cost of energy (LCOS) from the model (0.10 $\$$/kWhe) was higher than that estimated by EarthBridge (0.068 $\$$/kWhe). This is because of the low round-trip (38.7%) efficiency of the commercially available design. Sensitivity analysis reveals that the model is most sensitive to electricity price. Including electricity price in the TEA for CB-GeoTES leads to an increase in LCOS from the base value to 0.25 $\$$/kWhe. To determine storage sites suitable for GeoTES, we gathered and analyzed geological, petrophysical, and geophysical data of oil and gas reservoir and aquifers in California and Texas. We down-selected possible sites based on cut-off values for site characteristics (e.g., reservoir temperature, formation thickness, permeability, porosity, depth, and brine salinity) and preliminary costs. Using this approach, the Carrizo-Wilcox, Yegua-Jackson, and Dockum brackish aquifers in Texas were identified as having the highest suitability. Similarly, in the central California region, the White Wolf, Belridge South Tulare, and Belridge South Reef Ridge were the most suitable. Going further, we assessed the storage potential in the selected sites. To do this we developed distributions of reservoir characteristic data and applied a Monte Carlo-based analysis to account for intrinsic uncertainty in the acquired data. The analysis revealed that the Carrizo-Wilcox aquifer had the highest storage potential with a mean capacity of 554 TWhth (i.e., 63 TWhe). The estimated capacity serves as an upper limit of storage potential given that not all fields in the basin will be developed. We participated in multiple outreach activities including conference presentations, panel session discussions, and the facilitation of a GeoTES workshop at the NREL Golden campus.

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Integrating Electric Vehicles into the Grid

Historically, transportation and power systems operated independently, but the rise of electric vehicles is transforming this relationship. In the United States, EV demands are expected to become the largest source of electricity load growth, posing challenges for the grid if not properly managed. This presentation highlights how managed charging strategies and strategic infrastructure deployment can integrate EVs into the power system to enhance grid efficiency and support renewable energy.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗
DOE OSTI2025

An On-Demand Electric Transit Case Study of New Rochelle, New York

This work explores the extent to which an on-demand mobility service utilizing lightweight electric vehicles (EVs) provides community and sustainability benefits in New Rochelle, New York. Travel and survey data from September 2019 through 2023 are used to describe the system and estimate impacts on travelers. The system was found to be used more by women (nearly 60%) and younger demographics (>65% under the age of 42), with peak use in the middle of the day and a grocery store as a top origin and destination. The service is utilized primarily for short trips (86% under 2 miles), and the small, right-sized EVs have carbon dioxide emissions associated with charging the fleet that are roughly one-quarter of the fleet emissions of conventional hybrid vans and nearly 50 times less than a fleet of diesel buses. Mapping current socio-spatial dynamics of travel demand can inform equity performance, as well as assist future planning and service area development and possible extensions to similar smaller, lower-density environments that are nearby and connected to major metropolitan areas. The findings in this case study suggest on-demand electric transit may be a significant and growing space for advancing clean and highly valued public mobility services. Sustainable public transport interventions that consider right-sized, electric, on-demand vehicles can help achieve improved accessibility and reduce energy use and greenhouse gas emissions. This work was presented at the Transportation Research Board (TRB) 2025 Annual Meeting on January 7, 2025.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗
DOE OSTI2026

An On-Demand Electric Transit Case Study of New Rochelle, New York

Here, this article characterizes the performance and ridership patterns of an on-demand transit (ODT) service utilizing lightweight electric vehicles (EVs) in New Rochelle, New York. Ridership sociodemographics, travel patterns (both temporal and spatiotemporal), and energy use from the service were explored using travel and survey data from September 2019 through December 2023. The ODT service was found to be used more by women (nearly 60%) and younger demographics (>65% under the age of 42), with peak use in the middle of the day and a grocery store as a top origin and destination. The service was utilized primarily for short trips (86% under 2 mi), with approximately one-third of riders using the ODT service to connect to a train or bus. The costs associated with fueling/charging were compared for different types of fleet vehicles, and the small, right-sized EVs were found to have annual charging costs that were roughly half of the refueling costs for conventional hybrid vans, and 24 times lower than a fleet of diesel buses. Evaluating the vehicle fleet and mapping current socio-spatial travel demand can inform system performance, guide service area development, and support future planning such as expansion to nearby communities and transit hubs. The findings in this case study suggest that on-demand electric transit may be a significant and growing space for advancing highly valued public mobility services. Public transport interventions that consider right-sized, electric, on-demand vehicles can help improve mobility access and reduce energy use and refueling costs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

National Zero-Emission Freight Corridor Strategy

The United States has committed to decarbonizing freight transportation by advancing the deployment of commercial zero-emission medium- and heavy-duty vehicles (ZEMHDVs) and infrastructure. It is pursuing this goal by leveraging historic federal and private investments, policies, and partnerships. Through the U.S. National Blueprint for Transportation Decarbonization1 and the Global Memorandum of Understanding for Zero-Emission Medium- and Heavy-Duty Vehicles,2 the United States has committed to identifying viable pathways and implementation actions that promote at least 30% ZE-MHDV sales by 2030, with a goal of 100% by 2040. These actions, along with the investments laid out in the Bipartisan Infrastructure Law and Inflation Reduction Act, put the nation on a path to advancing transportation and infrastructure solutions that are better for freight movement, our communities, the environment, and the economy. Providing ubiquitous and convenient access to electric vehicle (EV) charging and hydrogen refueling along our nation’s freight corridors, and at truck depots within freight hubs, is key to successfully deploying ZE-MHDVs. Consistent with its charge in the Bipartisan Infrastructure Law, 3 the Joint Office of Energy and Transportation (Joint Office), in collaboration with the U.S. Department of Energy (DOE), Department of Transportation, and the Environmental Protection Agency, has developed the National Zero-Emission Freight Corridor Strategy (Strategy). The Strategy guides infrastructure deployment to meet growing market demands; catalyze public and private investment; and support utility and regulatory planning and action at local, state, and regional levels.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Behavior, Energy, Autonomy, Mobility Modeling Framework (BEAM) v1.0

The Behavior, Energy, Autonomy, and Mobility (BEAM) model is an integrated, agent-based travel demand simulation framework. Individual agents express preferences through a utility- maximizing evolutionary algorithm that minimizes each individual’s cost and time spent traveling via diverse modal options, including the competition for scarce supply resources such as parking spaces and charging infrastructure. BEAM simulates the essential elements that compose a dynamic transportation system. From the road network, parking and charging infrastructure, to the transit system and a synthetic population with plans and preferences, the virtual system is an amalgamation of multiple spatially resolved layers that together represent an integrated transportation system. BEAM is an extension to the MATSim (Multi-Agent Transportation Simulation) model, where agents employ reinforcement learning across successive simulated days to maximize their personal utility through plan mutation (exploration) and selecting between previously executed plans (exploitation). The BEAM model shifts some of the behavioral emphasis in MATSim from across-day planning to within- day planning, where agents dynamically respond to the state of the system during the mobility simulation. In BEAM, agents can plan across all major modes of travel including driving, walking, biking, transit, and demand-responsive ride hailing. It is designed to integrate with other open source transportation models, such as ActivitySim.

Lazarus, Jessica↗