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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Thermal Analysis of a 50 kW Three-Phase Wireless Charging System

In this paper, the thermal analysis of a 50 kW three-phase wireless charging system (WCS) is presented. Addressing the thermal challenge is essential for designing a compact charging pad for 50 kW and higher-power WCS pads. Low thermal conductivity of the Litz wire and ferrite, and uneven distribution of the coil, and core loss cause the high temperature in the charging pads. In this paper, the loss distribution of a 50 kW three-phase WCS is investigated, and the temperature distribution is simulated using finite element analysis (FEA) considering the magnetic and non-magnetic materials of a charging pad. The thermal characteristics of an extremely high-power density 50 kW WCS prototype are tested experimentally for 10 minutes of operation. The simulation and experimental results show that the coil temperature increases to 65°C, the core temperature varies between 50°C to 150°C, and the packaging temperature increases to 65°C after 10 minutes of operation at rated 50 kW output power.

Mohammad, Mostak↗
DOE OSTI2022

Nanostructured $\mathrm{GaAs/(Al,Ga)As}$ Waveguide for Low-Density Polariton Condensation from a Bound State in the Continuum

Exciton-polaritons are hybrid light-matter states that arise from strong coupling between an exciton resonance and a photonic cavity mode. As bosonic excitations, they can undergo a phase transition to a condensed state that can emit coherent light without a population inversion. This aspect makes them good candidates for thresholdless lasers, yet short exciton-polariton lifetime has made it difficult to achieve condensation at very low power densities. In this sense, long-lived symmetry-protected states are excellent candidates to overcome the limitations that arise from the finite mirror reflectivity of monolithic microcavities. In this work we use a photonic symmetry-protected bound state in the continuum coupled to an excitonic resonance to achieve state-of-the-art polariton condensation threshold in a GaAs/(Al,Ga)As waveguide. Most important, we show the influence of fabrication control and how surface passivation via atomic layer deposition provides a way to reduce exciton quenching at the grating sidewalls.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2020

Modeling Assessment of Tidal Energy Extraction in the Western Passage

Numerical models have been widely used for the resource characterization and assessment of tidal instream energy. The accurate assessment of tidal stream energy resources at a feasibility or project-design scale requires detailed hydrodynamic model simulations or high-quality field measurements. This study applied a three-dimensional finite-volume community ocean model (FVCOM) to simulate the tidal hydrodynamics in the Passamaquoddy–Cobscook Bay archipelago, with a focus on the Western Passage, to assist tidal energy resource assessment. IEC Technical specifications were considered in the model configurations and simulations. The model was calibrated and validated with field measurements. Energy fluxes and power densities along selected cross sections were calculated to evaluate the feasibility of the tidal energy development at several hotspots that feature strong currents. When taking both the high current speed and water depth into account, the model results showed that the Western Passage has great potential for the deployment of tidal energy farms. The maximum extractable power in the Western Passage was estimated using the Garrett and Cummins method. Different criteria and methods recommended by the IEC for resource characterization were evaluated and discussed using a sensitivity analysis of energy extraction for a hypothetical tidal turbine farm in the Western Passage.

16 TIDAL AND WAVE POWER↗
DOE OSTI2023

Automotive Silicon Carbide Power Module Cooling With A Novel Modular Manifold And Embedded Heat Sink

The next generation of integrated power electronics packages will implement wide-bandgap devices with ultrahigh device heat fluxes. Although jet impingement has received attention for power electronics thermal management, it is not used in commercial electric vehicles (EVs) because of the associated pressure drop and reliability concerns. Here, in this paper, we present a modular thermal management system designed for automotive power electronics. The system achieves superior thermal performance to benchmarked EVs, while adhering to reliability standards and with low pumping power. The system utilizes a low-cost and lightweight plastic manifold to generate jets over an optimized heat sink, which is embedded in the direct-bonded-copper (DBC) substrate. The embedded heat sink concept leverages additive manufacturing to add elliptical pin fins to the DBC substrate. The heat sink geometry is optimized for submerged jet impingement using a unit-cell model and an exhaustive search algorithm. The model predictions are validated using unit-cell experiments. A full-scale power module model is then used to compare the DBC-embedded heat sink against direct DBC cooling and baseplate-integrated heat sinks for single-sided (SS) and double-sided (DS) cooling concepts. Using the SS and DS DBC-embedded cooling concepts, the models predict a thermal resistance that represents a reduction of 75% and 85% compared to the 2015 BMW i3, respectively, for the same water-ethylene glycol inverter flow rate. We have shown that an inverter with a 100-kilo-Watt-per-liter power density is achievable with the proposed design.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Numerical investigation and experimental validation of water condensation in the gas diffusion layer with different properties

Liquid water in porous media hinders the transport of reactant to catalyst layer, where the electrochemical reactions occur, which in turn, reduces performance and lifetime of a proton exchange membrane fuel cell (PEMFC). In this study, two types of gas diffusion layer (GDL) materials are used to study the two-phase saturation distribution in a PEMFC. The correlations between the effective and anisotropic transport properties and porosity of the two GDLs are solved by the pore scale model. In addition, the anisotropic liquid water permeability and the relationship between saturation pressure and capillary pressure is determined by using the Lattice-Boltzmann method. Fuel cell performance as well as liquid water distribution in the GDL using neutron radiography are obtained for validation. Under wet conditions, the cell with Freudenberg GDL performs better than that using Toray GDL, especially at high current densities. The results of the two-phase model simulation show that the peak water saturation for Toray GDL occurs in the catalyst layer and can reach 40%, while the peak water saturation for Freudenberg GDL occurs inside the GDL directly under the ribs and only reaches 25% saturation. The combined results provide key insights to enable high power density operation of a PEMFC through GDL material optimization.

42 ENGINEERING↗
DOE OSTI2025

Nano-Engineered Interfaces in Dual-Layer Electrodes for Protonic Ceramic Cells with Enhanced Stability and Kinetics

Enhancing interfacial stability and charge transfer in protonic ceramic cells (PCCs) remains a critical challenge, as structural degradation and interfacial resistance often compromise durability and efficiency. Here, we report a nanoengineered dual-layer oxygen electrode architecture designed to address these limitations by introducing a fine-grained nanoparticle interfacial contact layer beneath a porous catalytic backbone. The nanoscale powders, through enhanced sintering activity, densify into a robust interfacial layer that promotes strong chemical bonding, uniform adhesion, and continuous ionic/electronic pathways with the BCZYYb electrolyte. This hierarchical architecture mitigates delamination, redistributes mechanical stress, and establishes efficient charge and mass transport channels without relying on corrosive surface treatments. Electrochemical evaluation demonstrates that the dual-layer design markedly reduces interfacial polarization resistance and accelerates electrode kinetics. Compared to the single-layer counterpart, the architecture achieves a peel strength of 44.53 N/cm 2 , a 40% improvement in peak power density (0.96 W cm –2 at 600 °C), and a 130% enhancement in electrolysis current density (4.78 A cm –2 at 1.57 V). Faradaic efficiency remains as high as 88% under high steam concentrations, underscoring minimal charge loss during practical operation. Notably, the electrode retains stability across 450–600 °C and under transient voltage cycling, with impedance spectra confirming suppressed interfacial resistance growth over prolonged use. These results highlight nanoscale interface engineering as a powerful route to enhance both mechanical robustness and electrochemical kinetics in PCCs. The demonstrated scalability and durability of this architecture provide a versatile platform for advancing solid-state electrochemical systems, including reversible fuel cells and high-efficiency hydrogen production technologies.

Faradaic efficiency↗
DOE OSTI2021

Non-Ionizing Millimeter Waves Non-Thermal Radiation of Saccharomyces cerevisiae—Insights and Interactions

Non-ionizing millimeter-waves (MMW) interact with cells in a variety of ways. Here the inhibited cell division effect was investigated using 85–105 GHz MMW irradiation within the International Commission on Non-Ionizing Radiation Protection (ICNIRP) non-thermal 20 mW/cm 2 safety standards. Irradiation using a power density of about 1.0 mW/cm 2 SAR over 5–6 h on 50 cells/μL samples of Saccharomyces cerevisiae model organism resulted in 62% growth rate reduction compared to the control (sham). The effect was specific for 85–105 GHz range and was energy- and cell density-dependent. Irradiation of wild type and Δrad52 (DNA damage repair gene) deleted cells presented no differences of colony growth profiles indicating non-thermal MMW treatment does not cause permanent genetic alterations. Dose versus response relations studied using a standard horn antenna (~1.0 mW/cm 2 ) and compared to that of a compact waveguide (17.17 mW/cm 2 ) for increased power delivery resulted in complete termination of cell division via non-thermal processes supported by temperature rise measurements. We have shown that non-thermal MMW radiation has potential for future use in treatment of yeast related diseases and other targeted biomedical outcomes.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Laser powder bed fusion parameter estimation with k-NN

Abstract Laser powder bed fusion (L-PBF) is a technique within additive manufacturing that uses a high power density laser to build parts from fused powdered metal alloy. This technology is well equipped to produce complex parts with otherwise impossible features, such as hidden voids or lattice structures. Alongside capability, reliability and quality are key characteristics considered when choosing a manufacturing method, and these are gaining attention as this method becomes more prevalent in industry. One main indicator of a stable L-PBF process is consistent melt pool geometry, and the properties of which are likely to determine the quality of the part produced. As computing power and sensing technologies become more advanced, this melt pool geometry could be studied in real time. This work addresses the challenge by leveraging a k-nearest neighbor (k-NN) model to identify key features within melt pool imagery and predict the energy density. The k-NN model was trained on data provided by the National Institute of Standards and Technology (NIST). Data preprocessing was performed on the images to extract features that were used in the k-NN model. This approach was used to accurately infer the energy density of unseen layers within the same part. The algorithm was subsequently tested with unique scan strategies and found to reasonably estimate the energy density of different parts. A fivefold cross validation found the algorithm to be consistently predicting the class of 91.4% of the in situ melt pool images.

Jung, Patrick (ORCID:0000000267890859)↗
DOE OSTI2024

Verification of a Monte Carlo binary collision model for simulating elastic and inelastic collisions in particle-in-cell simulations

We present the development and verification of a Monte Carlo binary collision model for simulating elastic and inelastic collisions in particle-in-cell simulations. We apply the corrected binary collision model originally developed for charged-particles collisions to all considered scattering channels, including Coulomb collisions, elastic neutral–neutral and charged–neutral collisions, ionization, excitation, and fusion. The model's implementation is described and verified through a series of simulations, including charged- and neutral-particle thermal equilibration, slowing of electrons in warm solid-density aluminum, collisional damping of a Langmuir wave, helium gas breakdown in an applied electric field, and thermonuclear and beam–target fusion. Then, we demonstrate the model within simulations of hydrogen plasma formation in the Princeton Field-Reversed Configuration as well as of the burning of aneutronic fusion fuel p-11B. The latter includes measurement of the fusion power density in a low-density plasma and fusion production due to the stopping of a proton ignitor beam in a compressed boron target.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Statorless mixed flow turbine for transonic pulsating inflow

Effective harvesting of power from high speed highly transient inflows such as the outflow of rotating detonation combustors (RDCs) is key to achieving their promised cycle efficiency step jump. To increase power density and efficiency simultaneously, a concept that can directly ingest transonic outflow, addressing the choking is needed, i.e. without additional transition elements. A new statorless design was assessed using a comprehensive approach to quantify all contributions to loss generation in transient flows, locally and globally. The turbine rotor was designed under steady flow conditions with a genetic algorithm. The comparison of power and loss generation between steady and unsteady flow results shows that a design methodology under steady-state conditions is suitable to characterize the performance of different designs. Three design families were further assessed under highly transient transonic conditions including traveling shock waves with a relative total pressure amplitude of 149.6% around the mean value and inflow angle variations from -26.5 deg to +51.8 deg. The oblique shock impinging on the pressure side (PS) of the turbine augments the shaft power extraction. When the oblique shock reflects between the pressure side and suction side (SS), its strength diminishes. This paper provides design guidelines on efficient turbine work extraction from the shocks emanating from detonation combustors.

rotating detonation engines↗
DOE OSTI2022

Predicted Impacts of Pt and Ionomer Distributions on Low-Pt-Loaded PEMFC Performance

Low-cost, high performance proton exchange membrane fuel cells (PEMFCs) have been difficult to develop due to limited understanding of coupled processes in the cathode catalyst layer (CCL). Low-Pt-loaded PEMFCs suffer losses beyond those predicted solely due to reduced catalyst area. Although consensus links these losses to thin ionomer films in the CCL, a precise mechanistic explanation remains elusive. In this publication, we present a physically based PEMFC model with novel structure-property relationships for thin-film Nafion, validated against PEMFC data with low Pt loading. Results suggest that flooding exacerbates kinetic limitations in low-loaded PEMFCs, shifting the Faradaic current distribution. As current density increases, protons travel further into the CCL, resulting in higher Ohmic overpotentials. We also present a parametric study of CCL design parameters. We find that graded Pt and ionomer loadings reduce Ohmic losses and flooding, but individually do not provide significant improvements. However, a dual-graded CCL (i.e., graded Pt and ionomer) is predicted to significantly improve the maximum power density and limiting current compared to uniformly loaded CCLs. This work highlights the importance of accurate transport parameters for thin-film Nafion and provides a pathway to low-cost PEMFCs via precise control of CCL microstructures.

08 HYDROGEN↗
DOE OSTI2025

Thermoradiative energy conversion in infrared interband cascade InAs/GaSb/AlInSb/GaSb type-II superlattice diodes

Thermoradiative energy conversion presents a means for the direct conversion of thermal energy through radiative transfer to a cold scene. However, much of the study of thermoradiative principles has been based on theory and simulations, with only sparse reports on the experimental demonstration of the concept. This work studies thermoradiative energy conversion in InAs/GaSb/AlInSb/GaSb type-II superlattice cascade devices. The devices exhibit a cutoff wavelength of 3.2 μm at 300 K, corresponding to a bandgap of 0.39 eV. Testing under a temperature-controlled chamber and scene demonstrates a maximum power density of 2.9 mW/m2 at a cell temperature of 121 °C. It is consistent with expected values for device operation limited by Shockley–Read–Hall non-radiative recombination. This result is a significant step in providing an experimental demonstration of thermoradiative energy conversion and a means to characterize cell performance, providing a foundation for further development to achieve practical values for power generation.

Islam, Md Toriqul (ORCID:0000000249871320)↗
DOE OSTI2023

Time dependent model for non-inductive ECH X-I current ramp-up for SHPD tokamak facility

Non-inductive (NI) plasma current start-up and ramp-up is an important research topic for spherical tokamak (ST) based reactors and fusion pilot plant (FPP). For a compact FPP, the OH flux availability is highly restricted due to its compact geometry. Efficient fundamental extraordinary mode (X-I) electron cyclotron heating (ECH) current start-up and ramp-up regime was identified for a reactor-like high toroidal magnetic field range which has more than a hundred times higher current drive efficiency compared to more conventional ECH methods for the relevant start-up temperature range. High current drive efficiency is possible due to the strong X-I fundamental ECH interaction only with unidirectional passing electrons constrained by the wave accessibility conditions. Here, we extend the X-I electron cyclotron current drive (ECCD) investigation to a time dependent model to simulate the non-inductive current ramp-up to 10 MA for the Sustained High-Power Density (SHPD) facility. As the X-I ECCD driven current I EC rises, due to the back EMF driven negative current, the net plasma current Ip rises more slowly with the current resistive time scale. For tokamak confinement time (both L-mode and H-Mode) which tends to rise with I p , a positive feedback results and even with constant applied ECH power, T e0 , I EC , and I p can continue to rise to very high values. However, in a realistic situation, the T e0 rise should saturate due to a number of factors such as enhanced core radiation and increased power loss at high temperature. To simulate this effect, we adopt a maximum T e0 model which would limit the temperature rise to certain T e0 . With this model, we investigated the current ramp-up for various ECH power levels and the maximum T e0 of 15, 20, and 25 keV. We find that while the power required is reduced with increasing T e0 limit due to increased current drive efficiency, the time to reach 10 MA tends to go up due to the reduced plasma resistivity for the higher T e0 limit. We also find for a given Te0 limit, the time to reach 10 MA tends to be reduced by increasing the applied ECH power by over driving the current ramp-up where I EC is driven at significantly higher level than 10 MA. While the current ramp-up time may not be an issue for the steady-state reactor systems, if it is desirable to minimize the current ramp-up time, it is prudent to have a sufficient ECH power for current over-drive and have some T e0 limiting tools such as impurity seeding for enhanced radiation. In conclusion, a well-controlled NI ECH start-up also has a potential of improving the tokamak start-up reliability and avoid run-away electrons while the NI off-axis current drive could enhance MHD stability and plasma performance improvements.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

T-Type Modular DC Circuit Breaker (T-Breaker) for Future DC Networks

The developed T-Type Modular DC Circuit Breaker (T-Breaker) technology offers an all-in-one solution to challenges in DC networks. This includes swift fault detection and protection, power transient stability, and power quality improvement, achieved through the utilization of wide bandgap (WBG) power semiconductors and energy storage devices. The T-Breaker not only facilitates rapid fault current detection and interruption but also implements fault current limiting through active insertion of storage devices or by operating WBG devices in the saturation region. Additionally, with the assistance of energy storage devices, potential overvoltage issues on power devices induced by control signal misalignment can be mitigated. The T-Breaker can be regulated to perform shunt current injection/absorption using the vertical arm and series voltage insertion via the horizontal arm, thereby enhancing DC system stability during voltage or load power fluctuation transients. The OSU team and Raytheon team actively worked together on designing, fabricating, assembling, and testing of two T-Breaker prototypes. The first prototype is rated at 1 kV, 500 A with half-bridge (unipolar) structure to validate the T-Breaker concept. The second prototype is rated at 20 kV, 50 A with full-bridge (bipolar) topology which can reach an efficiency of 99.977%, realize a power density of 60.2 MW/m3, and eliminate the 500-A fault current with a fault response time of around 20 µs. The prototypes show great feasibility of adopting this technology in multiple applications including electrified aircraft, super charging stations, data centers, etc.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Multiple ferroelectric nematic phases of a highly polar liquid crystal compound

Ferroelectric nematic liquid crystals represent not only fascinating, fundamental science, but they also hold promise for new technologies including high-density power storage or sub-millisecond switching information displays. In this work, we describe the synthesis and measurements of the physical properties of a new compound, 4-nitrophenyl 4-[(2,4-dimethoxylbenzoyl)oxy]-2-fluorobenzoate (RT11001). This material exhibits multiple, highly polar, ferroelectric nematic phases that have not been previously reported. Here we employ a wide range of physical characterisation methods including differential scanning calorimetry (DSC), mass density measurement, optical birefringence, polarising optical microscopy (POM), dielectric spectroscopy, electric current analysis, electro-optical switching, small-angle and wide-angle x-ray scattering measurements to show that RT11001 has multiple, distinct ferroelectric phases. We argue that the highest temperature phase is a polar nematic fluid with non-polar smectic clusters. Directly below appears to be a transition to another polar nematic phase containing polar positionally ordered clusters. Lastly, there are indications of an additional, polar biaxial liquid crystal phase at lower temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2020

A Tidal Hydrodynamic Model for Cook Inlet, Alaska, to Support Tidal Energy Resource Characterization

Cook Inlet in Alaska has been identified as a prime site in the U.S. for potential tidal energy development, because of its enormous tidal power potential that accounts for nearly one-third of the national total. As one important step to facilitate tidal energy development, a tidal hydrodynamic model based on the unstructured-grid, finite-volume community ocean model (FVCOM) was developed for Cook Inlet to characterize the tidal stream energy resource. The model has a grid resolution that varies from about 1000 m at the open boundary to 100–300 m inside the Inlet. Extensive model validation was achieved by comparing model predictions with field observations for tidal elevation and velocity at various locations in Cook Inlet. The error statistics confirmed the model performs reasonably well in capturing the tidal dynamics in the system, e.g., R2 > 0.98 for tidal elevation and generally > 0.9 for velocity. Model results suggest that tides in Cook Inlet evolve from progressive waves at the entrance to standing waves at the upper Inlet, and that semi-diurnal tidal constituents are amplified more rapidly than diurnal constituents. The model output was used to identify hotspots that have high energy potential and warrant additional velocity and turbulence measurements such as East Foreland, where averaged power density exceeds 5 kw/m2. Lastly, a tidal energy extraction simulation was conducted for a hypothetical turbine farm configuration at the Forelands cross section to evaluate tidal energy extraction and resulting changes in far-field hydrodynamics.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Molecular Fe-N 4 Moieties Coupled with Atomic Co-N 4 Sites Toward Improved Oxygen Reduction Performance

Research on high-efficiency and cost-efficient catalysts for oxygen reduction reaction (ORR) is still a vital but challenging issue for commercializing metal–air batteries. Herein, a single-molecule/atom hybrid catalyst is developed to boost the ORR, in which iron phthalocyanine molecules containing molecular Fe-N 4 moieties couple with atomic Co-N 4 sites on the surface of polyhedral carbon. Density functional theory calculations reveal that face-to-face laminated construction of Fe-N 4 and Co-N 4 in the hybrid catalyst can effectively modulate the electronic structure of active iron atoms and reduce the energy barrier of the rate-determining step for ORR. As a result, this hybrid catalyst demonstrates excellent ORR performance, featuring a half-wave potential of 0.904 V, a peak power density of 238.3 mW cm -2 for zinc–air battery, and outstanding electrocatalytic stability. Here, this work offers a distinctive and robust molecular/atomic engineering approach to creating efficient electrocatalysts, advancing the fields of metal–air batteries.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The anode supported internal cathode tubular solid oxide fuel cell: Novel production of a cell geometry for combined heat and power applications

An effective strategy for generating combined heat and power (CHP) systems is to use the combustion of hydrocarbons to provide fuel reforming and heat production for solid oxide fuel cell (SOFC) operation. Though tubular SOFCs (tSOFCs) are well suited to the thermal cycling associated with combustion systems, they have a geometric limitation which requires significant alteration to the combustion chamber. These alterations can be eliminated by producing an anode supported internal cathode-tSOFC (IC-tSOFC) which can be directly integrated into the chamber with minimal alterations. Novel methods used to produce IC-tSOFCs are discussed in this work. Scanning electron microscopy (SEM) and performance characterization are used to analyze fabricated cells. Finally, with a peak power density of 369 mW∙cm –2 , and an open circuit voltage (OCV) of 0.98 V, it is confirmed that novel production methods for IC-tSOFCs have been successful.

08 HYDROGEN↗