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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 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Development of Domestic Lyocell Based Phenolic Impregnated Carbon Ablator (PICA-D) for Future NASA Missions

Phenolic Impregnated Carbon Ablator (PICA) is a low-density ablator that has been used as the planetary entry heatshield for several NASA missions since the late 90's. Its low density and efficient performance characteristics have proven effective for use from Discovery to Flag-ship class missions. The rayon-based carbon precursor raw material used in PICA preform manufacturing has experienced multiple supply chain issues and required replacement and requalification at least twice in the past 25 years, and a third substitution is now needed. Due to the obsolescence of the input foreign rayon fiber source, a new variant of PICA has been developed using a domestic rayon-like fiber source, Lyocell. Results are presented from this effort including fiber conversion, fabrication of tile component and near net shaped heatshield preforms, and conversion to PICA materials. Thermal, mechanical, and representative environment arc-jet tests have been conducted. Initial testing of PICA-Domestic (PICA-D) indicates comparable performance with respect to "heritage" PICA materials and thus PICA-D is expected to be a sustainable solution for future NASA missions.

Drop-In Replacement↗
NASA NTRSDate not supplied

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Paul Gradl↗
DOE OSTI2022

TRANSSFORM Workshop Empowering the US manufacturing industry proceedings report

The U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy, and Advanced Manufacturing Office (AMO) hosted the TRANSSFORM (Transformative, Resilient, Adaptive, Nimble, Sustainable, Smart, Flexible, Optimal, Robust, and Model-based1 – A Bold Vision for the Future of U.S. Manufacturing) Workshop on September 8–10, 2021. The objective of the workshop was to hear from stakeholders about how manufacturing digitalization can improve manufacturing competitiveness and reduce energy consumption and emissions production from U.S. manufacturing, and what research, development, and demonstrations are needed to have the desired impact.

manufacturing digitalization, decarbonization, IoT↗
DOE OSTI2020

China’s Bid To Lead Artificial Intelligence Chip Development within the Decade

In 2017, the Chinese government announced an ambitious, broad strategy to become the global leader in artificial intelligence (AI) theories, technologies, and applications by 2030 and indicated that China’s ability to indigenously produce cutting-edge AI chips would be integral to its success. China’s goal to become a dominant producer of AI hardware within a decade is a bold undertaking because China faces domestic chip production challenges and fierce competition from US chip producers. Our review of Chinese AI chip product lines shows various levels where Chinese companies compete with global firms in the production chain. China lacks a robust indigenous AI chip production infrastructure, and the United States and its allies are tightening controls on the supply of advanced semiconductor manufacturing equipment (SME) and electronic design automation (EDA) software to China. In contrast to their Chinese counterparts, US companies operate in all areas of AI chip production and have consistently driven the development of new chip designs. AI chip production is a costly endeavor, and China’s chip producers currently lack the customer base to lead global AI chip development by the 2030 goal. An expanded customer base may help China attract the necessary expertise to bolster its AI chip production chain. This would also help Chinese producers make their investments in the requisite technology economically sustainable. Chinese researchers continue to pursue promising next-generation AI chip designs, such as neuromorphic computing-based architectures, which in the next five to ten years could position Chinese companies to make or contribute to key innovations in the field.

74 ATOMIC AND MOLECULAR PHYSICS↗
NASA NTRS2023

Progressively Enabling Earth Independent Medical Operations (EIMO)

This panel presents the findings from a series of Technical Interchange Meetings (TIMs) hosted by the Exploration Medical Capability Element (ExMC) in NASA’s Human Research Program. The topics for the TIMs were derived from a 2-day conference of senior leaders and subject matters experts that collectively outlined a multi-faceted strategy designed to optimize crew health and performance through an increasingly autonomous medical approach. The first abstract in this panel outlines the scope of issues related to data collection, usage, transmission and computing capacity to facilitate EIMO. The second presentation provides an overview of the challenges in developing curricula and advanced training tools to baseline knowledge, skills and abilities (KSA), verify clinical competency and assure retention during prolonged durations inherent in exploration-class missions. An overview of the complicated medical supply and resource chain necessary to facilitate EIMO is provided in the third presentation of this panel. The final presentation in this EIMO panel surveys the breadth and depth of demands on cognitive load expected to be experienced by crew on an exploration mission and proposes strategies to mitigate the prospect of cognitive overload through methods to shift task load from the crew to multi-modal artificial intelligence based medical support systems. Taken together, these presentations summarize the challenges to be expected and potential solution spaces to be explored and developed to progressively enable increasing autonomous medical operations to support crewed missions beyond low earth orbit. Through EIMO focused pre-mission planning, integrated data architecture design, innovative training development and AI-assisted task load management, the gradual transition of medical care and decision making from terrestrial to space-based assets enabling support of astronaut health and performance and reducing overall mission risk is achievable.

Jay Lemery↗
NASA NTRSDate not supplied

Progressively Enabling Earth Independent Medical Operations (EIMO)

This panel presents the findings from a series of Technical Interchange Meetings (TIMs) hosted by the Exploration Medical Capability Element (ExMC) in NASA’s Human Research Program. The topics for the TIMs were derived from a 2-day conference of senior leaders and subject matters experts that collectively outlined a multi-faceted strategy designed to optimize crew health and performance through an increasingly autonomous medical approach. The first abstract in this panel outlines the scope of issues related to data collection, usage, transmission and computing capacity to facilitate EIMO. The second presentation provides an overview of the challenges in developing curricula and advanced training tools to baseline knowledge, skills and abilities (KSA), verify clinical competency and assure retention during prolonged durations inherent in exploration-class missions. An overview of the complicated medical supply and resource chain necessary to facilitate EIMO is provided in the third presentation of this panel. The final presentation in this EIMO panel surveys the breadth and depth of demands on cognitive load expected to be experienced by crew on an exploration mission and proposes strategies to mitigate the prospect of cognitive overload through methods to shift task load from the crew to multi-modal artificial intelligence based medical support systems. Taken together, these presentations summarize the challenges to be expected and potential solution spaces to be explored and developed to progressively enable increasing autonomous medical operations to support crewed missions beyond low earth orbit. Through EIMO focused pre-mission planning, integrated data architecture design, innovative training development and AI-assisted task load management, the gradual transition of medical care and decision making from terrestrial to space-based assets enabling support of astronaut health and performance and reducing overall mission risk is achievable.

John Lemery↗
DOE OSTI2015

Reverse logistics system and recycling potential at a landfill: A case study from Kampala City

Highlights: • Quantifies the different waste streams delivered at the landfill. • Evaluates the amount of potential waste products that enters into the reverse cycle. • Drawing out the reverse logistics activities from Kampala City to Kiteezi landfill. • Identify the storage, collection and transportation mechanisms of products to the various destinations; and finally. • The study suggests efficient measures to improve reverse logistics system. - Abstract: The rapid growing population and high urbanisation rates in Sub-Saharan Africa has caused enormous pressure on collection services of the generated waste in the urban areas. This has put a burden on landfilling, which is the major waste disposal method. Waste reduction, re-use and recycling opportunities exist but are not fully utilized. The common items that are re-used and re-cycled are plastics, paper, aluminum, glass, steel, cardboard, and yard waste. This paper develops an overview of reverse logistics at Kiteezi landfill, the only officially recognised waste disposal facility for Kampala City. The paper analyses, in details the collection, re-processing, re-distribution and final markets of these products into a reversed supply chain network. Only 14% of the products at Kiteezi landfill are channeled into the reverse chain while 63% could be included in the distribution chain but are left out and disposed of while the remaining 23% is buried. This is because of the low processing power available, lack of market value, lack of knowledge and limited value addition activities to the products. This paper proposes possible strategies of efficient and effective reverse logistics development, applicable to Kampala City and other similar cities.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Next Generation Logistics Systems for Delivering Optimal Biomass Feedstocks to Biorefining Industries in the Southeastern U.S.

The diverse portfolio of biomass sources that is available in the Southeastern U.S., including a significant supply of pine “residue”, represents a valuable strategic position for the region. Through blends formulated based on critical properties, this project will take full advantage of the range in biomass properties afforded by the portfolio to produce a consistent, high-performance feedstock for the industry, while lowering cost. Key developments being targeted to enable this potential include whole-tree transport to a state-of-the-art merchandising depot that will further access biomass from ongoing, forest industry operations. The approach will more effectively utilize the tree and distribute cost, while minimizing in-woods contamination of the woody biomass component. To implement this vision, information on the chemical composition and changes that are induced during multiple preprocessing steps (size reduction, moisture removal, densification, etc.) is needed. New NIR sensor technology will be developed for online monitoring of important biomass properties. The data will be incorporated into a statistical process control platform to improve process efficiency and meet required specifications. Advanced process models are being developed to inform the techno-economic and life-cycle assessment of the program’s impact. The new system will ultimately reduce operational risks from supply chain disruptions, and allow operation of larger-scale biorefineries.

09 BIOMASS FUELS↗
DOE OSTI2025

Development of Calcined Clay/Calcium Sulfate Blends for Robust Performance of LC3 Concrete

This report documents the development of robust blends of calcined clays (CCs) with calcium sulfate (gypsum) for application in limestone calcined clay cement (LC3) systems. The U.S. cement industry faces supply chain constraints and high energy intensity, motivating the need for alternative supplementary cementitious materials. Calcined clays are abundant and highly reactive when properly processed, but their variable physical and chemical characteristics can negatively impact hydration balance, rheology, and admixture demand in LC3 concretes. To address this, five calcined clays, two Portland cements, ground limestone, gypsum, and a polycarboxylate dispersant were procured. Isothermal calorimetry and mini-cone flow tests were used to determine sulfate and dispersant demand. Results show that the addition of approximately 6.7% gypsum, relative to the calcined clay weight, consistently balanced sulfate consumption across the LC3 systems studied. Dispersant demand, however, varied significantly with clay source, demonstrating the need for tailored admixture strategies. These findings confirm that supplying CC–gypsum blends directly to concrete producers is a viable approach to overcoming current manufacturing constraints, enabling reliable fresh and hardened performance of LC3 concretes, and supporting broader adoption of calcined clays in the U.S. market.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Are quantum materials economically and environmentally sustainable?

Quantum materials have revolutionized energy, information, and healthcare technologies, yet their development has largely prioritized performance over economic and environmental impacts—key factors for industrial adoption. Using topological materials as a case study, we present a data-driven framework that evaluates over 16,000 materials based on cost, supply chain resilience, energy demand, toxicity, and environmental footprint. By integrating the recently proposed quantum weight – a metric quantifying quantum behavior – we reveal a striking trend: materials with stronger quantum effects often exhibit higher environmental impact, posing challenges for scalability and industrial adoption. To address this, we identify a small set of materials that achieve a balance between quantum functionality and sustainability. Furthermore, our approach enables high-throughput, AI-driven materials discovery that incorporates economic and environmental influences from the outset, guiding the development of quantum materials for next-generation microelectronics and energy harvesting technologies.

AI↗
DOE OSTI2012

Northern Power Systems ACCROSS (Final Report)

Northern Power Systems, Inc. has developed advanced Permanent Magnet Direct Drive (PMDD) technology that when fully commercialized will be able to expand the market for both Distributed Scale and Utility Scale wind power across the U.S. However, if Northern Power is to successfully commercialize this technology it will need to develop advanced manufacturing processes that will enable a jump from batch production to continuous flow manufacturing and to ensure that it fields a quality and reliable product for end users that reflects a necessary maturation of wind industry manufacturing in the U.S. The objective of the proposed Advanced Manufacturing and Supply Chain Automation Project is to create and implement a continuous manufacturing, supply chain and field support automated system that will initially be centered on commercialization of the NPS™ 100 turbine for Distributed Wind applications. As a result of implementing this system, Northern Power will publicize its findings and lessons learned to the broader U.S. wind industry as well as apply the system and methodology as part of development and commercialization of the NPS 2.3 turbine for utility scale wind farms.

17 WIND ENERGY↗
DOE OSTI2024

Modeling hydrogen markets: Energy system model development status and decarbonization scenario results

Hydrogen can be used as an energy carrier and chemical feedstock to reduce greenhouse gas emissions, especially in difficult-to-decarbonize markets such as medium- and heavy-duty vehicles, aviation and maritime, iron and steel, and the production of fuels and chemicals. Significant literature has been accumulated on engineering-based assessments of various hydrogen technologies, and real-world projects are validating technology performance at larger scales and for low-carbon supply chains. While energy system models continue to be updated to track this progress, many are currently limited in their representation of hydrogen, and as a group they tend to generate highly variable results under decarbonization constraints. Here, the present work provides insights into the development status and decarbonization scenario results of 15 energy system models participating in study 37 of the Stanford Energy Modeling Forum (EMF37), focusing on the U.S. energy system. The models and scenario results vary widely in multiple respects: hydrogen technology representation, scope and type of hydrogen end-use markets, relative optimism of hydrogen technology input assumptions, and market uptake results reported for 2050 under various decarbonization assumptions. Most models report hydrogen market uptake increasing with decarbonization constraints, though some models report high carbon prices being required to achieve these increases and some find hydrogen does not compete well when assuming optimistic assumptions for all advanced decarbonization technologies. Across various scenarios, hydrogen market success tends to have an inverse relationship to success with direct air capture (DAC) and carbon capture and storage (CCS) technologies. While most model-scenario combinations predict modest hydrogen uptake by 2050 – <10 million metric tons (MMT) – aggregating the top 10 % of market uptake results across sectors suggests an upper range demand potential of 42–223 MMT. The high degree of variability across both modeling methods and market uptake results suggests that increased harmonization of both input assumptions and subsector competition scope would lead to more consistent results across energy system models. The wide variability in results indicates strongly divergent conclusions on the role of hydrogen in a decarbonized energy future.

08 HYDROGEN↗
DOE OSTI2025

Global Regulations for Sustainable Battery Recycling: Challenges and Opportunities

With the rapid expansion of transportation electrification worldwide, the demand for electric vehicles (EVs) has increased dramatically, creating new and sustainable growth opportunities for the global economy. However, as the most expensive component of EVs, lithium-ion batteries pose significant sustainability challenges due to raw material consumption and supply chain constrains, as well as the complexities of end-of-life battery disposal and recycling. To address these concerns, many countries are actively establishing regulations to promote sustainable pathways for battery reuse and recycling. Despite these efforts, existing battery recycling regulations remain often inefficient and vary significantly across different countries in legal enforcement, producer responsibility, waste classification, recycling targets, design standards, public engagement, and financial incentives, particularly given the complexities of the global supply chain and resource distribution within the battery industry. Understanding these regulatory differences and establishing a unified framework are therefore crucial to ensuring sustainable and efficient battery recycling. This review provides a comprehensive analysis of the necessity of establishing robust regulations for sustainable development of battery recycling industry. The evolution and refinement of battery recycling regulations are deeply reviewed to identifying persistent gaps and challenges in key countries. Furthermore, we discuss the challenges associated with regulatory enforcement and propose strategies for developing a more cohesive legislative framework to ensure the effective utilization of retired batteries.

25 ENERGY STORAGE↗
DOE OSTI2018

Comprehensive Report on Design and Development of a 100-kW DSSRM

Switched reluctance machines (SRMs) are low cost and fault tolerant alternatives for traction applications. Due to their relatively low torque density and high torque ripple, these machines have not been used in commercialized electrified power trains yet. The double-stator magnetic configuration, where a segmental rotor shared between two stators, is proven to have superior torque density, lower acoustic noise, and torque pulsation. The double-stator SRM (DSSRM) has a high potential of being the next generation of traction motors since it combines the advantages of permanent magnet-free machines, such as low cost and independence from supply chain issues associated with rare metals, while providing high torque and power densities. In this paper, we introduce the complete design process of a 100-kW DSSRM including electromagnetic, structural, thermal, and system level design. The performance of the developed DSSRM is verified with the experimental data. This paper presents overall study of DSSRM and describes merits of DSSRM drive system.

42 ENGINEERING↗
DOE OSTI2026

Oakland University Cybersecurity Center (Final Scientific/Technical Report)

This report summarizes the outcomes of Award DE-CR0000023, “Oakland University Cybersecurity Center,” a 31-month project funded by the U.S. Department of Energy Office of Cybersecurity, Energy Security, and Emergency Response (CESER). The project addressed cybersecurity risks facing small and medium-sized manufacturers (SMMs) transitioning to Industry 4.0. The project integrated customer discovery, applied research, and cybersecurity training development. A total of 51 cybersecurity assessments identified significant gaps in baseline practices, incident response, and workforce capability. Research efforts produced a scalable mitigation framework tailored to SMM environments, and workforce analysis identified persistent talent gaps. Eight cybersecurity training modules were developed and deployed via Oakland University’s Professional and Continuing Education (PACE) platform. All objectives were completed, with 98.93% federal budget utilization and cost share exceeding requirements. The project establishes a scalable model for strengthening cybersecurity resilience and workforce capacity across U.S. manufacturing supply chains.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Advanced Mineral Separations with Novel Simulated Moving Beds

Lithium is a critical mineral that is widely used in batteries and energy storage applications, making it increasingly important in the next few decades. To meet the growing demand for lithium and secure domestic supply chains, there is a need to exploit unconventional lithium resources. However, utilizing current lithium extraction processes is challenging due to the high salinity in those resources. Thus, it is essential to develop energy-efficient, and less chemical-intensive separation processes that can exploit high-salinity lithium resources. Accordingly, this project aims to design a novel zwitterionic stationary phase and use it to develop a continuous chromatography process to recover LiCl minerals from traditionally unexploited domestic saline resources. The developed zwitterionic stationary phase allows fractionating minerals based on their different sorbent affinities under water elution. A systematically designed continuous process can separate lithium from other minerals, reducing the risk of material fouling and the overall chemical consumption to produce battery-grade lithium. This approach is expected to significantly enhance the efficiency and sustainability of the lithium extraction process while also reducing the environmental impact associated with traditional processes. At the end of the project, the technology will be demonstrated in continuous mode using a simulated moving bed (SMB) to recover >100 g of LiCl from real resource waters. The U.S.-based resources that this project targets for LiCl recovery are formation water, oil-produced water, and geothermal brines, supplied by Standard Lithium Ltd. and Shell Inc, respectively.

critical minerals↗
DOE OSTI2016

ENVI-PV: An Interactive Web Client for Multi-Criteria Life Cycle Assessment of Photovoltaic Systems Worldwide

Solar photovoltaics (PV) is the second largest source of new capacity among renewable energies. The worldwide capacity encompassed 135 GW in 2013 and is estimated to increase to 1721 GW in 2030 and 4674 GW in 2050, according to a prospective high-renewable scenario. To achieve this production level while minimizing environmental impacts, decision makers must have access to environmental performance data that reflect their high spatial variability accurately. We propose ENVI-PV (http://viewer.webservice-energy.org/project_iea), a new interactive tool that provides maps and screening level data, based on weighted average supply chains, for the environmental performance of common PV technologies. Environmental impacts of PV systems are evaluated according to a life cycle assessment approach. ENVI-PV was developed using a state-of-the-art interoperable and open standard Web Service framework from the Open Geospatial Consortium (OGC). It combines the latest life cycle inventories, published in 2015 by the International Energy Agency (IEA) under the Photovoltaic Power Systems Program (PVPS) Task 12, and some inventories previously published from Ecoinvent v2.2 database with solar irradiation estimates computed from the worldwide NASA SSE database. ENVI-PV is the first tool to propose a worldwide coverage of environmental performance of PV systems using a multi-criteria assessment. The user can compare the PV environmental performance to the environmental footprint of country electricity mixes. ENVI-PV is designed as an environmental interactive tool to generate PV technological options and evaluate their performance in different spatial and techno-economic contexts. Its potential applications are illustrated in this paper with several examples.

14 SOLAR ENERGY↗
DOE OSTI2025

Securing the Modern Grid: Federal Investments, Digitization, and Supply Chain Strategy

Across the United States (U.S.) grid expansion and modernization is underway, paving the way for accelerated load growth and intelligent resource management. Digitization of the grid is supported by several state and federal programs, providing support for utilities installing advanced metering infrastructure (AMI), AI-powered analytics systems, battery energy storage systems (BESS), and distributed energy resource management systems (DERMS) to transform the grid from a one-way power delivery system into an intelligent, responsive network that will enable faster load growth and power expansion of data centers for advanced artificial intelligence (AI) applications. The digital transformation of America's grid presents opportunity for increased efficiency and resiliency but also introduces new digital risks that require careful management. Digital equipment often contains several vulnerabilities such as unencrypted communication protocols, and persistent remote access capabilities that could be exploited to manipulate device settings, coordinate service disruptions, or inject false data into grid operations. These digital risks become particularly important as the grid must rapidly scale to support AI-driven data centers, which the administration has identified as essential for maintaining U.S. technological leadership and economic competitiveness. These vulnerabilities are compounded by supply chain realities: Chinese manufacturers currently produce 70-90% of essential grid components including inverters, batteries, and control systems, with the U.S. lacking domestic manufacturing capacity for critical assets like extra-high voltage transformers. Recent federal legislation has established Foreign Entity of Concern (FEOC) restrictions to address these risks, requiring projects to achieve escalating thresholds of non-FEOC content to receive tax credits while utilities work to expand sourcing channels for their supply chains and strengthen security measures. These restrictions arrive precisely when utilities face unprecedented electricity demand growth driven by the rapid growth in data centers, creating a considerable challenge: rapidly expanding infrastructure while navigating complex compliance requirements while lacking viable alternatives for many critical components. Idaho National Laboratory (INL) and its partners have developed practical approaches to help utilities navigate these intersecting challenges as they leverage federal investment to strengthen and grow the grid. These solutions include Cyber-Informed Engineering (CIE) principles that build resilience directly into systems, the Cirrus tool for secure cloud migration, and enhanced procurement guidance that embeds security requirements throughout equipment lifecycles. Federal initiatives, such as the Technical Assistance for Digital Assurance (TADA) project, provide direct support to utilities implementing these approaches while facilitating knowledge sharing across the industry. While these tools and frameworks cannot eliminate all risks inherent in foreign supply chain dependencies, they offer pragmatic pathways for strengthening security posture without sacrificing the deployment momentum essential to meeting surging electricity demand. Ultimately, securing America's digital energy infrastructure demands dedicated coordination across multiple fronts: building domestic supply chains, implementing robust digital assurance practices, and maintaining the aggressive modernization timeline necessary for reliability, resilience, and energy independence.

24 POWER TRANSMISSION AND DISTRIBUTION↗