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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 55 records · Page 3

PMU Data Quality and Sensor Health Monitoring

Phasor Measurement Units (PMUs) play a critical role in the evolution of the electric power industry by providing high-precision, real-time monitoring of essential power system metrics. However, effectively detecting abnormalities and critical events from PMU data is a complex task, complicated by intricate temporal patterns, a scarcity of labeled data for training algo- rithms, and constraints on online computational power. In this study, we apply TranAD, an innovative algorithm that combines transformer architectures with the refinement of adversarial learning, to both synthetic and real-world PMU datasets for developing a data quality and sensor online health monitoring platform for utilities. Our findings reveal that TranAD not only provides efficient detection and localization but also enhances the detail with which abnormalities are detected, marking a a significant step forward in the field of clean data acquisition processes for power system monitoring

deep neural network, machine learning (ML)↗

FIU Project 2: Environmental Remediation Science & Technology [Slides]

FIU’s research under this project involves conducting basic and applied science to fill knowledge gaps and validate potential remediation technologies for contaminated soil and groundwater and the assessment of the fate and transport of contaminants in the environment. The aim of FIU’s research is to reduce the potential for contaminant mobility or toxicity in the surface and subsurface through the development and application of state-of-the-art scientific and environmental remediation technologies at the Hanford Site, Savannah River Site (SRS), and the Waste Isolation Pilot Plant (WIPP), which is the Nation’s only mined geologic repository for permanent disposal of transuranic waste. FIU collaborates with scientists from Pacific Northwest National Laboratory (PNNL), Savannah River National Laboratory (SRNL), Savannah River Ecology Laboratory (SREL), Los Alamos National Laboratory (LANL) and the DOE Carlsbad Field Office (CBFO) in order to plan and execute research that is synergistic with the work being conducted at the sites, and that supports the resolution of critical science and engineering needs which leads to a better understanding of the long-term behavior of subsurface contaminants. The knowledge gained through this research will be used to transform experimental and modeling innovations into practical applications deployed at the sites to support EM’s primary goal of expediting the closure of major contaminated soil and groundwater sites and waste units. Collaborative relationships between FIU and the national laboratories have provided large benefits over the years to FIU, the national laboratories, the DOE complex, and the DOE EM mission. By working closely with the national laboratories, FIU’s research is not only closely aligned with the cleanup mission priorities at the DOE sites, but complements and supports ongoing work at the national laboratories for screening of new remedial technologies. This coordination and leveraging of research efforts results in time- and cost-savings, and will accelerate progress of the DOE EM environmental restoration mission.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Tunable Oxygen Reduction Electrocatalysis by Phenazine-Modified Carbons (Final Report)

This project aims to systematically investigate the fundamental interfacial chemistry that underlies the four-electron, four-proton oxygen reduction reaction (ORR) mediated by heteroatom-doped graphitic carbon electrodes. Heteroatom-doped (Fe, N, etc.) graphitic carbons have emerged as a rich class of materials that are promising ORR catalysts in low temperature fuel cells because of their earth-abundant elements, extremely low cost, environmental harmlessness, and high tolerance to impurities in the fuel stream. However, despite decades of research, systematic efforts to improve the activity, selectivity, and durability of these catalysts has been hampered both by a complex heterogeneous distribution of potential N- and Fe-dopant active sites and by the inability to tune the local electronic structure and environment of the active site with molecular precision. Understanding the fundamental chemistry that influences the turnover-limiting and selectivity determining steps for ORR and other multielectron/multiproton electrocatalytic transformations requires new and innovative methods to prepare heteroatom active sites with molecular precision on carbon surfaces.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Mathematical methods for optimal polynomial recovery of high-dimensional systems from noisy data

The goal of our Early Career Research Project (ECRP) is to establish a modern mathematical foundation that will enable next-generation computational methods for polynomial approximation of high-dimensional systems, having a certain set of constraints, from a limited amount of noisy data. Such a foundation is critical to realizing the future potential of the DOE user facilities, and will ultimately empower scientists to address a fundamental question, namely, “how many realizations of a nonlinear manifold are required to recover the entire high-dimensional solution map, with optimal approximation guarantees and minimal computational cost?” The central theme of this effort aims to conquer this challenge by pioneering the development of extraordinarily innovative theoretical analysis and transformational non-intrusive computational methodologies. Such approaches will enable the reconstruction of the entire high-dimensional solution map, with accuracy comparable to the best approximation, while utilizing an optimal number of samples. During this reporting period we have made significant progress on four thrusts.

97 MATHEMATICS AND COMPUTING↗

TRANSENSOR: Transformer Real-time Assessment INtelligent System with Embedded Network of Sensors and Optical Readout. Final Report

Utilities across the world are wrestling with evolving market dynamics, population growth and climate change. Distributed Energy Resources (DERs) such as solar photovoltaics, distributed generators and energy storage systems are becoming important parts of the U.S. energy mix. These factors are driving an increasing need for low-cost grid asset monitoring. Aside from being costly, traditional utility monitoring systems are not sufficiently robust and do not provide real-time visibility into the condition of grid assets such as transformers. Lack of accurate real-time measurements on performance has resulted in the use of lagging indicators, such as oil sample analysis. To address this need, an innovative embedded optical sensing technology, Transformer Real-time Assessment Intelligent System (TRANSENSOR) was developed, validated and demonstrated in this project. To date, TRANSENSOR has focused on transformers but is extendable to other grid assets. In addition to the technology being embedded into new transformers during manufacturing, a retrofit configuration that can be installed on existing transformers in the field was also developed. It is anticipated that the ability to retrofit existing transformers will help accelerate adoption of the underlying TRANSENSOR technology. Phase 1 of the project focused on laboratory development and qualification of the technology. Following iterations and exploration of relevant optical sensing modalities and multiplexed configurations of interest for the transformer environment, an effective candidate configuration was agreed upon, down-selected and custom-designed for embedding into General Electric (GE) network transformers. Two new GE 500 kilovolt ampere (kVA), 27 kilovolt (kV) distribution network transformers were built with embedded fiber-optic (FO) sensors and successfully qualified per industry standards at GE’s Shreveport, Louisiana facility during Phase 1 of the project. Following the successful completion of Phase 1, the team proceeded to Phase 2, which focused on a field demonstration of the technology. Over Phase 2, the first new GE transformer built with embedded fiber-optic sensors was installed in an above-ground cage and connected to the grid at Con Edison’s Astoria facility. A second transformer equipped with TRANSENSOR was installed in an underground vault. Additionally, an older (1982 year model) GE transformer in an above-ground cage was retrofitted with fiber- optic sensors and reconnected to the grid at ConEd’s facility. Analysis of data acquired from the sensors showed interesting correlations with transformer loading. Additionally, key events such as transformer low-voltage network connection, primary-side energizing, and a pressure loss event from an oil sampling were detected by the TRANSENSOR system. Online data processing/feature extraction algorithms for the second transformer in the underground vault detected key features and event alerts that were transmitted through a wireless 4G connection. The remote deployment concept showed promising results with data collection running for a total of 8 months across the three (3) GE transformers instrumented for the Phase 2 field demonstration. This sets the stage well for further development and commercialization.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Transforming Energy Through Computational Excellence: High-Performance Computing for Energy Innovation

The challenges associated with energy efficiency of manufacturing and advanced materials often cannot be addressed through experimentation alone, whether because of scale, complexity, or practicality. High-performance computing (HPC) enables fast tackling of these challenges in the manufacturing sector - vital to achieving net-zero carbon emissions by 2050. The National Renewable Energy Laboratory (NREL) and industry partners leverage HPC to apply advanced modeling, simulation, and data analysis to improve manufacturing efficiency, explore new materials for energy applications, and develop technologies to manage carbon across the life cycle. From improving additive manufacturing processes to increasing the energy efficiency of jet-engine components, advanced computing can help manage emissions produced by manufacturing in a wide variety of ways.

advanced materials↗

Simulation Tools for Characterizing Stress Distribution in Laser Welded Dissimilar Joints

This project focuses on developing a thermo-metallurgical-mechanical modeling method to accurately predict the microstructural evolution and residual stress in laser welding between dissimilar metals, such as HSLA steel and high carbon equivalent (CE) gear steel. The method leverages a comprehensive material database to model the temperature and rate dependent phase transformations, along with their associated effects on material properties, such as thermal expansion and flow stress, throughout the welding process. A key innovation is the incorporation of phase transformation and phase-specific properties, which enhances the accuracy of residual stress predictions. The mixture material in the fusion zone due to the dissimilar metals will also be addressed in the numerical model. This is especially critical in scenarios involving phase transformations in the fusion zone and heat-affected zone (HAZ), where the phase changes can induce substantial residual stress variations. The material database has been generated using JMatPro. The modeling approach is implemented through a custom User Material (UMAT) subroutine, executed with the commercial finite element software Abaqus.

36 MATERIALS SCIENCE↗

Simulation Tools for Characterizing Stress Distribution in Laser Welded Dissimilar Joints

This project focuses on developing a thermo-metallurgical-mechanical modeling method to accurately predict the microstructural evolution and residual stress in laser welding between dissimilar metals, such as HSLA steel and high carbon equivalent (CE) gear steel. The method leverages a comprehensive material database to model the temperature and rate dependent phase transformations, along with their associated effects on material properties, such as thermal expansion and flow stress, throughout the welding process. A key innovation is the incorporation of phase transformation and phase-specific properties, which enhances the accuracy of residual stress predictions. The mixture material in the fusion zone due to the dissimilar metals will also be addressed in the numerical model. This is especially critical in scenarios involving phase transformations in the fusion zone and heat-affected zone (HAZ), where the phase changes can induce substantial residual stress variations. The material database has been generated using JMatPro. The modeling approach is implemented through a custom User Material (UMAT) subroutine, executed with the commercial finite element software Abaqus.

36 MATERIALS SCIENCE↗

Irradiation response of innovatively engineered metastable TRIP high entropy alloy

For this work, properties and radiation responses of a metastable high alloy (HEA) exhibiting the transformation induced plasticity (TRIP) effect were studied. Innovative engineering used to manufacture this HEA has shown superior mechanical and corrosion properties in 3.5% NaCl than most advanced stainless steels. The microstructural evolution and corresponding mechanical response after irradiation have been evaluated using detailed transmission electron microscopy, and nanoindentation. The study shows a change in metastability of the alloy with irradiation via a recovery mechanism, where the irradiation-induced transformation is reversed by the temperature-induced transformation, thereby introducing the concept of self-healing, made possible due to the TRIP behavior of HEA.

36 MATERIALS SCIENCE↗

Manipulating Aromaticity to Redirect Topochemical Polymerization Pathways

Topochemical polymerization (TCP) represents an essential route to create regio- and stereoregular polymers through solid-state transformations. Herein, we present an innovative strategy for controlling topochemical polymerization pathways by tailoring the terminal group aromaticity in the para-azaquinodimethane (AQM) ring system. Substituting phenyl groups with less aromatic furyl units extends significant spin density delocalization across the conjugated core upon thermal activation, inducing significant diradicaloid characters at furyl positions and enabling unconventional reactivities in both solution and solid states. Thermal treatment in toluene yields a unique cyclophane dimer formed via furyl-methine C-C coupling, confirmed by X-ray crystallography, while solid-state reactions produce polymers formed via both intercolumnar furyl-methine coupling and intracolumnar methine-methine coupling. The spin-center-directed mechanism underlying these transformations is validated through theoretical modeling and isotopic labeling experiments. This study highlights the prowess of aromaticity modulation in functional pro-aromatic systems, which enables the synthesis of polymers with main chain structures that are otherwise difficult to access.

Zhang, Qingsong↗

From IMPEL to Impact: Lessons Learned in Accelerating Innovative Building Technologies

The built environment is a complex ecosystem of social institutions and physical infrastructures. Innovation and entrepreneurship in the building industry are critical levers for market transformation toward equitable climate action. However, climate tech innovation for the built environment is not moving fast enough for global needs, and it lacks fundamental diversity, leading to inequitable outcomes. IMPEL (Incubating Market-propelled Entrepreneurial-mindset at the Labs and Beyond) - a U.S. Department of Energy incubator–addresses these critical issues. Over five years, IMPEL has enabled 250 innovators, including 55% women and diverse founders, to accelerate their buildings and clean energy technologies towards market and climate impact. IMPEL provides access to strategic mentoring and coaching, carbon tools training, testbeds, and powerful public-private pipelines, including industry demonstrations, non-dilutive grants, and venture capital networks. The IMPEL innovation ecosystem has accelerated the pace of innovation and market adoption of building decarbonization technologies. In this paper, leverage the IMPEL stakeholder ecosystem - from innovators to investors and product industry to policymakers - to analyze the critical barriers to decarbonization still encountered in the building industry. We study the IMPEL approach and highlight lessons learned that benefit young businesses pursuing innovative building and building-edge energy technologies to develop new ideas and products. Finally, we propose a ‘market forming’ framework to improve the quality and efficiency of the entrepreneurial ecosystem in the building industry. This framework could scale vetted technologies and the participation of diverse founders to de-risk the climate tech

Singh, Reshma↗

In-situ hydrogen microstructural characterization of Si heterojunction passivation: Addressing V OC degradation and mitigation pathways

Si heterojunction (SHJ) solar cells have demonstrated record efficiency >27%, approaching the theoretical limit of ≈ 29%, primarily due to best surface/interface defect passivation provided by deposited thin layers of hydrogenated amorphous silicon (a-Si:H). Such excellent surface/interface passivation reduces recombination loss and result in >100 mV improvement of cell open circuit voltage (V OC ) to ≈ 750 mV, thus the cell efficiency. However, fielded SHJ modules exhibit loss of V OC and hence efficiency over time in years, presumably due to degradation related to a-Si:H layers. This adversely affects the technology’s market acceptance, and levelized cost of energy (LCOE). It is hypothesized that the origin of a-Si:H degradation is somehow related to the presence of weak Si–Si bonds and hydrogen in a-Si:H films. The objective of this project is to test this hypothesis by directly measuring chemical and structural changes occurring within SHJ component layers and solar cells. This is achieved by developing an innovative in-situ Fourier transform infrared (FTIR) spectrometry apparatus to monitor hydrogen microstructural changes occurring within amorphous silicon and decipher hydrogen evolution kinetics over time when samples are exposed to heat and/or light stress. These in-situ measured hydrogen microstructural changes are correlated to the changes in effective minority carrier lifetime (τ eff ), implied V OC (iV OC ), surface recombination velocity (S), and cell V OC . These mechanistic understandings will provide critical guidance to mitigate the V OC -driven degradation of SHJ solar cell performance. Passivation optimization and degradation analysis of individual SHJ component structures were achieved through systematic deposition of three symmetric structures and the completed SHJ solar cell structure. The three symmetric structures used were intrinsic a-Si:H [(i)a-Si:H] layers in a bilayer structure, intrinsic and p-type doped stacked layers [(i-p)a-Si:H] representing the front heterojunction in the SHJ cell, and intrinsic and n-typed doped stacked layers [(i-n)a-Si:H] representing the back-side back surface field (BSF) in the SHJ cell. State-of-the-art passivation qualities are demonstrated by a champion iV OC of 740 mV for the (i)a-Si:H layers, and the (i-n)a-Si:H symmetric structure. A 725 mV iV OC is observed for the (i-p)a-Si:H symmetric structure. These symmetric passivated SHJ component structures were subsequently subjected to different accelerated lifetime (ALT) stressors to identify which conditions contribute the most to iV OC degradation. Degradation of the thin (10 nm) (i)a-Si:H passivation layers without any additional overlying layers is minimal; complexity of this study arises due to unavoidable surface oxidation of (i)a-Si:H layer during most of the stress application, which is likely irrelevant for a full SHJ cell configuration with overlying protective layers. The iV OC degradation of symmetric structures is found to occur primarily at the (i-p)a-Si:H passivation stack under dark heat stress with associated hydrogen loss from the (p)a-Si:H layer. An activation energy for increase in S (defect creation) of 0.65 eV can be correlated to the activation energy of ≈ 0.4 eV for hydrogen loss from the (i-p)a-Si:H stack. This also suggests the presence of weakly bonded hydrogen in the (p)a-Si:H films, which effuses out of the film stack at such low activation energy. When light and heat stress are applied together, similar hydrogen loss from (i-p)a-Si:H stack is observed, however, does not appreciably degrade iV OC or increase S. This is an important result and departure from direct correlation between hydrogen loss and defect creation. This perhaps indicates additional defect chemistries or annealing that might be occurring in the presence of light requiring further detailed defect measurements. The full SHJ cell structure used for this project is depicted in Fig.1(d). SHJ cells with an initial V OC ≈ 700 mV were fabricated and subjected to similar ALT stress conditions. Cell V OC is found to degrade the most under dark heat stress and is confirmed by observed hydrogen migration out of the (i-p)a-Si:H stack. However, hydrogen cannot escape from the cell stack, it accumulates near the (p)a-Si:H/ITO contact interface, where ITO acts as a barrier preventing hydrogen loss. Furthermore, light-heat combined stress does not degrade V OC appreciably, confirming the occurrence of a defect annealing process.

14 SOLAR ENERGY↗

Complete Evaluation of ION Cost Reduction Opportunities for LWRS Pathways

The Light Water Reactor Sustainability (LWRS) Program, sponsored by the U.S. Department of Energy (DOE), plays a pivotal role in enhancing the sustainability, safety, and economic viability of the nation's fleet of nuclear power plants. This program collaborates extensively with industry, vendors, suppliers, regulatory agencies, and research and development organizations within the nuclear energy sector. The overarching goals of the LWRS program are twofold: to provide innovative science and technology-based solutions to the nuclear industry, surpassing current performance models, and to manage the aging of systems, structures, and components (SSCs) to extend the operational lifetimes of nuclear power plants safely, efficiently, and economically. The program focuses on five research and development pathways: Plant Modernization: This pathway seeks to enhance the economic viability of nuclear power plants in evolving energy markets through innovation, efficiency improvements, and digital transformation. The integration of digital technologies into plant operations is a central theme, aiming to create a seamless digital environment that improves plant economics and safety. Flexible Plant Operation and Generation: Research efforts in this pathway explore opportunities for light-water reactors (LWRs) to directly supply energy to industrial processes, diversifying revenue generation approaches and improving economic sustainability.

42 ENGINEERING↗

Electrolytically Assisted Surface Decontamination (EASD{sup TM}) for POCO Operations - 20282

NNL in collaboration with C-Tech Innovation Ltd and Sellafield Ltd has been exploring innovative technologies to enable a significant reduction of radiological hazards within facilities during the Post Operational Clean Out (POCO) phase of a nuclear plant's life cycle. Reducing the hazard by effectively decontaminating plants in-situ during POCO delivers huge cost reductions for future decommissioning operations. These cost reduction benefits are realized by reducing the number and complexity of remote operations as well as lowering the long-term waste disposal costs. Whilst chemical decontamination can achieve the desired level of decontamination, applying aggressive chemical reagents is hazardous, potentially difficult to control and requires there to be complimentary effluent treatment and waste routes. This work has aimed to develop flexible and controllable decontamination processes which could be operated without the additional complexity and issues associated with chemical decontamination. The processes needed to be relatively fast and effective to minimize the time operators would spend in an active area. In addition, there was a driver to produce decontamination methodologies which generated a secondary waste compatible with current routes and which takes advantage of current waste capacity. The strategy therefore was to come up with a solution that works with, rather than against, the science and engineering behind process plants at Sellafield. Electrolytically Assisted Surface Decontamination (EASD{sup TM}) is an innovative electrochemical decontamination process (developed by NNL and C-Tech Innovation Ltd) that can remove activity from contaminated metal in very short time periods. Application of the patented electric waveform to the surface when treating contaminated metal with nitric acid has been shown to significantly enhance the decontamination performance. When compared to proposed baseline washout procedures at Sellafield, the only change to the process is the applied electrical waveform which is temporary and controllable. The current causes dissolution of the metal surface being decontaminated which leads to activity transferring from the plant item into the nitric acid effluent stream. This innovation has the potential to transform the POCO process and allow a nitric acid based washout approach to deliver POCO quickly and cost effectively within the existing infrastructure. Several devices have now been designed that incorporate this EASD{sup TM} technology and enable the decontamination process to be applied to a range items commonly identified as being contaminated during nuclear decommissioning programmes such as pipework, tanks and hotspots of walls/floors. Inactive and active laboratory-scale testing has been completed using both simulated and 'real-life' contaminated (low level waste) metallic items retrieved from different nuclear sites. Active trials demonstrated that contaminated items could be treated to free release levels within minutes. Engineering scale tests are currently being performed, with guidance from Sellafield's system engineers and plant managers, to provide the necessary re-assurance the designed devices could be successfully deployed in an on-plant scenario. The final stage of this development work is to carry out an active demonstration of the decontamination technology on Thorp at Sellafield. This paper aims to highlight progress made to date with the EASD{sup TM} technology and, more specifically, the development of an in-situ decontamination device for deployment within radioactive pipework. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

The Power of a Network

The Solar Energy Innovation Network (SEIN) helps communities discover transformative ways of adopting solar energy. Teams develop their ideas in real-world contexts, yielding results that can unlock tomorrow's solar markets.

analysis↗

Cross-cutting concepts to transform agricultural research

Agriculture is an important link to many issues that challenge society today, including adaptation to and mitigation of climate change, food security, and communicable and non-communicable diseases in animals and humans. Transformation of agriculture and food systems has become a priority for a range of federal agencies and global organizations. It is imperative that food and agricultural researchers effectively harness the global convergence of priorities to overcome research “silos” through deep and sustained systemic change. Herein, we identify intersections in federal and global initiatives encompassing climate adaptation and mitigation; human health and nutrition; animal health and welfare; food safety and security; and equity and inclusion. Many agencies and organizations share these priorities, but efforts to address them remain uncoordinated and opportunities for collaboration untapped. Based on the interconnectedness of the identified priority areas, we present a research framework to catalyze agricultural transformation, beginning with the research enterprise. We propose that transformation in agricultural research should incorporate (1) innovation, (2) integration, (3) implementation, and (4) evaluation. This framework provides approaches for food and agricultural research to contribute to sustainable, flexible, and coordinated transformation in the agricultural sector.

60 APPLIED LIFE SCIENCES↗

Transforming Energy Through Computational Excellence: NREL HPC Resources for High Performance Computing for Energy Innovation (HPC4EI) Program

NREL hosts computing facilities for the U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy (EERE). In 2024, NREL introduced Kestrel, the 3rd generation, EERE-sponsored supercomputer dedicated to renewable energy and energy efficiency research. Kestrel has already been used for hundreds of research projects by NREL, other national laboratories, and university partners. This includes HPC4EI-sponsored industrial partnerships.

high-performance computing↗

7 Innovations in high-rate composite manufacturing: integrating additive manufacturing with compression molding process

Advanced composites play a pivotal role in modern engineering, offering exceptional strength-to-weight ratios and tailored properties, essential for various industries. High-rate composite manufacturing techniques have rapid production capabilities, which are essential for meeting the demands of industries requiring cost-saving, efficiency, and quick turnaround times. This chapter explores the Additive Manufacturing- Compression Molding (AM-CM) system developed by Oak Ridge National Laboratory (ORNL) for advanced composites manufacturing. The AM-CM system integrates additive manufacturing with compression molding, facilitating the production of polymer composite parts with superior mechanical properties and meticulously controlled microstructures. This innovative system not only ensures precise material deposition but also operates as a fast composite manufacturing process, enhancing productivity and performance, which are needed attributes across industrial applications. Through comprehensive mechanical testing and microstructural analysis, AM-CM promotes remarkable fiber alignment and reduced porosity in composite parts compared to alternative thermoplastic high-rate composite manufacturing methods. Furthermore, AM-CM enables overmolding reinforcement using continuous carbon fiber and supports selective reinforcement through customizable toolpaths. It also facilitates the production of hybrid materials to achieve tailored mechanical properties. Future advancements in AM-CM technology aim to enhance process efficiency, broaden material versatility, and improve part performance. This involves exploring novel materials, advancing process monitoring, implementing automation technologies, and integrating artificial intelligence (AI) and machine learning (ML) for predictive modeling and real-time optimization in composite manufacturing. These developments will establish the AM-CM system as a transformative technology in composite manufacturing, driving innovation across industries.

Hassen, Ahmed [ORNL] (ORCID:0000000328521222)↗