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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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DOE OSTI2020

A predictive strain-gradient model with no undetermined constants or length scales

A general meso–scale (GM) crystal plasticity (CP) model was developed that accounts for lower-order (strain hardening) and higher-order (internal stress) effects of geometrically necessary dislocations (GNDs). It is predictive: no arbitrary parameters or length scales were invoked and no ad hoc numerical techniques were employed. It uses general stress field equations for GND content and a novel harmonization technique to enforce consistency of elastic long-range singular defect fields with applied elastic-plastic fields. The model facilitates implementation in commercial finite element programs without requiring special elements, special boundary conditions, or access to element shape functions. GM simulations confirmed, with improved accuracy, previously published predictions of the Hall-Petch effect, Bauschinger effect, and anelasticity. Previously unpredicted phenomena were also predicted: anelasticity and hysteresis for single Ta crystals and strain-hardening stagnation. The internal stresses (higher-order effect) dominate at large length scales, while at small length scales, the GND density hardening (lower-order effect) dominates. As a result, GM predicts that strain heterogeneity and consequent GND internal stresses are important factors in anelasticity.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Operational resilience of additively manufactured parts to stealthy cyberphysical attacks using geometric and process digital twins

Cyberphysical attacks on the digital backbone of Additive Manufacturing (AM) can compromise the printed part’s functionality. They can alter features in the digital geometry to introduce geometric defects (e.g., missing fillets) or alter process parameters to create local defects (e.g., voids). Addressing the downtime, waste, and quality deterioration associated with existing solutions requires operational resilience, i.e., rapid elimination or disruption of defect formation (to retain part function) without production stoppage or part disposal (to retain yield). This need is unmet due to the inherently unpredictable nature of attack-induced alterations, lack of access to the original geometric model for identification of altered geometric features, and in-process imposition of unknown process dynamics via attack-driven alteration of real-time-uncontrolled (or exogenous) parameters. This work establishes the above-mentioned operational resilience for the first time by creating two Digital Twins (DT). The Geometric DT (Geo-DT) is based on a unique physical-field-driven soft sensor and topology optimization method. The Process Digital Twin (Pro-DT) combines local defect quantification with a novel Reinforcement Learning formulation and training method. The importance of these methodological advances and the scalability of our approach are examined on a real AM testbed. It is shown that Geo-DT can correct geometric defects without access to the original digital geometry or explicit knowledge of attack-altered geometric features. Further, Pro-DT can accelerate real-time disruption of local defects despite attack-driven imposition of unknown process dynamics. We discuss how our framework goes beyond the contemporary focus on pre-attack security and in-attack detection towards resilience for AM and beyond.

Additive Manufacturing↗

DOE OSTI2022

Discharge intermittency considerably changes ZnO spatial distribution in porous Zn anodes

Porous Zn anodes are ubiquitous in primary batteries and are under development for low-cost rechargeable batteries. Spatial distribution of ZnO discharge product is a critical factor in these, because it can passivate the active material. In rechargeable cells this is related to a major failure mechanism called shape change, in which ZnO is relocated to inactive locations. In this work we demonstrate rest steps during discharge of primary Zn anodes dramatically alter the placement of ZnO in the anode. In alkaline electrolyte, ZnO discharge product is typically modeled as precipitating close to Zn particles, forming a porous ZnO shell around the Zn core. Further, anodes discharged continuously at low-rate are compared to anodes similarly discharged intermittently, using in situ computed tomography from a synchrotron source. Zn–ZnO core-shell structures are produced during continuous discharge but are not found in cells discharged intermittently. Continuously discharged cells showed that ZnO was formed most strongly near the separator, in agreement with Zn anode battery models. In pulse-discharged cells, ZnO was more radially distributed and was in large formations not physically connected to Zn particles. Thus, discharge intermittency changes spatial distribution of ZnO in ways that are unpredicted by Zn anode models.

25 ENERGY STORAGE↗

DOE OSTI2023

Challenges in cybersecurity: Lessons from biological defense systems

Defending against novel, repeated, or unpredictable attacks, while avoiding attacks on the ‘self’, are the central problems of both mammalian immune systems and computer systems. Both systems have been studied in great detail, but with little exchange of information across the different disciplines. Here, we present a conceptual framework for structured comparisons across the fields of biological immunity and cybersecurity, by framing the context of defense, considering different (combinations of) defensive strategies, and evaluating defensive performance. Throughout this paper, we pose open questions for further exploration. In this work we hope to spark the interdisciplinary discovery of general principles of optimal defense, which can be understood and applied in biological immunity, cybersecurity, and other defensive realms.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

CLC: A cross-level program characterization method

Characterization of program execution plays a key role in performance improvement. There are numerous transformations applied to each step that a program takes on its lowering from source code to a compiler intermediate representation to machine language to microarchitecture-specific execution. The unpredictable benefit of each transformation step could lead a notionally superior algorithm to exhibit inferior performance once actually run, and it can be hard to discern which step in the transformation path contradicted the code developer’s assumptions. Conventional approaches to program-execution characterization consider the behavior after only a single one of those steps, which limits the information that can be provided to the user. To help address the issue of myopic views of program execution, this paper presents a novel cross-level characterization approach for understanding the behavior of program execution at different levels in the process of writing, compiling, and running a program. We show that this approach provides a richer view of the sources of performance gains and losses and helps identify program execution in a more accurate manner.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Rheological effects of moisture content on the anatomical fractions of loblolly pine (Pinus taeda)

Here, this study focused on assessing the influence of moisture content on the rheological properties of different anatomical fractions of pine residue using the FT4 powder rheometer. Moisture content exhibited some influence on the 2 mm bark and needle fractions, increasing their cohesion, angle of internal friction, unconfined yield strength, and major principal stress. Stem and whole, on the other hand, presented minimal changes upon moisture introduction. All 4 mm fractions did not show many changes in their rheological properties with moisture introduction, which can be due to less particle-particle interactions and consequently reducing any liquid bridging the particles might undergo; however, they were shown to have a more unpredictable behavior compared to the 2 mm analogues (i.e., higher standard deviation) which can be due to a higher degree of particle-interlocking. Out of the three fractions, needle presented the poorest rheological properties for flowability in addition to being susceptible by moisture, unlike other fractions.

36 MATERIALS SCIENCE↗

DOE OSTI2025

A visco-plastic constitutive model for accurate densification and shape predictions in powder metallurgy hot isostatic pressing

Powder metallurgy hot isostatic pressing (PM-HIP) is an advanced manufacturing process that produces near net shape parts with high material utilization and uniform microstructures. Despite being used frequently to produce small-scale components, the application of PM-HIP to large-scale components is limited due to inadequate understanding of its complex mechanisms that cause unpredictable post-HIP shape distortions. A computational model can provide necessary information about the intermediate and final stages of the HIP process that can help understand it better and make accurate predictions. Generally, two types of computational models are employed for PM-HIP of metal powders, namely, plastic and visco-plastic models. Between these, the plastic model is preferred due to its cheaper calibration approach requiring less experimental data. However, the plastic model sometimes produces incorrect predictions when slight variations of the HIP conditions are encountered in practical situations. Therefore, this work presents a visco-plastic model that addresses these limitations of the plastic model. A novel modified calibration approach is employed for the visco-plastic model that utilizes less experimental data than existing approaches. With the new approach, the data requirement is same for both plastic and visco-plastic models. This also enables a quantitative comparison of plastic and visco-plastic models, which have been only qualitatively compared in the past. When calibrated with the same experimental data, both the models are found to produce similar results. In conclusion, the calibrated visco-plastic model is applied to several complex geometries, and the predictions are found to be in good agreement with experimental observations.

Hot isostatic pressing↗

DOE OSTI2024

Modern deep neural networks for Direct Normal Irradiance forecasting: A classification approach

The escalating energy demand and the adverse environmental impacts of fossil-fuel use necessitate a shift towards cleaner and renewable alternatives. Concentrated Solar Power (CSP) technology emerges as a promising solution, offering a carbon-free alternative for power generation. The efficiency and profitability of CSP depend on the Direct Normal Irradiance (DNI) component of solar radiation; hence, accurate DNI forecasting can help optimize CSP plants’ operations and performance. The unpredictable nature of weather phenomena, particularly cloud cover, introduces uncertainty into DNI projections. Existing DNI forecasting models use meteorological factors, which are both challenging to estimate numerically over short prediction windows and expensive to model through data at a sufficiently high spatial and temporal resolution. This research addresses the challenge by presenting a novel approach that formulates DNI prediction as a multi-class classification problem, departing from conventional regression-based methods. The primary objective of this classification framework is to identify optimal periods aligning with specific operational thresholds for CSP plants, contributing to enhanced dispatch optimization strategies. We model the DNI classification problem using four advanced deep neural networks – rectified linear unit (ReLU) networks, 1D residual networks (ResNets), bidirectional long short-term memory (BiLSTM) networks, and transformers – achieving accuracies up to 93.5% without requiring meteorological parameters.

14 SOLAR ENERGY↗

DOE OSTI2025

Hydroclimate-coupled framework for assessing power system resilience under summer drought and climate change

Extreme drought, exacerbated by climate change, increasingly threatens power system resilience, and a systematic assessment of such impacts is challenging due to the unpredictability of drought and their associated modeling complexity. Here, to address the challenge, this research develops a hydroclimate-coupled power system resilience assessment framework that enables systematic modeling of drought and climate change impacts on generation, transmission, and demand sectors. Applying the framework to the 2025 Eastern U.S. power grid — comprising 6,055 at-risk generators — under climate-induced summer drought scenarios (including SSP126, SSP245, SSP370, and SSP585) from 2023 to 2100, the study finds that climate-induced droughts could jeopardize the power system’s reliability to a greater extent than historical events, potentially leading to widespread load shedding. More specifically, the study reveals that under the twenty-one representative drought scenarios, the loss of load expectation (LOLE) of the grid could range from 34.77 to 91.48 days per summer. The simulations indicate that implementing resilience enhancement strategies is crucial to ensure reliable system operation, which encompasses initiatives such as demand response, upgrading open cooling systems, and transmission expansion. In all, these findings underscore the urgent need for proactive planning and investment in resilient U.S. power systems to mitigate the impacts of extreme drought events.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

A dynamic price model based on supply and demand with application to techno-economic assessments of rare earth element recovery technologies

Rare Earth Elements (REEs) are essential for sustainable energy technologies. Techno-economic Assessments (TEAs) have been conducted to evaluate innovative approaches to recover REEs from waste streams. However, most TEA studies do not consider the price volatility of REEs, which raises concern over the reliability of the analysis in an unpredictable dynamic market. To address this shortcoming, a dynamic price model is proposed that adjusts REE price based upon supply-demand conditions. The dynamic market behavior is simulated and its effect on a TEA is examined via a case study. The results of the dynamic simulation indicate a growing trend of the market price for REE materials/products. Compared to a conventional TEA that does not consider price dynamics, a significant difference in economic performance metrics is identified from the dynamic TEA results. Finally, the proposed dynamic TEA method is not limited to a specific application and can provide insights for evaluating a broad range of technologies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2026

Rational engineering to enhance C8-fatty acid biosynthesis in Picosynechococcus sp. PCC 7002

Medium-chain fatty acids (e.g., C8-C14) are important biofuel precursors that can be produced from CO2 by cyanobacteria and other photoautotrophs. However, cyanobacteria naturally direct a relatively small fraction of fixed carbon to lipid synthesis, primarily producing long-chain membrane-bound fatty acids. We investigated whether mitigating kinetic bottlenecks within the fatty acid biosynthesis (FAB) pathway could enhance flux to free fatty acid (FFA) production in Picosynechococcus sp. PCC 7002. Previous in vitro studies proposed that the FAB initiating enzyme FabH is the primary rate-controlling enzyme in PCC 7002. We hypothesized that enhancing fatty acid initiation could increase in vivo FFA production while shifting the kinetic bottleneck further downstream in the pathway. We enabled C8-FFA accumulation by knocking out the native acyl-acyl carrier protein synthetase gene (aas) and expressing the highly active Cuphea palustris-derived mutant thioesterase CpFatB1.2-M4-287 (CupTE), which selectively catalyzes C8 chain termination. We then expressed the diatom-derived Chaetoceros sp. GSL56 FabH ortholog (chKASIII), to enhance initiation, and a medium-chain selective E. coli ketosynthase ecFabF[I108F] (ecFabF∗), to enhance elongation. When expressed individually or in combination with ecFabF∗, chKASIII slowed growth and decreased net carbon fixation rates relative to the parental Δaas-CupTE strain. However, co-expression of chKASIII, ecFabF∗, and CupTE redirected a larger fraction of fixed carbon toward FFA production, increasing relative carbon flux to C8-FFA and decreasing the projected minimum selling price by four-fold. This work demonstrates how systems metabolic engineering can be applied to enhance C8-FFA production in cyanobacteria while highlighting the unpredictable physiological consequences of host metabolic burden.

09 BIOMASS FUELS↗

DOE OSTI2020

A data mining approach to investigate food groups related to incidence of bladder cancer in the BLadder cancer Epidemiology and Nutritional Determinants International Study

Abstract At present, analysis of diet and bladder cancer (BC) is mostly based on the intake of individual foods. The examination of food combinations provides a scope to deal with the complexity and unpredictability of the diet and aims to overcome the limitations of the study of nutrients and foods in isolation. This article aims to demonstrate the usability of supervised data mining methods to extract the food groups related to BC. In order to derive key food groups associated with BC risk, we applied the data mining technique C5.0 with 10-fold cross-validation in the BLadder cancer Epidemiology and Nutritional Determinants study, including data from eighteen case–control and one nested case–cohort study, compromising 8320 BC cases out of 31 551 participants. Dietary data, on the eleven main food groups of the Eurocode 2 Core classification codebook, and relevant non-diet data (i.e. sex, age and smoking status) were available. Primarily, five key food groups were extracted; in order of importance, beverages (non-milk); grains and grain products; vegetables and vegetable products; fats, oils and their products; meats and meat products were associated with BC risk. Since these food groups are corresponded with previously proposed BC-related dietary factors, data mining seems to be a promising technique in the field of nutritional epidemiology and deserves further examination.

Nutrition & Dietetics↗

DOE OSTI2026

Synthetic Biology of Plants and Microbes for Agriculture, Environment, and Future Applications

Agriculture is under pressure to provide food for a growing population and the feedstock required to drive the bioeconomy. Methods to breed and genetically modify plants are inadequate to keep pace. When engineering crops, traits are painstakingly introduced into plants one-at-a-time, combine unpredictably, and are continuously expressed. Synthetic biology is changing these paradigms with new genome construction tools, computer aided design (CAD), and artificial intelligence (AI). “Smart plants” contain circuits that respond to environmental change, alter morphology, or respond to threats. Further, the plant and associated microbes (fungi, bacteria, archaea) are now being viewed by genetic engineers as a holistic system. Historically, plant health has been enhanced by many natural and laboratory-evolved soil microbes marketed to enhance growth, provide nutrients, or confer pest/stress resistance. Synthetic biology has expanded the number of species that can be engineered, increased the complexity of engineered functions, controlled environmental release, and assembled stable consortia. New CAD tools will manage genetic engineering projects spanning multiple plant genomes (nucleus, chloroplast, mitochondrion) and the thousands of genomes of associated bacteria/fungi. Here, this review covers advanced genetic engineering techniques to drive the next agricultural revolution, as well as push plant engineering into new realms for manufacturing, infrastructure, sensing, and remediation.

Clauer, Phillip [Massachusetts Inst. of Technology↗

DOE OSTI2025

Postfire Biogeochemical Processes: Implications to Source Water Quality in Fire-Influenced Watersheds

Forested watersheds are instrumental in providing purified and reliable water to millions of people worldwide. The changing climate has increased the frequency and severity of global fire events. Forested watersheds and their ecosystem functions are greatly disrupted during fire activity. Postfire concerns in forested watersheds include unpredictable and potentially simultaneous alterations in source water quality and hydro-biogeochemical processes. Here, the degree of fire severity can complexly modify water quality through the production of fire-transformed constituents on the burned forest floor (i.e., nutrients, metal(loid)s, dissolved organic matter, and the formation of disinfection byproducts). Correspondingly, fire severity and postfire rainfall patterns can refine hydro-biogeochemical processes that influence the transport of the fire-transformed constituents (i.e., vegetation function, soil structure, hydrological pathways, and microbial communities). Postfire alterations to water quality and hydro-biogeochemical processes introduce further complexity with varying temporal influence, which ranges from months to decades. As postfire water quality and watershed response research progresses, it is essential to homogenize interdisciplinary expertise to bridge knowledge gaps between fields ranging from forest ecology, hydrology, microbiology, and geochemistry. A multidisciplinary approach in wildfire research will facilitate a comprehensive perception of the diverse water quality risks associated with fire activity and mitigate fire concerns on a global level.

Disinfection Byproducts↗

DOE OSTI2021

Immobilization of Cyanines in DNA Produces Systematic Increases in Fluorescence Intensity

Cyanines are useful fluorophores for a myriad of biological labeling applications, but their interactions with biomolecules are unpredictable. Cyanine fluorescence intensity can be highly variable due to complex photoisomerization kinetics, which are exceedingly sensitive to the surrounding environment. This introduces large errors in Förster resonance energy transfer (FRET)-based experiments where fluorescence intensity is the output parameter. However, this environmental sensitivity is a strength from a biological sensing point of view if specific relationships between biomolecular structure and cyanine photophysics can be identified. We describe a set of DNA structures that modulate cyanine fluorescence intensity through the insertion of adenine or thymine bases. These structures simultaneously provide photophysical predictability and tunability. We characterize these structures using steady-state fluorescence measurements, fluorescence correlation spectroscopy (FCS), and time-resolved photoluminescence (TRPL). Here, we find that the photoisomerization rate decreases over an order of magnitude across the adenine series, which is consistent with increasing immobilization of the cyanine moiety by the surrounding DNA structure.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2023

An Innovative Insight into Performance Degradation of NCM111 Cathode Induced by Suspension of Operation

The lifespan of lithium-ion batteries varies enormously from fundamental study to practical applications. This big difference has been typically ascribed to the high degree of uncertainty in unpredictable and complicated operation conditions in real-life applications. Here, in this paper, we report that the pause of the charging–discharging process, which is frequently operated in practice but rarely studied in academics, is an important reason for the performance degradation of the NCM111 cathode. It is found that the pause during cycling could trigger a remarkable drop in capacity, giving rise to ~30% more capacity decay compared with the continuously cycled sample. In situ synchrotron X-ray diffraction analysis reveals that the harmful H1–H2 phase transition, which typically appears in the initial cycle but disappears in subsequent cycles, is reactivated by the pausing process. The anisotropic lattice strains that occur during the H1–H2 transition result in mechanical fractures that terminate with an inert NiO-type rock-salt phase on the surface of particles. The present study indicates that the discontinuous usage of rechargeable batteries is also a key factor for cycle life, which might provide a distinct perspective on the performance decay in practical applications.

25 ENERGY STORAGE↗

DOE OSTI2025

Three-Dimensional Bubble Fluidics in Architected Porous Media

Gas bubble flows in porous media often exhibit complex and seemingly unpredictable behaviors that are difficult to control. This lack of control limits the ability to design effective devices which manage multiphase flows. Here, we show how the design of 3D printed pores can deterministically control the flow path of an injected gas stream. Open cell structures can be designed to shape the gas/liquid interface with fidelity to control how the two phases are distributed throughout a porous material. The distributed gas volume is free to interact physically and chemically with the surrounding liquid phase, an effect we exploit to create a logical control gate to redirect flows within a lattice. This also allows us to design architectures for reactive capture and aerating bioreactors, resulting in patterned boundaries which can make more effective use of the liquid and gas reagents.

3D microfluidics↗

DOE OSTI2021

Role of Mineralogy in Controlling Fracture Formation

The presence of fractures in caprocks can pose increased risks in subsurface energy systems and processes like CO 2 sequestration by introducing high-permeability leakage paths. Fracture apertures and permeability can be altered through mineral dissolution and precipitation reactions, but the reactive evolution of fractures is not well understood. In fractures, minerals that are otherwise inaccessible to reactive fluids can become exposed, resulting in mineral reactions unpredicted by bulk formation data. This work seeks to understand the relationship between mineralogy and fracture formation to enhance our understanding of reactive fracture evolution and CO 2 leakage potential. Here, the mineral compositions of mechanically induced fracture surfaces in samples of the Mancos and Marcellus shales have been quantified and compared to those of the near-fracture matrices using imaging and bulk X-ray diffraction (XRD) data. In the Mancos shale, the concentrations of clay minerals are enhanced along fracture surfaces with respect to the bulk, and the fracture is most likely to form at kaolinite–kaolinite interfaces. Further, evaluation of the mineralogical spatial variability through cross-correlation analysis of the surrounding matrix in images of samples cut perpendicular to the fracture shows that clay is 16.7 times more likely to be present than carbonate minerals near the fracture surface. The high correlation persists roughly 200 μm into the surrounding matrix for the Mancos sample and implies that the fracture formed within a defined clay-rich lithofacies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗