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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Performance of a MQXF Nb 3 Sn Quadrupole Magnet Under Different Stress Level

In a dipole or in a quadrupole accelerator magnet, the displacement of the coil turns induced by the electromagnetic forces can cause quenches limiting the magnet performance. For this reason, an azimuthal preload is applied to avoid azimuthal movements of the coil up to the required operational current. However, several tests showed that accelerator magnets can operate with a partial preload, i.e. that coil unloading during the ramp does not prevent reaching higher currents. This issue is particularly relevant for Nb 3 Sn magnets, where the loads applied to the Nb3Sn filaments can reach the degradation limits of critical current. In order to investigate the impact of coil preload on the quench performance, the MQXFS6 short model quadrupole for the High Luminosity Upgrade was tested under an azimuthal preload at 80% of the short sample current, reaching 93% of short sample current at 1.9 K. The preload was then released to 60%, still showing ability to operate in the range of 80-85% of short sample current as required by HL-LHC project. With this lower preload, the ability of going above 90% of short sample was lost, and a significant training appeared above 85%. When the preload was restored to the original 80% value, the magnet reached with few quenches 95% of short sample (13.4 T peak field). Magnetic measurements confirm the larger movement of the coil in the case with lower preload, and agree with finite element simulations.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Experimental studies of a high-gradient X-band welded hard-copper split accelerating structure

We report on recent research on high-gradient radio frequency (RF) accelerating structures indicates that the use of hard copper alloys provides improvement in high gradient performance over annealed copper. Such structures are made by bonding individually manufactured parts. However, there are no well-established bonding techniques that preserve the hardness, surface finish and cleanliness required for high gradient operation. To preserve the copper hardness, RadiaBeam has developed a novel high-gradient split accelerating structure, based on electron beam welding joining technique. This technique provides efficient bonding with strong, clean welds and minimal thermal loading, while maintaining a clean inner RF environment. Our RF design and fabrication methodology limits the small heat affected zone to the outer cavity envelop, with virtually no distortions or thermal loading of critical RF surfaces. It also incorporates provisions to precisely control the gap despite conventional issues with weld joint shrinkage. To date we have manufactured and validated an RF accelerating structure joined by electron-beam welding that incorporates a novel open split design to significantly reduce the assembly complexity and cost. In this paper, we will present the electromagnetic design of this structure, discuss bonding, and present the results of high-power tests, where the accelerating gradients of 140 MV m -1 with surface peak fields of 400 MV m -1 were achieved for flat-top pulse length of 600 ns with an RF breakdown rate of 10 -4 1/(pulsecm).

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Next-generation anion exchange membrane water electrolyzers operating for commercially relevant lifetimes

Alkaline anion exchange membrane (AEM) water electrolysis has gained increasing attention due to its potential to achieve low-cost, high performance hydrogen production. However, most existing membranes are not durable in industrial settings. In this work, we demonstrate good performance relative to industrial parameters using Sustainion® anion exchange membranes. Long-duration tests showed stable performance of 1 A/cm 2 at 1.85 V with a degradation rate of less than 1 μV/h over 10,000 h. The projected lifetime is thus over 20 years. Daily on/off cycling performance over the course of 30 years was simulated experimentally through accelerated voltage shock tests, resulting in a performance loss of only 0.15 μV/cycle over 11,000 cycles. As shown through impact and crossover testing, an improvement in performance is achieved by the addition of zirconia to the polymer matrix and mechanically reinforcing the membrane.

08 HYDROGEN↗
DOE OSTI2025

Accelerating Nuclear-Integrated Data Centers in the USA: SWOT Analysis, Power-Thermal Management Strategies, and Industrial-Scale Demonstration and Potential Deployment

Driven by the growth in digital services, cloud computing, AI, and manufacturing, data centers face rising energy demands that challenge traditional power sources and cooling efficiency. This study explores using nuclear power to meet these demands, focusing on accelerated reactor technology deployment and highlighting needs such as N+1/N+2 power supplies and integrated power-thermal management. A SWOT analysis addresses grid connectivity, reactors, and site selection, particularly DOE sites. Reactor technology demonstration and deployment could be accelerated by leveraging test facilities such as MARVEL, MAGNET, TED, FAS, DOME, LOTUS, ATR, Energy System Proving Grounds, and upcoming Energy Launch Pads, along with modeling and simulation tools such as RELAP5, MOOSE, VERA, RAVEN, and FORCE. The potential power and thermal management options, including various cooling technologies, waste-heat utilization, and an industrial-scale demonstration plan, aim to accelerate the integration of nuclear power and data centers in the USA, while emphasizing community and stakeholder engagement and synergistic efforts.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2026

Feedback, physics, and forecasts: The emerging paradigm of machine learning-driven battery research

Machine learning (ML) is reshaping how we understand, predict, and optimize electrochemical systems. In batteries, ML accelerates discovery across chemistry, design, and operation by transforming massive experimental and simulated datasets into predictive, interpretable models. This review consolidates a decade of progress in ML-driven battery innovation, from early-cycle feature extraction to operando image analysis and physics-informed modeling. We categorize approaches by data domain and physical fidelity, emphasizing interpretable ML for diagnostics, reinforcement learning for control, and multi-objective optimization for lifetime extension strategies. Additionally, we demonstrate how integrated models accelerate discovery, reduce testing time, and guide sustainable design. Economic analyses furthermore illustrate how these advances can lower cost per cycle and improve circularity. Together, these developments chart a path toward self-optimizing, sustainable battery technologies.

artificial intelligence↗
DOE OSTI2024

Scaling methodologies and similarity analysis for thermal hydraulics test facility development for water-cooled small modular reactor

Small modular reactors (SMRs) represent a promising option for providing clean and sustainable energy due to their potential for enhanced safety, reduced capital costs, and increased siting flexibility. However, new reactor systems require the development and operation of representative scaled-down test facilities to support the verification and validation of system computer codes and models. Here this study reviews the research on scaling methodologies and similarity principles pivotal in developing non-nuclear integral effects test and separate effects test facilities for water-cooled SMRs. The study focuses on a review of the scaling methods, similarity approaches, and possible challenges posed by the unique and compact design features of integral-pressurized water reactor-type SMRs, and their representative test facilities. This study also reviews previous research related to scaling and similarity methodologies and provides insights into design considerations for achieving prototypic conditions in test facilities. The findings and recommendations emphasize the broader impact of appropriate scaling and similarity principles to ensure meaningful and transferable results from non-nuclear test facilities to accelerate the safe and efficient deployment of next-generation water-cooled SMRs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Package Development for Reliability Testing of Perovskites

Metal halide perovskite solar cells have reached a critical point in their development. At a current certified record efficiency of 25.7% for a single-junction, research-scale cell, they now garner serious attention from the solar cell industry as a promising route to widespread, low-cost photovoltaics in single- or tandem-junction configurations. However, more work to demonstrate their durability under real-world outdoor test conditions is necessary to ensure the long-term success and deployment of the technology. Differences in chemistry, processes, and their combination result in unique performance limiters for both efficiency and stability. Further, as many active formulations and layer/cell stack combinations are sensitive to temperature, air, and moisture, it is important to separate intrinsic limitations to stability relative to these extrinsic sources. This presents a particular need for the development of an appropriate and reliable package for environmental (i.e., accelerated and outdoor) testing that will permit these different factors to be evaluated and understood.

14 SOLAR ENERGY↗
DOE OSTI2021

Performance of concrete under accelerated physical salt attack and carbonation

Conventional testing of physical salt attack (PSA) on concrete does not consider concomitant factors that may exist in service and alter the mechanisms and kinetics of PSA. This study adopted a combined testing approach where concrete was concurrently investigated under accelerated PSA and carbonation, simulating elements serving in heavy traffic and industrial zones, while implementing ambient conditions similar to that in geographic locations with previous cases of PSA. Based on the tested mixture design parameters [water-to-binder ratio, cement type, and supplementary cementitious materials], potential performance improvement and risks were identified. Thermal, mineralogical, and microscopy analyses elucidated the co-occurrence of complex degradation processes in concrete subjected to accelerated PSA and carbonation, which were distinctive from that induced by the single-factor PSA exposure. The synoptic results from this study may informatively improve guidance on mixture design of concrete when dual exposure to PSA and carbonation is expected in the field.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Discovery of complex oxides via automated experiments and data science

Significance Automation is accelerating the discovery of useful materials, yet testing even a small fraction of the billions of possible materials for a desired property is beyond the reach of workflows involving resource-intensive property measurements. Due to relationships among composition, structure, and properties, identifying a complex material with one interesting property makes it the proverbial needle in a haystack that merits testing for additional properties. We accelerate materials synthesis and optical characterization by employing physics-aware data science to identify materials for further investigation. With this approach, one does not need high-throughput methods for measuring every material property of interest since a single ultra-high–throughput workflow can guide material selection for other properties, which is a new paradigm for accelerated materials discovery.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Research in Advanced Artificial Intelligence Techniques for Modern Accelerator Control

The major goals for the project were to remain in contact with accelerator stewardship customers, develop and test new techniques based to further improve accelerator and peripheral systems, and train early career persons to participate on the project and teach them aspects of the field of accelerator science and technology.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Accelerating nuclear fuel development and qualification: Modeling and simulation integrated with separate-effects testing

In this work, an approach to transform and accelerate nuclear fuel development and qualification is outlined. The approach exploits advanced modeling and simulation at the outset to inform constituent and system selection and to enable integral fuel performance analyses. Analyses using these tools identify and prioritize the most important fuel performance parameters and phenomena for subsequent targeted characterization with separate-effects tests. Separate-effects testing spans out-of-pile and in-pile tests and is meant to iterate with and inform engineering-scale integral fuel performance analyses throughout the development process. Exercising this cycle in an agile fashion will increase confidence in the integral fuel performance predictions while reducing uncertainties. This process sets the stage for executing a much more limited set of well-defined integral irradiation tests designed to validate engineering-scale fuel performance codes and to confirm the performance and safety of the fuel system under prototypic conditions. This approach will reduce the time for development and qualification of a new fuel system, and it will also reduce associated costs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Millions of Small Pressure Cycles Drive Damage in Cracked Solar Cells

Here, we applied time-varying air pressure to a PV module containing newly cracked cells. The test used a new dynamic mechanical acceleration (DMX) apparatus. We applied pressure cycles similar to natural, wind-driven cycles. Compared to standard dynamic mechanical load (DML) tests, we applied much lower pressure (10 Pa to 300 Pa RMS) and many more cycles (one million at each of four pressure levels). We present a case study on a single cell in a commercial module. We monitored electrical continuity loss across cracks using electroluminescence (EL) imaging. 10 Pa pressure cycles caused negligible change. 30 Pa pressure cycles caused permanent damage that continued worsening even after tens of thousands of cycles. After one million 30 Pa cycles, a series of 100 Pa cycles still caused new, permanent damage to existing cracks. 300 Pa cycles caused further worsening and introduced new cracks.

14 SOLAR ENERGY↗
DOE OSTI2024

Investigating the Crosslinking, Degradation, and Adhesion Behavior of Photovoltaic Encapsulants Under Thermal Accelerated Aging

Degradation of photovoltaic (PV) module encapsulant characteristics that lead to mechanical embrittlement and delamination remains a cause of failure in solar installations. A multiscale reliability model connecting the encapsulant mechanical and fracture properties to the degraded molecular structure and interfacial bonding to adjacent solar cell and glass substrates was previously published. The model, developed primarily for poly(ethylene-co-vinyl acetate) acetate (EVA) encapsulants, remains to be experimentally validated. Determining the degradation and crosslinking kinetics of alternative encapsulants, such as polyolefin elastomer (POE) and EVA/POE/EVA composites (EPE), can generalize the model. In this work, we subject fully cured EVA, POE, and EPE encapsulants to accelerated thermal aging to determine how high temperatures impact reaction kinetics. An increase in gel content (crosslinking) and decrease in crystallinity of the encapsulants under hot-aerobic (90 degrees C, 22% RH) and hot-anaerobic (90 degrees C, sealed in N 2 air) aging were observed, even in the absence of UV and crosslinking initiators. Fourier transform infrared spectroscopy (FTIR)-attenuated total reflectance analysis showed insignificant encapsulant degradation, demonstrating the critical role of UV and moisture in accelerating degradation. Adhesion testing performed on coupon-level specimens (cell/encapsulant/glass laminates) showed decreases in adhesion energy, Gc , from 5000 h of hot-dry (90 degrees C, ~1% RH) and hot-humid (90 degrees C, 60% RH) aging. POE coupons demonstrated the best stability, followed by EPE then EVA. For EVA and POE, hot-humid aged coupons experienced a larger decrease in Gc due to enhanced hydrolytic degradation. Hot-dry aging condition demonstrated that thermal degradation of the interface could be significant even if the encapsulant experiences negligible degradation in the absence of UV and elevated humidity.

accelerated aging↗
DOE OSTI2023

Determining the Effects of Neutron Irradiation on the Structural Integrity of Additively Manufactured Heat Exchangers for Very Small Modular Reactor Applications, DOE Final Report (Project # 19-16980)

Auburn University (AU) teamed with the University of Missouri Research Reactor (MURR) and Kansas State University (KSU) to determine how to best use laser-powder bed fusion (L-PBF) additive manufacturing (AM) methods for generating radiation resistant nickel-based superalloys, Inconel alloy 625 and 718, for special purpose reactor (SPR) or very small modular reactor (vSMR) heat-exchangers (HeXs). Compact, conformal, and durable HeXs that are tolerant of extreme environments are needed for supporting the technical maturity of next-generation, portable compact reactors. AM is an enabler for realizing this new wave of HeXs – providing a means to make customizable hot and cold stream architectures with novel flow path geometries (e.g., tortuous channels with non-uniform, asymmetric cross-sections) and reduced layer-to-layer contact resistance (i.e., no separate bonding procedure required). AM further enables a more time/cost efficient means for fabricating SPRs by reducing the number of suppliers required for HeX assembly and allowing for on-site HeX fabrication. The project aim has been to better understand how neutron irradiation affects the microstructure and properties of additively manufactured nickel-based superalloys, to accelerate their safe, reliable use in the modular reactor industry. The major objective was to qualify/quantify the microstructure and microhardness of nickel-based superalloys (including Inconel 718 and 625) additively manufactured via the L-PBF process in the neutron-dosed (irradiated) and non-irradiated states over a course of 3 years. Effects of build orientation during L-PBF and post-AM heat treatments on neutron resistance, microstructure and mechanical properties were also investigated. Neutron damage mechanisms via hardening were characterized. This project combined subject-matter experts in AM, mechanical/microstructure metallic part characterization, and neutron irradiation, as well as unique assets and capabilities at AU and MURR at MU, to ensure project results translated to effectively addressing known gaps in nuclear science and engineering. Parts were fabricated using L-PBF systems readily available at AU. Specimens were then irradiated using MURR facilities; a manipulator equipped hot cell was also used to measure material hardness after dosing. MURR, a 10 MW, light-water nuclear reactor, is the largest, highest powered, highest-flux university owned research reactor in the U.S. The major findings in this project provide evidence that AM can serve as an alternative way to build structural components for future advanced small modular reactors using advanced materials like Inconel 625 (IN625) or Inconel 718 (IN718). After full spectrum neutron irradiation, vertically as-built AM IN625 samples were observed to display better resistance towards radiation-induced-hardening defects relative to traditionally machined metals. A Vickers microhardness tester, using settings of 1 kgf and dwell time of 15 seconds per indentation, was used to measure hardness in this study. The as-built, vertically printed samples experienced 1.2% of radiation hardening vs. 5.25% radiation hardening observed in wrought IN625. Another set of IN625 and IN718 samples were exposed to fast neutron irradiation. It was observed that IN718 showed more resistance towards radiation hardening compared to IN625 samples indicating IN718 had a better performance. Results showed that the IN718 samples experienced less change (-2.5 to 3.24 %) in microhardness. On the other hand, IN625 samples underwent more (0.9 to 7.21%) change in microhardness after fast neutron irradiation. AM IN625 samples were irradiated using an ion (proton) beam in cyclotron. The mechanical properties of AM samples post irradiation were compared with wrought samples. The irradiated region on the samples were tested using nano-hardness indention. It was observed that the beam current and time used in this study generated an annealing effect and thus reduced the hardness of the samples. The sum of the project results provide precious insight into how one may minimize radiation hardening in AM materials while maintaining material property constraints. Results should assist engineers in selecting an appropriate heat treatment for AM nickel-based superalloys for increased radiation resistance. Results should increase confidence levels for adopting AM for building nuclear reactor components which perform the same or better than conventionally manufactured components. Fast neutron irradiation testing provided an accelerated means of obtaining radiation effects without making materials radioactive and difficult to handle.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Cryogenic and safety design of the future high field cable test facility at Fermilab

The HFVMTF (High Field Vertical Magnet Test Facility) is a new experimental facility under development at Fermi National Accelerator Laboratory (FNAL) to test large superconducting magnets (up to 20 tons weight and 1.3 m diameter) in a double bath superfluid helium cryostat (1.9 K and 1.2 bar). Coupled with a superconducting dipole magnet fabricated by Lawrence Berkeley National Laboratory (LBNL), this facility will be able to test future high-temperature superconductor (HTS) cables under a background magnetic field of 15 T for fusion magnets. This paper describes the design of the cryostat and its 1.4-meter diameter lambda plate, as well as the different components for a safe operation of the facility, even during critical events such a magnet quench or a vacuum breaking situation. The project is funded by US DOE Offices of Science, High Energy Physics (HEP), and Fusion Energy Sciences (FES).

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

High‐Performance Low‐Emissivity Paints Enabled by N‐Doped Poly(benzodifurandione) (n‐PBDF) for Energy‐Efficient Buildings

Abstract Low‐emissivity (low‐e) paints reduce radiative heat exchange between buildings and the environment, stabilizing indoor climates and lowering air conditioning demand. However, low‐cost, durable, and colored low‐e paints have yet to be demonstrated. Here, an approach is proposed using n‐doped poly(benzodifurandione) (n‐PBDF), a transparent organic conducting polymer, coated over colored commercial paints. This achieves a low thermal emissivity of 0.19 in the mid‐infrared spectrum, attributed to the efficient charge transport of delocalized π‐electrons in n‐PBDF structure. The reduction in thermal emissivity aids in regulating building temperatures by minimizing heat transfer between buildings and their surroundings across diverse climate zones and seasons. The n‐PBDF coating preserves the underlying paint's color due to its high visible transparency, meeting aesthetic requirements. It also shows strong stability in accelerated indoor weathering tests, ensuring long‐term performance. Simulations estimate annual HVAC energy savings of over 10,800 kWh in San Francisco and 5,500 kWh in Chicago for the typical mid‐rise apartments. The paint's versatility, scalability, and durability make it suitable for buildings, vehicles, and greenhouses, aiding urban heat island mitigation.

Liu, Xiaojie [School of Mechanical Engineering and↗
DOE OSTI2021

Simultaneously Blocking Chemical Crosstalk and Internal Short Circuit via Gel-Stretching Derived Nanoporous Non-Shrinkage Separator for Safe Lithium-Ion Batteries

The separator, an ionic permeable and electronic insulating membrane between cathode and anode, plays a crucial role in the electrochemical and safety performance of batteries. However, the commercial polyolefin separators not only suffer from inevitable thermal shrinkage at elevated temperature, but also fail to inhibit the hidden chemical crosstalk of reactive gases such as O 2 , leading to often reported thermal runaway (TR) and hence preventing large-scale implementation of high-energy-density lithium-ion batteries. Herein, a nanoporous non-shrinkage separator (GS-PI) was fabricated via a novel gel-stretching orientation approach to eliminate TR. In situ synchrotron small angle X-ray scattering during heating clearly showed that the as-prepared thin GS-PI separator exhibits superior mechanical tolerance at high temperature, thus effectively preventing internal short circuit. Meanwhile, the unique nanoporous structure design further blocks chemical crosstalk and the associated exothermic reactions. Accelerating Rate Calorimetry test revealed that the practical 1 Ah LiNi 0.6 Co 0.2 Mn 0.2 O 2 (NCM622)/graphite pouch cell using GS-PI nanoporous separator show a maximum temperature rise (dT/dt max ) of only 3.7 °C s -1 compared to 131.6 °C s -1 in the case of Al 2 O 3 @PE macroporous separator. Furthermore, despite the reduced pore size, the GS-PI separator demonstrates better cycling stability than conventional Al 2 O 3 @PE separator at high temperature without sacrificing specific capacity and rate capability.

25 ENERGY STORAGE↗