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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Towards Commercialization of Low-Cost, Crack-Tolerant, Screen-Printable Metallization by Full-Size Module Testing and Field Characterization

This project is motivated by the need to develop a materials engineering solution to reduce solar module degradation caused by cell cracks. The cell-crack-induced power loss is a long-term degradation mechanism and one of the main causes of solar panel field failures. Cell cracks can occur during module fabrication, transportation, installation, and long-term operation due to thermomechanical stressors. Our team’s internal estimation – based on the national weather pattern, frequency of severe weather, and 39- GW asset survey by Heliolytics – reveals that the cell-crack-induced module degradation translates to lost revenues >$17B over an average 5-year period for solar farm owners and to reduced reliability (<25 years panel lifetime) for solar energy consumers. In response to this challenge, the prime recipient offers a metal matrix composite (MMC) silver paste that is tailor-engineered for screen-printing gridlines and busbars, which serve as the electrical contacts on solar cells. We formulate our MMC paste by adding low-cost (∼0.02¢/WDC for research grade), surface-engineered carbon nanotubes to commercially available silver paste. The MMC paste offers a drop-in, cost-effective solution to cell cracks for solar cell and module manufacturers. The main goal of this project was to conduct field-relevant, module-level analysis and qualification of MMC metallization.

14 SOLAR ENERGY↗
DOE OSTI2020

Phase 1 NuScale SMR FOAK Nuclear Demonstration Readiness Project (Final Scientific/Technical Report)

The overarching objective of the Phase 1 NuScale SMR First-of-a-Kind (FOAK) Nuclear Demonstration Readiness Project was to enhance competitiveness of the U.S. nuclear industry by enabling timely deployment of the NuScale small modular reactor (SMR). The scope of this Phase 1 project continued to advance the licensing and design maturity, particularly in those areas related to supporting customer readiness, supply chain integration, cost competitiveness, and cost confidence. This investment provided by the Government has accelerated development of these designs and technologies so that the existing domestic fleet of nuclear power plants remains viable and the most mature in the nuclear industry. The intent is to have the new, advanced U.S. designs be deployed as early 2026, and be globally competitive. As a part of the First-of-a-Kind Nuclear Demonstration Readiness Project, NuScale has been developing an advanced reactor design, leading the path for other development projects or complex technology advancements for existing plants that have significant technical and licensing risk. The NuScale Power team (NuScale) is advancing licensing, engineering, supply chain development, testing, and other required activities to enhance the innovation and competitiveness of the U.S. nuclear industry by enabling timely deployment of the NuScale SMR. Specifically, NuScale is performing the following activities in Phase 1. Fully supporting the NRC review of the NuScale DCA to ensure approval of a final safety evaluation report by the end of 2020. Improving plant cost confidence and cost competitiveness through design and supply chain advancement, incorporation of constructability best practices, and margin recovery to increase plant power output. Accelerating design maturity, technology development, and operational program readiness to support a customer commitment for plant deployment. The Department of Energy (DOE) Office of Scientific and Technical Information (OSTI), a unit of the Office of Science, fulfills agency-wide responsibilities to collect, preserve, and disseminate both unclassified and classified scientific and technical information (STI) emanating from DOE-funded research and development (R&D) activities at DOE national laboratories and facilities and at universities and other institutions nationwide. This scientific and technical report provides summaries of the analyses and research that was performed by NuScale under this project that achieves the objective of disseminating information to the nuclear industry to ensure the innovations realized are shared for the benefit of the industry at large.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

A Review of Sociotechnical Approaches for Nuclear Power Plant Modernization

The current United States nuclear power plant fleet is in need of transforming the way work is performed to remain competitive with other electricity-generating sources. The use of new digital technologies can be applied to significantly reduce operating and maintenance costs. Recent research by the United States Department of Energy Light Water Reactor Sustainability Program has identified new opportunities to leverage advanced digital technologies to transform the way work is performed at existing plants. However, to ensure that the capabilities of people and advanced digital technologies are jointly optimized, a sociotechnical approach should be considered. This work explores recently introduced sociotechnical approaches to address the function allocation and data visualization considerations in the integration of new digital technologies to ensure safety, reliability, and maximizing the capabilities of proposed technological solutions that ensure the economic viability of the existing United States nuclear power plant fleet.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

Probing Coherent States of Light and Matter in Two-Dimensional Semiconductors. Final Report

The ability to enhance light-matter interactions in engineered optical environments is well-established in micro- and nano-photonics. New classes of materials bring new rich correlations between spin, momentum, and light polarization that can be exploited in these photonic systems for information processing and low-power electronics. Interfacing these novel material features with strong optical interactions suggests the compelling capability to create hybrid light-matter systems harnessing low-energy and protected material properties such as spin. The long-term objective of this program was to investigate the interplay between pseudospin in 2D materials and light, revealing new coherent phenomena. The materials studied are the monolayer transition metal dichalcogenides (TMDs), which support polarization-sensitive optical transitions when isolated to a single sub-nanometer crystal layer in thickness. In particular, monolayer TMD semiconductors such as MoS 2 exhibit degenerate valleys in momentum space with distinct spin character. These valleys can be separately addressed by circularly polarized light, providing a tool for manipulation. Integrating this valley pseudospin of excitons in monolayer TMDs with engineered strong optical excitations to create novel coherent phenomena was a key long-term goal of this research. The scope of this research primarily focused on studying light-matter interactions of valley-sensitive excitations in monolayer TMDs. The scope also included the integration of monolayer materials that support valley-polarized emission into photonic devices. This approach extends prior work on exciton-polaritons in 2D materials toward a platform with far more control and improved light input and output characteristics to aid scalability of these polarization-sensitive phenomena to many-body, long-range optical networks. During the course of the five-year Early Career program, the approaches led to successful progress on each proposed aim. Initial successful work seeded additional research that developed from the main themes, while this program focus evolved toward coherent manipulation of valley polaritons and integration with photonics. Both of these advanced topics set the stage for new capabilities in future innovative research. The results of this project provide advances in materials and methods relevant for new visions of opto-electronics and photonics that can improve information processing in an era of increased focus on quantum and coherent phenomena. The research has also contributed to the training of two postdoctoral scholars and five graduate students.

2D Materials↗
DOE OSTI2023

Evaluation of the Reconstruction Accuracy of the Ultrasound Model–Based Image Reconstruction (U-MBIR) Method for Concrete to Optimize Damage Detection

Reinforced concrete is a critical structural material used to construct nuclear power plants (NPPs). As such, its safety and performance must be thoroughly examined throughout the life cycle of the NPP infrastructure system. Ultrasonic measurements have been an industry standard for both surface and subsurface inspections. To support the development of these techniques, Oak Ridge National Laboratory (ORNL) has researched and developed advanced image reconstruction algorithms to capture internal damage. The results and discussion presented herein summarize the current state of the ultrasonic model–based iterative reconstruction (U-MBIR) algorithm developed at ORNL. In the work documented in this report, the U-MBIR methodology was applied to four sets of ultrasonic data collected from concrete specimens. The results demonstrate that the U-MBIR algorithm can successfully detect defects within the four concrete samples. The reconstruction images help identify the specimen thickness, regions of delamination, and location of rebar embedded within the concrete. The reconstruction images allow engineers and technicians to characterize the internal defects within concrete specimens and structural members. Ultimately, this knowledge can guide engineers in making informed decisions regarding the performance, safety, and reliability of structural materials (i.e., reinforced concrete) throughout the life cycle of NPPs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Roadmap on energy harvesting materials

Ambient energy harvesting has great potential to contribute to sustainable development and address growing environmental challenges. Converting waste energy from energy-intensive processes and systems (e.g. combustion engines and furnaces) is crucial to reducing their environmental impact and achieving net-zero emissions. Compact energy harvesters will also be key to powering the exponentially growing smart devices ecosystem that is part of the Internet of Things, thus enabling futuristic applications that can improve our quality of life (e.g. smart homes, smart cities, smart manufacturing, and smart healthcare). To achieve these goals, innovative materials are needed to efficiently convert ambient energy into electricity through various physical mechanisms, such as the photovoltaic effect, thermoelectricity, piezoelectricity, triboelectricity, and radiofrequency wireless power transfer. By bringing together the perspectives of experts in various types of energy harvesting materials, this Roadmap provides extensive insights into recent advances and present challenges in the field. Additionally, the Roadmap analyses the key performance metrics of these technologies in relation to their ultimate energy conversion limits. Building on these insights, the Roadmap outlines promising directions for future research to fully harness the potential of energy harvesting materials for green energy anytime, anywhere.

14 SOLAR ENERGY↗
DOE OSTI2022

Development of self-sensing materials for extreme environments based on metamaterial concept and additive manufacturing

Structural health monitoring of an engineered component in a harsh environment is critical for multiple DOE missions including nuclear fuel cycle, subsurface energy production/storage, and energy conversion. Supported by a seeding Laboratory Directed Research & Development (LDRD) project, we have explored a new concept for structural health monitoring by introducing a self-sensing capability into structural components. The concept is based on two recent technological advances: metamaterials and additive manufacturing. A self-sensing capability can be engineered by embedding a metastructure, for example, a sheet of electromagnetic resonators, either metallic or dielectric, into a material component. This embedment can now be realized using 3-D printing. The precise geometry of the embedded metastructure determines how the material interacts with an incident electromagnetic wave. Any change in the structure of the material (e.g., straining, degradation, etc.) would inevitably perturbate the embedded metastructures or metasurface array and therefore alter the electromagnetic response of the material, thus resulting in a frequency shift of a reflection spectrum that can be detected passively and remotely. This new sensing approach eliminates complicated environmental shielding, in-situ power supply, and wire routing that are generally required by the existing active-circuit-based sensors. The work documented in this report has preliminarily demonstrated the feasibility of the proposed concept. The work has established the needed simulation tools and experimental capabilities for future studies.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High Strength Steel-Aluminum Components by Vaporizing Foil Actuator Welding

This project aimed to address the challenge of effectively welding dissimilar materials—high-strength steel and high-strength aluminum for creating lightweight, multi-material automotive components. For automotive companies, reducing weight of a vehicle is critical task regulated by the government to solve the issue of greenhouse gas emissions. Production of lightweight cars and trucks can be achieved by substitution of current all-steel structures with multi-material lightweight structures that include high strength-to-weight-ration materials such as high-strength steels, aluminum alloys, magnesium alloys, titanium alloys, coupled with lightweight designs. This requires dissimilar metal welding, which is challenging for state of the art joining processes such as resistance spot welding. The cycle of melting-cooling-freezing during traditional welding that can easily ruin the designed outstanding properties of the advanced base metals, such as aluminum alloys, making the welded area much weaker than the base metals. To weld two different metals with great difference in melting points, such as aluminum and steel, it’s even more difficult or impossible because of the formation of brittle intermetallic compounds at the welded interface. In this project, a novel welding method, developed at OSU, was selected for validation and development. This novel technology enables welding by impact without melting and proves to be robust to join various dissimilar lightweight metals. Termed as vaporizing foil actuator welding or VFAW, the technology uses a thin aluminum foil that is rapidly vaporized by a high current pulse to produce an explosive-like pressure pulse to drive one metallic piece into another at the high speed required for impact welding. This project entailed development of the early-stage welding technology in terms of (a) the consumables, the welding apparatus and the power sources, (b) coupon scale screening of many material combinations including corrosion studies, (c) computational modeling and design of the welded interface as well as of the multi-material prototype component, and (d) mechanical testing for strength and durability at coupon scale and to a certain extent the prototype scale. The all-steel engine cradle of 2016 Chevrolet Cruze was chosen as the baseline prototype component. The target set for the project was to demonstrate a 20% weight reduction at a cost premium of less than $\$ $5/lb saved without compromising on baseline mechanical properties. At project completion, a 12% lighter prototype component was demonstrated with an estimated cost premium of $\$ $9.8/lb saved. Besides prototype level demonstration of the technology, this project also enabled elevation of the technology’s readiness level to where a hydraulically actuated welding head was developed and made ready for deployment at a research and development facility for Tier 1 automotive supplier.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Integrating an Ensemble Reward System into an Off-Policy Reinforcement Learning Algorithm for the Economic Dispatch of Small Modular Reactor-Based Energy Systems

Nuclear Integrated Energy Systems (NIES) have emerged as a comprehensive solution for navigating the changing energy landscape. They combine nuclear power plants with renewable energy sources, storage systems, and smart grid technologies to optimize energy production, distribution, and consumption across sectors, improving efficiency, reliability, and sustainability while addressing challenges associated with variability. The integration of Small Modular Reactors (SMRs) in NIES offers significant benefits over traditional nuclear facilities, although transferring involves overcoming legal and operational barriers, particularly in economic dispatch. This study proposes a novel off-policy Reinforcement Learning (RL) approach with an ensemble reward system to optimize economic dispatch for nuclear-powered generation companies equipped with an SMR, demonstrating superior accuracy and efficiency when compared to conventional methods and emphasizing RL’s potential to improve NIES profitability and sustainability. Finally, the research attempts to demonstrate the viability of implementing the proposed integrated RL approach in spot energy markets to maximize profits for nuclear-driven generation companies, establishing NIES’ profitability over competitors that rely on fossil fuel-based generation units to meet baseload requirements.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

High-throughput Li plating quantification for fast-charging battery design

Fast charging of most commercial lithium-ion batteries is limited due to fear of lithium plating on the graphite anode, which is difficult to detect and poses considerable safety risk. In this report we demonstrate the power of simple, accessible and high-throughput cycling techniques to quantify irreversible Li plating spanning data from over 200 cells. We first observe the effects of energy density, charge rate, temperature and state of charge on lithium plating, use the results to refine a mature physics-based electrochemical model and provide an interpretable empirical equation for predicting the plating onset state of charge. We then explore the reversibility of lithium plating and its connection to electrolyte design for preventing irreversible Li accumulation. Finally, we design a method to quantify in situ Li plating for commercially relevant graphite|LiNi 0.5 Mn 0.3 Co 0.2 O 2 (NMC) cells and compare with results from the experimentally convenient Li|graphite configuration. The hypotheses and abundant data herein were generated primarily with equipment universal to the battery researcher, encouraging further development of innovative testing methods and data processing that enable rapid battery engineering.

25 ENERGY STORAGE↗
DOE OSTI2024

AOI [1] Advanced Manufacturing of Ceramic Anchors with Embedded Sensors for Process and Health Monitoring of Coal Boilers

Researchers at West Virginia University (WVU) developed methods to fabricate and test ceramic anchors with an embedded sensor technology for monitoring the health and processing conditions within pulverized coal (PC) and fluidized-bed combustion (FBC) boiler systems. The technology included the development of advanced manufacturing processes for 2D/3D printing electroceramic (conductive ceramic) sensor designs within the ceramic anchor microstructure during the manufacturing process. This advanced manufacturing process would allow for the precise control of local microstructure and composition in order to engineer layer-by-layer any protective and electrically active materials within the refractory anchor. This 3D printing technology would permit the rapid and controlled design of the refractory microstructure and embedded sensor design throughout the volume of the ceramic anchor. The work also included a method to interconnect the sensors to boiler shell through the anchor clamp, where the sensor signals will be processed by low-power electronics and transmitted wirelessly to a central processing hub. The end-goal of the program was to produce a ceramic anchor sensor system which would be ready for implementation within a coal boiler, and/or other similar refractory liner systems (such as that in the glass and metal manufacturing areas). The project objectives were to: 1) Define the chemical and microstructural stability, in addition to the electrical properties, of oxide and non-oxide ceramic composites to be embedded within the ceramic anchor compositions that may operate up to 1400ºC; 2) Develop and implement the 2D/3D printing technology to pattern and control the microstructure of the ceramic anchor and embedded sensor circuits; 3) Develop an interconnect technology which will permit easy installation of the ceramic anchors and signal collection at the boiler shell; 4) Develop low power analog electronics and wireless communication hardware to efficiently collect the sensor signal at each processing unit and transmit data to a central hub for data analysis; 5) Demonstrate the smart ceramic anchor system for temperature and liner fracture within a high-temperature processing unit, such as a boiler furnace or glass melting furnace floor/wall liner.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Stabilization of high-performance rock-salt LiMnSbTe3 thermoelectrics with embedded van der Waals-like gaps

Rock-salt-structured compounds like lead chalcogenides are promising thermoelectrics, as their high symmetry, strong anharmonicity, and favorable phase behavior collectively lead to high performance by enabling large power factors and ultralow thermal conductivity. Here, we report LiMnSbTe 3 , a new rock-salt semiconductor stabilized through targeted chemical design by combining hexagonal MnTe with cubic LiSbTe 2 . Embedded in the highsymmetry matrix, van der Waals-like gaps form due to Sb 2 Te 3 nanoscale segregation, which acts as effective phonon-scattering centers, leading to a low lattice thermal conductivity of 0.37Wm- 1 K -1 at 873 K with alloy scattering from disordered cations. The ordered local structure of Sb2Te 3 -type vdW-like gaps and the cross-gap interaction facilitate the carrier transport. Aided by energyconverged valence bands and a paramagnon drag effect, high Seebeck coefficients and enhanced power factor can be achieved, leading to a high ZT of 1.2 at 873 K. Furthermore, introducing Mn deficiency increases ZT to 1.5, highlighting the potential for higher performance through optimized doping or alloying. A segmented single-leg thermoelectric module achieves an output power density of 0.52 Wcm -2 and an efficiency of 8.7% under ΔT of 478 K, further demonstrating its promising thermoelectric applications.

42 ENGINEERING↗
DOE OSTI2020

Load Composition Analysis in Support of the NERC Load Modeling Task Force. 2019-2020 Field Test of the Composite Load Model

In 2015, NERC’s reliability standards were revised to require the use of dynamic load models in transmission planning studies. To comply with the standards, planners must use load models that explicitly represent the dynamic behavior of the different constituents of load at each load bus within their transmission planning models. The most important of these constituents are motor-driven and power electronics-based loads. Collectively, these representations are known as composite load models. In anticipation of the compliance date for the new standards, NERC’s Load Modeling Task Force (LMTF), in 2019, initiated a field test of composite load models involving the regional reliability planning entities. In support of the field test, DOE and BPA researchers developed region-specific composite load models that could be assigned to each non-industrial load bus in the planning models for each of the North American interconnections. Separate models were developed for each hour of a summer peak day, a winter peak day, and a spring light-load day. This report is the technical documentation for the load composition analysis that was conducted to develop these non-industrial composite load models.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Science & Technology Review September 2024

At Lawrence Livermore National Laboratory, we focus on science and technology research to ensure our nation’s security. We also apply that expertise to solve other important national problems in energy, bioscience, and the environment. Science & Technology Review is published eight times a year to communicate, to a broad audience, the Laboratory’s scientific and technological accomplishments in fulfilling its primary missions. The publication’s goal is to help readers understand these accomplishments and appreciate their value to the individual citizen, the nation, and the world.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

SAS4A/SASSYS-1 Validation with the EBR-II Tests SHRT-17 and SHRT-45R

The EBR-II sodium-cooled fast reactor supported a wide range of fast reactor research activities. The final fifteen years of operations at EBR-II were used for experiments and tests to demonstrate the importance of passive safety in liquid metal reactors and the capability of such systems to provide strong passive responses during off-normal conditions. The Shutdown Heat Removal Test program at EBR-II provided test data supporting the validation of computer codes for design, licensing, and operation of LMRs, among other objectives. The program included nearly sixty tests, most of which were protected and unprotected loss of flow and loss of heat sink tests run at various initial powers and flow rates.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Performance of Public Film Cooling Geometries Produced Through Additive Manufacturing

Abstract Film cooling is an essential cooling technology to allow modern gas turbines to operate at high temperatures. For years, researchers in this community have worked to improve the effectiveness of film cooling configurations by maximizing the coolant coverage and minimizing the heat flux from the hot gas into the part. Working toward this goal has generated many promising film cooling concepts with unique shapes and configurations. However, until recently, many of these designs were challenging to manufacture in actual turbine hardware due to limitations with legacy manufacturing methods. Now, with the advances in additive manufacturing, it is possible to create turbine parts using high-temperature nickel alloys that feature detailed and unique geometry features. Armed with this new manufacturing power, this study aims to build and test the promising designs from the public literature that were previously difficult or impossible to implement. In this study, different cooling hole designs were manufactured in test coupons using a laser powder bed fusion process. Each nickel alloy coupon featured a single row of engine scale cooling holes, fed by a microchannel. To evaluate performance, the overall cooling effectiveness of each coupon was measured using a matched Biot test at engine relevant conditions. The results showed that certain hole shapes are better suited for additive manufacturing than others and that the manufacturing process can cause significant deviations from the performance reported in the literature.

Engineering↗
DOE OSTI2020

Recent Developments at the U.S. Navy Wave Energy Test Site.

The U.S. Navy’s Wave Energy Test Site (WETS) in Hawaii has hosted two wave energy conversion (WEC) devices since its June 2015 commissioning – the Fred. Olsen BOLT Lifesaver and the Northwest Energy Innovations (NWEI) Azura – each for two deployments. Several additional devices will be tested in the coming years, beginning with the Ocean Energy device in summer 2019. The Hawaii Natural Energy Institute (HNEI) provides research and logistics support to WETS. We will provide an overview of three major activities that we have recently undertaken in this capacity. First, we will discuss results from a project in which modifications were made to the hull and float of the Azura, aimed at improving power performance for a second WETS deployment. Second, HNEI undertook a redeployment of Lifesaver beginning in October 2018, with the dual intent of achieving improvements in reliability and power performance, while also conducting an important demonstration of the use of wave power for non-grid applications. HNEI partnered with the University of Washington to integrate their Adaptable Monitoring Package (AMP) into the hull of BOLT Lifesaver. Included for this deployment was a subsea inductive charging capability from WiBotic, Inc.. These systems are powered entirely by electricity generated by the Lifesaver itself. Finally, HNEI has undertaken design improvements for the deeper berth moorings at WETS, with principal engineering guidance from DNV GL. This has included extensive numerical analysis of strength and fatigue aimed at establishing moorings that can persist for as long as possible. The resulting design will be discussed.

Wave energy conversion devices, Alternative market↗
DOE OSTI2025

Energy-resolved neutron imaging and diffraction including grain orientation mapping using event camera technology

Time-of-flight neutron diffraction and energy-resolved imaging each provide unique perspectives into material properties. Neutron diffraction is useful for assessing microstructural parameters such as phase composition, texture, and dislocation densities, though it typically provides averaged data over the sampled volume. Energy-resolved imaging, on the other hand, offers both spatial and spectral information by detecting Bragg edges and neutron absorption resonances, which enables detailed mapping of microstructure and isotopic composition. When combined, these techniques have the potential to enrich our understanding of material behavior across different scales, enhancing our understanding of complex materials. Traditionally, these modalities are conducted on separate instruments, which is time-consuming and poses challenges for data integration. Here, we report the integration of the LumaCam, an event-mode energy-resolved neutron imaging camera with the HIPPO time-of-flight diffractometer at LANSCE. This integration enables simultaneous diffraction and imaging across the full spectrum, with analysis optimized for diffraction and Bragg-edge imaging in the thermal range (0.45–10 Å) and resonance imaging in the epithermal range (0.5–3000 eV), facilitating comprehensive multi-modal analysis. We demonstrate its capabilities through case studies, including spatial mapping of grain orientations in a steel sample and accurate thickness estimations for irregular samples including a depleted uranium cylinder and a natural silver-containing mineral specimen. The combined setup enhances real-time sample alignment and provides comprehensive data for crystal structure, texture, and isotopic composition analysis. This approach opens new possibilities for advanced applications in nuclear engineering, archaeology, and materials science.

36 MATERIALS SCIENCE↗