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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 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Why ionizing radiation enhances surface wettability

Radiation-Induced Surface Activation is an inherent phenomenon where surfaces that are exposed to gamma irradiation are observed to undergo an increase in wettability. This increase in wettability as a result of the ionizing radiation exposure has so far been demonstrated to have a pronounced impact on Leidenfrost temperature and two-phase fluid dynamics. Test results from previous experiments have shown that incorporation of this effect on heat transfer equipment design may increase the thermal-hydraulic margin leading to higher thermal efficiency. However, the mechanism behind the increased wettability is not clearly understood. In the present work, three different materials (Zircaloy-4, 316 stainless steel, and copper) were exposed at two different dose rates with use of two different gamma irradiation facilities. A detailed surface characterization on the post-irradiated samples is carried out to understand the changes in surface chemistry, wettability and surface morphology. It is observed from the experiments that the increase in wettability upon irradiation depended on the total dose and not on the dose rate. Moreover, localized oxidation and porosity induced by radiolysis was seen to be the predominant mechanism behind increased wettability which leads to improved Leidenfrost temperature.

Seshadria, Arunkumar↗
DOE OSTI2021

Automated Parameterized CFD Simulations of Phase-Change Material Embedded Heat Exchangers

Thermal storage can be implemented using Phase-Change Materials (PCM), which absorb significant latent heat with a relatively small temperature change. PCM phase-change processes are transient and are driven by thermal diffusion and natural convection – the latter, especially for melting process. Modeling and simulation of PCM heat exchangers is typically computationally intensive due to the relative complex time-dependent underlying physics. This paper presents a study investigating a single straight tube with circular transverse fins in the vertical orientation, using PCM’s with 37oC nominal melting temperature, leveraging automated parametric CFD simulations. The computational domain is reduced to 2D axisymmetric for a segment of the HX comprising a region in between two fins with constant wall temperature as boundary condition. This approach allows for faster evaluations of the transient thermal characteristics for a given design space of interest. Correlations and reduced order models (ROM’s) are developed. Results indicate that the ROM’s reproduce the CFD simulations with high accuracy for designs from the training data set, however, designs from cross-validation and test sets do not always have good agreement. The limited number of designs in the training set is a possible cause for the lack of robustness of the ROM’s and thus additional training designs will be added in future work. The ROM’s solve the simulations on average 500,000 times faster than CFD.

25 ENERGY STORAGE↗
DOE OSTI2023

Preliminary Results for Uncertainty Quantification on Asymptotic Hydrogen Redistribution in a Prototypical Yttrium-Hydride Moderated Heat-Pipe-Cooled Microreactor

Yttrium hydride is one of the most promising materials for moderating nuclear microreactors. This is due to its high hydrogen concentration at high operating conditions, high value of thermal conductivity, and chemical stability. However, when subject to thermal and concentration spatial gradients, the hydrogen tends to migrate within the yttrium matrix, potentially leading to power swings and reactivity changes. This paper aims to present selected results concerning the sensitivity of the thermal and hydrogen redistribution response for a prototypical heat-pipe-cooled yttrium-hydride moderated microreactor to thermal properties uncertainty and selected design characteristics. To the best knowledge of the authors, this is the first study examining the impact of uncertainties on microreactor hydrogen redistribution response. To achieve this goal, Bison was used in conjunction with Dakota to create a framework able to perform Uncertainty Quantification (UQ) for the Simplified Microreactor Benchmark Assessment (SiMBA) problem.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Design-Point Techno-Economics of Brayton Cycle PTES for Combined Heat and Power

Pumped thermal energy storage (PTES) systems are grid batteries that use heat pumps to create both hot and cold thermal energy stores when there is excess electricity and then use a power cycle to convert the thermal energy into electricity when there is demand for electricity. In normal operation, Joule-Brayton PTES discharges low-grade heat at temperatures useful for thermal energy consumers like district and industrial heating. Furthermore, PTES designs, like conventional combined heat and power (CHP) technology, can be modified to sacrifice some round-trip efficiency RTE to increase the temperature of heat rejection. This paper uses design-point performance and cost models that provide a detailed understanding of the efficiency and cost trade-offs of rejecting heat at various temperatures in ideal-gas Brayton PTES configurations. First, we keep the heat rejection in its nominal location in the PTES system: in the discharge cycle after the low-pressure exit of the recuperator before the cold-storage heat exchanger. Next, we move the heat rejection to the discharge turbine exit. We define design-point metrics that isolate both the cost and performance penalty associated with the hotter heat rejection and attribute it exclusively to the heat economic metrics. Finally, we estimate the performance of electric heater technology to generate heat at equivalent temperatures. We find that the levelized cost of heat, including the cost of thermal energy storage (TES) buffering the PTES and heat off-taker, compares favorable versus electric technologies and is less than the cost of natural gas for low temperature scenarios and competitive with the cost of natural gas in some regions of the contiguous United States in high temperature scenarios.

CHP↗
DOE OSTI2023

Structural design challenges and implications for high temperature concentrating solar power receivers

High operating temperatures along with diurnal cycling and high operating stresses bring many material and engineering challenges for concentrated solar power (CSP) receivers. Current design rules in ASME Boiler and Pressure Vessel (B&PV) Code for high temperature structural components were not intended for CSP components. The paper reviews the design rules in several sections of ASME B&PV Code in terms of their applicability in designing high temperature CSP receivers. With some restrictions and modifications, the conditions assumed in the design rules in Section III, Division 5 of ASME B&PV Code are found to closely resemble the loading conditions of CSP receiver, including accounting for the interaction between creep and fatigue damage. Further, the paper applies the proposed design rules to an external tubular receiver design and discusses several lessons learned from the design study. The creep damage accumulation due to high thermal stresses resulting from circumferentially non-uniform flux distribution is found to control the design of CSP receivers. Several mitigation actions to improve the design life of receivers are also discussed.

14 SOLAR ENERGY↗
DOE OSTI2026

A bioinspired approach for adaptive solid-solid phase change material coatings with optimized surface features for passive thermal regulation

The necessity to reduce global energy consumption calls for innovative strategies in building thermal management. Passive thermal regulation, particularly through bio-inspired designs, offers a promising avenue by mimicking nature's efficient control of optical properties. This research introduces a novel, climate-responsive coating that integrates optimized bio-inspired surface features with a solid-solid phase change material (SS-PCM) to dynamically manage solar absorptivity without adding additional thickness, enabling both heating and cooling as needed. Drawing on the photonic architectures of the Saharan silver ant and Morpho Didius butterfly, we employed a modeling and multi-objective optimization framework to tailor these surface features. Simulations reveal that surface texture, rather than the intrinsic phase transition of the SS PCM, dominates optical control. Relative to a flat SS PCM coating, optimized isotropic random roughness and broader range features yielded the highest passive heating power increase of about 144 % and 319 % respectively suitable for cold climates. Saharan ant-inspired features enhanced passive cooling for hot climates, achieving a 21.8 % improvement. For moderate climates, Butterfly-wing-inspired surface features provided a balanced enhancement of 19 % for heating and 7 % for cooling. Across all cases, the optimized surface features reduced combined heating and cooling energy demand more effectively than the baseline coating, while preserving material thickness. These findings demonstrate that climate-adaptive, optimized bio-inspired surface features can unlock the full potential of SS PCM coatings, providing a versatile pathway to significant energy savings in buildings and other applications. The methodology establishes a framework for designing next-generation adaptive envelopes that leverage natural photonic principles for high-impact, low-cost thermal regulation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Structured illumination with thermal imaging (SI-TI): A dynamically reconfigurable metrology for parallelized thermal transport characterization

The recent push for the “materials by design” paradigm requires synergistic integration of scalable computation, synthesis, and characterization. Among these, techniques for efficient measurement of thermal transport can be a bottleneck limiting the experimental database size, especially for diverse materials with a range of roughness, porosity, and anisotropy. Traditional contact thermal measurements have challenges with throughput and the lack of spatially resolvable property mapping, while non-contact pump-probe laser methods generally need mirror smooth sample surfaces and also require serial raster scanning to achieve property mapping. Here, we present structured illumination with thermal imaging (SI-TI), a new thermal characterization tool based on parallelized all-optical heating and thermometry. Experiments on representative dense and porous bulk materials as well as a 3D printed thermoelectric thick film (~50 μm) demonstrate that SI-TI (1) enables paralleled measurement of multiple regions and samples without raster scanning; (2) can dynamically adjust the heating pattern purely in software, to optimize the measurement sensitivity in different directions for anisotropic materials; and (3) can tolerate rough (~3 μm) and scratched sample surfaces. Here, this work highlights a new avenue in adaptivity and throughput for thermal characterization of diverse materials.

42 ENGINEERING↗
DOE OSTI2023

Materials Surveillance Development

This presentation is to update DOE at the Molten Salt Program review in May on the work at INL and Argonne National Laboratory on surveillance specimen development. This includes thermal-mechanical testing and test article designs.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Distributed Thermal Response Multi-Source Modeling to Evaluate Heterogeneous Subsurface Properties

A thorough assessment of thermal properties in heterogeneous subsurface is necessary in design of low-temperature borehole heat exchangers (BHEs). For this study, a distributed thermal response test (DTRT), which combines distributed temperature sensing (DTS) with a conventional thermal response test (TRT), was conducted in a U-bend geothermal loop installed in an open borehole at the University of Illinois at Urbana-Champaign to estimate thermal properties by analyzing the thermal response of different geologic materials while applying a constant heat input rate. Fiber-optic cables in the DTRT were deployed both inside the U-bend geothermal loop and in the center of the borehole to improve the accuracy of calculated heat-loss rates and borehole temperature profile measurements. To assess the subsurface thermal conductivity during the heating phase of the DTRT, a single-source model and a multi-source model, both based on the infinite line source method, were developed using the borehole temperature data and temperatures inside and along the outside of the loop, separately. The two models returned similar thermal conductivity values. The multi-source modeling has the advantage of predicting the thermal conductivity of heterogeneous geologic materials from borehole temperature profiles during the DTRT heating phase. Additionally, based on the distributed thermal conductivity measured in the borehole, estimates were made for both radial thermal impacts and the rate of heat loss in the BHE.

58 GEOSCIENCES↗
DOE OSTI2021

Thermal stability and magnetization switching of composite free layer with perpendicular magnetic anisotropy

We present a micromagnetic study of a ferromagnetically exchange-coupled composite free layer design for perpendicular magnetic tunnel junctions. The thermal stability factor and critical switching current density depend on the exchange coupling strength and effective anisotropy ratio between the sublayers of the composite free layer. The energy barrier increases with an increase of the exchange coupling strength until it reaches a plateau in the strong-coupling limit. An optimal exchange coupling strength exists that leads to the minimal critical switching current and a significant improvement of the figure of merit defined as the ratio between the energy barrier and critical switching current. This behavior is obtained for smaller device sizes with uniform reversal and larger sizes with domain wall reversal.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Heterogeneous oxidation of hydrogen-natural gas blends in a safe, clean, and efficient burner design

The growth of hydrogen as an alternative clean fuel for fulfilling thermal energy needs of multiple economic sectors globally requires access to reliable, safe, energy efficient, emission free combustion technology. The work described in this short communication shows the applicability of a novel heterogeneous combustion design in utilizing a wide range of hydrogen blended methane concentrations to cleanly and safely generate thermal energy. The utilization of a simple first principles design approach along with engineered materials yielded a fuel-flexible hybrid infrared-convection burner design capable of lowering NOx emissions by more than 95% while simultaneously improving the heat transfer efficiency by 15% with a wide range of hydrogen concentrations. Here, the safety and performance of the combustion design was demonstrated in an burner at capacities of up to 12,000 Btu/h in producing temperatures of 900 °C. The atmospheric burner concept was integrated in a cooktop configuration with combined thermal power rating of 30,000 Btu/h and operated with hydrogen blended natural gas.

08 HYDROGEN↗
DOE OSTI2021

Plastic and low-cost axial zero thermal expansion alloy by a natural dual-phase composite

Zero thermal expansion (ZTE) alloys possess unique dimensional stability, high thermal and electrical conductivities. Their practical application under heat and stress is however limited by their inherent brittleness because ZTE and plasticity are generally exclusive in a single-phase material. Besides, the performance of ZTE alloys is highly sensitive to change of compositions, so conventional synthesis methods such as alloying or the design of multiphase to improve its thermal and mechanical properties are usually inapplicable. In this study, by adopting a one-step eutectic reaction method, we overcome this challenge. A natural dual-phase composite with ZTE and plasticity was synthesized by melting 4 atom% holmium with pure iron. The dual-phase alloy shows moderate plasticity and strength, axial zero thermal expansion, and stable thermal cycling performance as well as low cost. By using synchrotron X-ray diffraction, in-situ neutron diffraction and microscopy, the critical mechanism of dual-phase synergy on both thermal expansion regulation and mechanical property enhancement is revealed. These results demonstrate that eutectic reaction is likely to be a universal and effective method for the design of high-performance intermetallic-compound-based ZTE alloys.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Pilgrim : A thermal rate constant calculator and a chemical kinetics simulator

Pilgrim is a program written in Python and designed to use direct dynamics in the calculation of thermal rate constants of chemical reactions by the variational transition state theory (VTST), based on electronic structure calculations for the potential energy surface. Pilgrim can also simulate reaction mechanisms using kinetic Monte Carlo (KMC). For reaction processes with many elementary steps, the rate constant of each of these steps can be calculated by means of conventional transition state theory (TST) or by using VTST. In the current version, Pilgrim can evaluate thermal rates using the canonical version of reaction-path VTST, which requires the calculation of the minimum energy path (MEP) associated with each elementary step or transition structure. Multi-dimensional quantum effects can be incorporated through the small-curvature tunneling (SCT) approximation. These methodologies are available both for reactions involving a single structure of the reactants and the transition state and also for reactions involving flexible molecules with multiple conformations of the reactant and/or of the transition state. For systems with many conformers, the program can evaluate each of the elementary reaction rate constants by multipath canonical VTST or multi-structural VTST. Moreover, the reactant can be unimolecular or bimolecular. Torsional anharmonicity can be incorporated through either the MSTor or the Q2DTor programs. Dual-level calculations are also available in Pilgrim: automatic high-level single-point energies can be used to correct the energy of reactants, transition states, products, and MEP points using the interpolated single-point energies (ISPE) algorithm. When the rate constants of all the chemical processes of interest are known, by means of their calculation using Pilgrim or alternatively through analytical fits to the rate constants as functions of temperature, it is possible to simulate a multistep mechanism under specified laboratory conditions using KMC. Finally, this algorithm allows performing a kinetic simulation to monitor the evolution of each chemical species with time and obtain the product yields.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Concrete Thermal Energy Storage Enabling Flexible Operation without Coal Plant Cycling

The work described in this report is responsive to the Office of Fossil Energy program “Energy Storage for Fossil Power Generation.” The pilot plant built as a result of this project demonstrated the feasibility and performance of a concrete thermal energy storage (CTES) system integrated with a supercritical coal power plant. The 10 MWh electrical (>25 MWh thermal) CTES unit, developed by Storworks Power, was designed to enable flexible operation of coal plants without cycling damage. The project's key technical achievements showcase a significant advancement in energy storage technology. A modular CTES system using 42 “Bolderblocs” units was successfully designed and constructed at Alabama Power’s Plant Gaston Unit 5, with each block containing embedded stainless-steel coils in specialized, cost-effective high-temperature concrete. The system interfaced seamlessly with the plant's 3500 psig (241 barg), 1000°F (538°C) supercritical steam, demonstrating operational flexibility. Over 86 full cycles, the CTES exhibited rapid charging and discharging capabilities, effectively mimicking steam turbine feed conditions and handling varying load profiles and storage durations. Performance validation confirmed the system's ability to consistently meet design target steam conditions of 75 bar-a and ~400°C for nominal baseline discharge. The concrete material withstood repeated thermal cycling without degradation, validating earlier lab-scale tests. Integration of balance of plant components, including a condensate management system with storage tank and air-cooled condenser, minimized plant interfaces and water consumption. A robust control scheme ensured safe, automated operation across various scenarios. Key learnings from the project were invaluable: 1. Initial concrete drying and commissioning procedures were refined for future deployments, enhancing efficiency in subsequent installations. 2. System flexibility exceeded expectations, with rapid response to changing conditions. 3. Design improvements were identified including optimized insulation and piping that will enhance overall system efficiency in future deployments 4. Full cycle thermal roundtrip efficiencies exceeded 88%. While the roundtrip electrical efficiency was somewhat limited by known challenges using input steam, such constraints may be mitigated by swapping steam for hot air as thermal input. 5. A summary of key performance parameters for the pilot test and predicted performance of a full scale commercial system with specified improvements determined from the pilot are shown in Section 8. The project faced challenges, including COVID-19 delays and host plant availability constraints. However, these were overcome through adaptive planning and execution. The successful management of these obstacles demonstrated the resilience and adaptability of the project team and the robustness of the CTES technology. This successful pilot demonstrates the potential for CTES to enhance coal plant flexibility, supporting grid stability as renewable penetration increases. The validated design and operational data provide a solid foundation for scaling up to utility-scale implementations, potentially transforming how thermal plants operate in evolving energy landscapes. The system's ability to rapidly respond to changing grid conditions while maintaining high efficiency makes it a promising solution for balancing intermittent renewable energy sources. Furthermore, the project highlighted the potential for even greater efficiencies in future iterations. The use of air as an input medium could potentially eliminate the limitations observed with steam input, opening new possibilities for energy storage applications beyond coal plant integration. In conclusion, this pilot project not only achieved its primary goals but also uncovered additional benefits and potential applications of the CTES technology. It represents a significant step forward in addressing the challenges of grid stability and flexibility in an increasingly renewable-driven energy landscape.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Internal insulation and corrosion control of molten chloride thermal energy storage tanks

A chloride-based molten-salt system that uses a ternary blend of MgCl 2 /KCl/NaCl is investigated to provide higher-temperature thermal energy storage capability than conventional nitrate salt-based systems. Despite their high thermal stability and operating temperature, molten chlorides present several challenges, including the design of internal liners to prevent the corrosion and thermal stress of alloy tank shells. This work discusses issues and potential solutions related to containment of molten chloride salt, specifically the optimization of the hot face refractory materials for use as internal liners. Furthermore, three down-selected refractory materials were analyzed with respect to permeation of salt through the material as well as chemical stability during high temperature operation. Through the application of X-ray imaging and electron spectroscopy techniques, highly stable secondary surface phases in equilibrium with the molten salt were identified, as well as time-dependent changes in the salt composition itself.

25 ENERGY STORAGE↗
DOE OSTI2022

Design Enhancements for the SNS RFQ Coaxial Coupler

The H⁻ ion linear accelerator at the Spallation Neutron Source (SNS) at Oak Ridge National Laboratory operates with reliability that routinely surpasses 90% during scheduled beam operation. With the ambitious goal of eventually achieving at least 95% availability, several upgrade and improvement projects are ongoing. One such project is the modification of the coaxial couplers that transfer radio frequency (RF) power to the accelerator’s Radio Frequency Quadrupole (RFQ). The proposed modification utilizes stub sections and capacitive coupling to construct a physically separable assembly with DC isolation. With a separated coupler assembly, the section that includes the magnetic coupling loop can be permanently mounted to the RFQ which would eliminate the need to re-adjust the couplers after maintenance activities, upgrades, and repairs. Additionally, the modified design would provide increased multipaction suppression with DC biasing and potentially lower thermal gradients across the device. This paper presents the design and simulation results of the project.

Toby, George↗
DOE OSTI2023

CoolPINNs: A physics-informed neural network modeling of active cooling in vascular systems

Emerging technologies like hypersonic aircraft, space exploration vehicles, and batteries avail fluid circulation in embedded microvasculatures for efficient thermal regulation. Modeling is vital during the design and operational phases of these engineered systems. However, many challenges exist in developing a modeling framework. What is lacking is an accurate framework that (i) captures sharp jumps in the thermal flux across complex vasculature layouts, (ii) deals with oblique derivatives (involving tangential and normal components), (iii) handles nonlinearity because of radiative heat transfer, (iv) provides a high-speed forecast for real-time monitoring, and (v) facilitates robust inverse modeling. Here, this paper addresses these challenges by availing the power of physics-informed neural networks (PINNs). We develop a fast, reliable, and accurate Scientific Machine Learning (SciML) framework for vascular-based thermal regulation—called CoolPINNs: a PINNs-based modeling framework for active cooling. The proposed mesh-less framework elegantly overcomes all the mentioned challenges. The significance of the reported research is multi-fold. First, the framework is valuable for real-time monitoring of thermal regulatory systems because of rapid forecasting. Second, researchers can address complex thermoregulation designs since the approach is meshless. Finally, the framework facilitates systematic parameter identification and inverse modeling studies, perhaps the most significant utility of the current framework.

97 MATHEMATICS AND COMPUTING↗