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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 703 records · Page 39
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Development of a Test-Bed for Testing and Refining EarthEn’s Supercritical CO 2 Based Energy Storage System

EarthEn’s energy storage concept leverages supercritical carbon dioxide (sCO 2 ) as a working fluid and relies on compact, high-performance components operating at elevated pressures and temperatures. To accelerate component development and reduce technical risk prior to larger-scale demonstrations, Oak Ridge National Laboratory (ORNL) developed a 100 kW-scale sCO 2 test-bed under a Cooperative Research and Development Agreement with EarthEn (CRADA NO. NFE-24-10050). The objective of the work was to design and construct a flexible experimental facility capable of reproducing key thermodynamic state points and heat-transfer conditions relevant to EarthEn’s thermal energy storage (TES) cycle, with particular emphasis on enabling development and evaluation of next-generation heat exchangers and TES concepts. The test-bed consists of a closed-loop sCO 2 circulation system housed within an open-topped enclosure. In its as-installed configuration, dense-phase sCO 2 is recirculated through a printed circuit recuperator, an electrically heated section, a throttling device used to simulate turbine expansion, and a water-cooled printed circuit heat exchanger that rejects heat to the building chilled-water system before returning to the pump. The pump is driven by a variable frequency drive, enabling controlled adjustment of flow and operating point. A comprehensive instrumentation suite was integrated to support both safe operation and high-quality data collection. Installed sensors include Coriolis flow meters for sCO 2 flow rate and density, resistance temperature detectors and thermocouples distributed throughout the loop (including the heated section and key heat exchanger ports), and pressure transducers for absolute and differential pressure measurements. The facility was designed to support high-pressure (19 MPa nominal) and high-temperature (575°C nominal) operation with credited overpressure protection provided by a rupture disk. Nominal operating conditions were selected to support 100 kW-class testing while maintaining flexibility for non-heated and heated shakedown, control development, and future integration of advanced TES test sections. In parallel with facility development, a system-level thermal-hydraulic model was created using Modelica-based tools to support component sizing, anticipate performance over targeted test conditions, and establish a framework for future model calibration against experimental data. At the conclusion of the project performance period, the facility was in final assembly, and the pressure boundary was nearly completed. However, several practical challenges associated with high-pressure/high-temperature systems and specialized component procurement impacted schedule and prevented initial pump-driven operation and full commissioning within the available resources. This report documents the as-built design, operating capabilities, and instrumentation, and it summarizes key lessons learned related to heater fabrication and testing, first-of-a-kind assembly factors, specialty flange supply constraints, and fill pump corrective actions. Finally, it outlines a phased plan for future commissioning and experimental campaigns, including control and instrumentation shakedown, heater characterization, model calibration, and testing at state points representative of EarthEn’s TES cycle.

25 ENERGY STORAGE↗
DOE OSTI2024

Zero and Finite Temperature Quantum Simulations Powered by Quantum Magic

We introduce a quantum information theory-inspired method to improve the characterization of many-body Hamiltonians on near-term quantum devices. We design a new class of similarity transformations that, when applied as a preprocessing step, can substantially simplify a Hamiltonian for subsequent analysis on quantum hardware. By design, these transformations can be identified and applied efficiently using purely classical resources. In practice, these transformations allow us to shorten requisite physical circuit-depths, overcoming constraints imposed by imperfect near-term hardware. Importantly, the quality of our transformations is t u n a b l e : we define a 'ladder' of transformations that yields increasingly simple Hamiltonians at the cost of more classical computation. Using quantum chemistry as a benchmark application, we demonstrate that our protocol leads to significant performance improvements for zero and finite temperature free energy calculations on both digital and analog quantum hardware. Specifically, our energy estimates not only outperform traditional Hartree-Fock solutions, but this performance gap also consistently widens as we tune up the quality of our transformations. In short, our quantum information-based approach opens promising new pathways to realizing useful and feasible quantum chemistry algorithms on near-term hardware.

Physics↗
DOE OSTI2020

Accelerating Hanford Site Cleanup through Operations Research Modeling - 20238

The Hanford Site cleanup effort will require the integration of dozens of unique facilities and processes, many of which will be first-of-a-kind in implementation and design. Each facility will be governed by its own set of operating logic, configured with a unique array of unit operations, and subject to a set of constraints that will affect its behavior. The collection of facilities have multiple points of interface, making the operations of any one facility potentially significant to the operations of other up- or downstream processes. It is therefore highly desirable to accurately predict these operations, as it allows for Site officials to identify and preempt bottlenecks and vulnerabilities before they unexpectedly inhibit the cleanup mission. With the quantity and complexity of the processes that will be on Site, building a pen-and-paper or even a spreadsheet-assisted model of the cleanup mission quickly becomes overwhelming in scope and inaccurate in execution. The Engineering organization for the Site's Tank Operations Contract (TOC) has therefore implemented the use of operations research (OR) modeling to simulate and predict future operations of Site facilities. These models are created using a discrete event simulation tool that allows for the development of detailed, versatile, and robust models. Not only can these models account for complex logical behaviors, but they can also simulate process details down to the level of vessel sizing, labor utilization, equipment reliability, and resource availability. To date, the TOC has developed OR models for several facilities on Site, including for single-shell tank (SST) farms, double-shell tank (DST) farms, the Effluent Treatment Facility (ETF), and the waste transfer system. These models have focused on identifying bottlenecks and operational constraints, and have been used to quantify the effects of implementing process changes. This latter point is particularly valuable, as it allows for several alternatives to be studied in a virtual setting before committing resources to making a change in the field. The decision to develop OR models has gained tremendous support from the Site's stakeholders and the U.S. Department of Energy (DOE) management, and has prompted the use of the tool to support additional internal and external initiatives. Recently, an initiative was proposed to use the models to help identify and provide quantitative backing for risks and opportunities for the TOC. This application of OR could not only help inform how the TOC manages its risks (e.g. quantities and types of spare parts), but could also help drive process improvements whose benefits might otherwise be hard to quantify. The models have also been used to drive the TOC's cloud computing, artificial intelligence (AI), and machine learning (ML) initiatives. These initiatives will not only improve the ability of the TOC to more rapidly respond to the needs of its customers, but it will also aid in the ability of the TOC to analyze and improve the processes it studies. Partnership with two external software development and consulting companies (Lanner and Ynformed) has furthered not only the application of AI and ML within the TOC, but has also spurred the development of new/improved software tools and platforms used by the companies. These partnerships have proven to be mutually beneficial and productive, and have set a precedent for the types of gains that can be made by exploring such options. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Multi-objective optimization of PWR core design using NSGA-II in RAVEN’s optimization framework

Designing an PWR loading pattern is a combinatorial problem challenging to solve by brute force or traditional methods due to the sheer amount of possible combination, and constraints. Nature-inspired algorithms, such as the genetic algorithm, have demonstrated the potential to tackle this problem. The goal of this work was to improve and demonstrate the capabilities for constrained, multi-objective optimization (MOO) of loading patterns using NSGA-II in RAVEN’s optimization framework.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

2 Kelvin helium distribution system for the Electron Ion Collider’s 10 o’clock satellite refrigerator

The Electron-Ion Collider (EIC) at Brookhaven National Laboratory (BNL) will involve superfluid helium cooling of superconducting magnets and Superconducting Radio Frequency (SRF) cavities at several sites around the existing Relativistic Heavy Ion Collider (RHIC) accelerator tunnel. While the majority of the cooling power for these loads is provided by BNL’s central cryogenic plant, Jefferson Lab is designing satellite equipment which augments the central plant and enables 2 Kelvin operation. The 2 K cryogenic distribution system for the collider’s 10 o’clock location (Interaction Region 10 or IR10) includes all necessary interfaces to the IR10 Satellite Refrigerator, to the overall EIC cryogenic distribution system, and to 12 SRF cryomodules for the electron and hadron storage rings. In addition to providing the required cooling capacities in all operating modes, the IR10 2 K cryogenic distribution system also stabilizes the supply temperature and enables safe connection and disconnection of individual IR10 cryomodules. Moreover, the layout of the IR10 2 K cryogenic distribution system copes with challenging spatial constraints and adapts to the process configuration and routing of existing RHIC cryogenic distribution components which will be re-used for EIC. This paper gives a full overview of the IR10 satellite cryogenic distribution system design, and highlights some of the challenges encountered.

Laverdure, Nathaniel [Thomas Jefferson National Ac↗
DOE OSTI2025

Advances in high-pressure and high-temperature heat exchangers: Innovations via additive manufacturing and their applications

This paper provides a comprehensive overview of technological developments and applications for high-pressure and high-temperature (HPHT) heat exchangers produced through additive manufacturing (AM) techniques. As the demand for high-efficiency energy systems has been rising, the role of heat exchangers for thermal management and transport is becoming increasingly crucial. In this context, AM has emerged as a promising manufacturing solution to address the challenges posed by higher operating temperatures and/or pressures. This paper delves into three primary areas: the exploration of HPHT regimes supported by conventional heat exchangers, the impact of AM processes on thermal transport devices, and the discussion focused on HPHT heat exchangers produced via AM. The study examines the traditional manufacturing processes, materials, structures and geometries, and limitations of the commonly used heat exchangers for HPHT applications. Furthermore, it highlights the potential of AM in optimizing HPHT heat exchanger design, by reviewing studies that enable uniform flow distribution, minimization of fouling, and thermo-hydraulic performance augmentation without compromising structural stability. While addressing the limitations of cost, size, and other constraints, this study offers insights into the possibilities of AM in revolutionizing HPHT heat exchanger technology. The goal has been to fill the gap in literature by summarizing key studies, findings, and limitations, presenting a detailed examination, and proposing new areas for research. In conclusion, this review contributes to a deeper understanding of AM’s role in advancing HPHT heat exchangers for future energy systems.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Organizing bacterial vortex lattices by periodic obstacle arrays

Recent experiments have shown that the complex spatio-temporal vortex structures emerging in active fluids are susceptible to weak geometrical constraints. This observation poses the fundamental question of how boundary effects stabilize a highly ordered pattern from seemingly turbulent motion. Here we show, by a combination of continuum theory and experiments on a bacterial suspension, how artificial obstacles guide the flow profile and reorganize topological defects, which enables the design of bacterial vortex lattices with tunable properties. To this end, the continuum model is extended by appropriate boundary conditions. Beyond the stabilization of square and hexagonal lattices, we also provide a striking example of a chiral, antiferromagnetic lattice exhibiting a net rotational flow, which is induced by arranging the obstacles in a Kagome-like array. Recent experiments showed that weak geometrical constraints can organize topological defects in turbulent bacterial suspensions. Here, the authors use a continuum model to study the connection between symmetry and stability of emergent vortex patterns and the geometry of constraining pillar arrays.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Design and Analysis of an Advanced Three-Point Bend Test Approach for Miniature Irradiated Disk Specimens

Candidate tungsten armor materials in a magnetic confinement fusion device must be able to withstand thermal variation that leads to internal stresses caused by the impinging heat load. In addition, the thermomechanical properties of these materials are degraded by irradiation-induced defect accumulation. Fission reactor–based irradiation data are used to predict the fusion neutron damage and property change. This study examines the motivation and design of a custom-designed three-point bend test for neutron-irradiated disk specimens that are 3 mm in diameter to be able to define the flexural strength of advanced tungsten materials, alloys, and composites—and to the extent that embrittlement occurs after neutron irradiation. The theory provided shows a calculation for the flexural deflection and shear deflection due to the small-geometry constraints. A finite element deformation analysis is performed to evaluate the mechanical stress field of disk bend specimens. The stress values above 80% of the maximum stress are concentrated in 2.4 mm of the 3.0-mm length of the centerline across the tungsten disk diameter. A bend test fixture has been designed and fabricated to enable testing of these specimens with precisely engineered tolerance and minimal machine compliance. This fixture will be able to be placed inside a universal testing frame at elevated temperatures for the mechanical property evaluation of future neutron-irradiated disk specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Optimization of leaf morphology in relation to leaf water status: A theory

The leaf economic traits such as leaf area, maximum carbon assimilation rate, and venation are all correlated and related to water availability. Furthermore, leaves are often broad and large in humid areas and narrower in arid/semiarid and hot and cold areas. We use optimization theory to explain these patterns. We have created a constrained optimization leaf model linking leaf shape to vein structure that is integrated into coupled transpiration and carbon assimilation processes. The model maximizes net leaf carbon gain (NPPleaf) over the loss of xylem water potential. Modeled relations between leaf traits are consistent with empirically observed patterns. As the results of the leaf shape-venation relation, our model further predicts that a broadleaf has overall higher NPPleaf compared to a narrowleaf. In addition, a broadleaf has a lower stomatal resistance compared to a narrowleaf under the same level of constraint. With the same leaf area, a broadleaf will have, on average, larger conduits and lower total leaf xylem resistance and thus be more efficient in water transportation but less resistant to cavitation. By linking venation structure to leaf shape and using water potential as the constraint, our model provides a physical explanation for the general pattern of the covariance of leaf traits through the safety-efficiency trade-off of leaf hydraulic design.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Joining technique for in-oven/autoclave molds manufactured by large scale polymer additive manufacturing

Large scale additive manufacturing (AM) of fiber-reinforced polymer composites has gained traction in the mold and die community over the last decade, largely due to reduced material cost and lead time. However, limitations in mold size remain present due to printer volume constraints and costs associated with large format machines. Here, this paper describes a method for producing additively manufactured polymer molds in segments with an O-ring joint design, which can be machined and subsequently assembled for autoclave applications. The developed joining mechanism allows for maintaining the vacuum integrity during the cure cycle while accounting for the anisotropic nature of the additively manufactured polymer molds. Over a range of tested temperatures, 20–200 °C, the multi-part mold joining design was able to achieve full vacuum of ∼73.7 cmHg (29 inchHg) and maintain a vacuum integrity with vacuum losses less than 1.5 cmHg/5min (0.6 inchHg).

Joining↗
DOE OSTI2024

Design and modeling of indirectly driven magnetized implosions on the NIF

The use of magnetic fields to improve the performance of hohlraum-driven implosions on the National Ignition Facility (NIF) is discussed. The focus is on magnetically insulated inertial confinement fusion, where the primary field effect is to reduce electron-thermal and alpha-particle loss from the compressed hotspot (magnetic pressure is of secondary importance). We summarize the requirements to achieve this state. The design of recent NIF magnetized hohlraum experiments is presented. These are close to earlier shots in the three-shock, high-adiabat (BigFoot) campaign, subject to the constraints that magnetized NIF targets must be fielded at room-temperature, and use ≲1 MJ of laser energy to avoid the risk of optics damage from stimulated Brillouin scattering. We present results from the original magnetized hohlraum platform, as well as a later variant that gives a higher hotspot temperature. In both platforms, imposed fields (at the capsule center) of up to 28 T increase the fusion yield and hotspot temperature. Integrated radiation-magneto-hydrodynamic modeling with the Lasnex code of these shots is shown, where laser power multipliers and a saturation clamp on cross-beam energy transfer are developed to match the time of peak capsule emission and the P2 Legendre moment of the hotspot x-ray image. The resulting fusion yield and ion temperature agree decently with the measured relative effects of the field, although the absolute simulated yields are higher than the data by 2.0−2.7×. The tuned parameters and yield discrepancy are comparable for experiments with and without an imposed field, indicating the model adequately captures the field effects. Self-generated and imposed fields are added sequentially to simulations of one BigFoot NIF shot to understand how they alter target dynamics.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Powersheds

Powersheds is an open scientific software project for simulating river–reservoir cascades. It combines the performance of Rust with a friendly Python interface to model storage, pool elevation, head, releases, spills, routing lags, and power generation at hourly resolution. Designed for coupling with power-system models, simulations are driven by plant-level target power schedules and report realized generation after accounting for hydrologic and operational constraints.

Turner, Sean [Oak Ridge National Laboratory (ORNL)↗
DOE OSTI2023

Ultimate: Birdshot (Final Technical Report)

In ULTIMATE Phase 1, BIRDSHOT aimed to discover alloys capable of operating reliably above 1300°C, compatible with coatings. The challenge addressed by BIRDSHOT is how to find suitable alloys in the vast refractory high entropy alloy (RHEA) space efficiently and effectively, under stringent resource constraints? This challenge is unsolvable with traditional alloy R&D approaches; however, using a closed-loop multi-objective, multi-information source Bayesian approach to alloy design, we made significant progress in solving this materials design problem.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Huge ensembles – Part 1: Design of ensemble weather forecasts using spherical Fourier neural operators

Abstract. Simulating low-likelihood high-impact extreme weather events in a warming world is a significant and challenging task for current ensemble forecasting systems. While these systems presently use up to 100 members, larger ensembles could enrich the sampling of internal variability. They may capture the long tails associated with climate hazards better than traditional ensemble sizes. Due to computational constraints, it is infeasible to generate huge ensembles (comprised of 1000–10 000 members) with traditional, physics-based numerical models. In this two-part paper, we replace traditional numerical simulations with machine learning (ML) to generate hindcasts of huge ensembles. In Part 1, we construct an ensemble weather forecasting system based on spherical Fourier neural operators (SFNOs), and we discuss important design decisions for constructing such an ensemble. The ensemble represents model uncertainty through perturbed-parameter techniques, and it represents initial condition uncertainty through bred vectors, which sample the fastest-growing modes of the forecast. Using the European Centre for Medium-Range Weather Forecasts Integrated Forecasting System (IFS) as a baseline, we develop an evaluation pipeline composed of mean, spectral, and extreme diagnostics. With large-scale, distributed SFNOs with 1.1 billion learned parameters, we achieve calibrated probabilistic forecasts. As the trajectories of the individual members diverge, the ML ensemble mean spectra degrade with lead time, consistent with physical expectations. However, the individual ensemble members' spectra stay constant with lead time. Therefore, these members simulate realistic weather states during the rollout, and the ML ensemble passes a crucial spectral test in the literature. The IFS and ML ensembles have similar extreme forecast indices, and we show that the ML extreme weather forecasts are reliable and discriminating. These diagnostics ensure that the ensemble can reliably simulate the time evolution of the atmosphere, including low-likelihood high-impact extremes. In Part 2, we generate a huge ensemble initialized each day in summer 2023, and we characterize the simulations of extremes.

Mahesh, Ankur↗
DOE OSTI2024

Gains in operational flexibility, safety margins, and cost efficiencies via integrated Plant Reload Optimization platform

The U.S. Department of Energy Light Water Reactor Sustainability Program Risk-Informed Systems Analysis Pathway Plant Reload Optimization Project aims to develop an integrated, comprehensive framework offering an all-in-one solution for reload evaluations with a special focus on optimizing core design. Optimizing the fuel loading pattern is one of the most important considerations in reducing the amount of new fuel used in the core. Due to thousands of possible core configuration options, finding optimal solutions is an unachievable task for a human. The Plant ReLoad Optimization platform, which supports artificial-intelligence-based reactor core designing, is now fully capable of handling realistic problems. The Plant ReLoad Optimization platform development project aims to build a reactor core design tool that includes reactor safety and fuel performance analyses and uses artificial intelligence to support the optimization of core design solutions. The NSGA-II (Non-dominated Sorting Genetic Algorithm II) optimizer was developed and tested within RAVEN (Risk Analysis and Virtual ENvironment) to handle many constraints by using an augmented objectives methodology. The demonstration was performed with constrained multiobjective optimization of a 17 × 17 pressurized-water reactor core loading patterns to minimize fuel cost and maximize fuel cycle length.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Large Scale Caching and Streaming of Training Data for Online Deep Learning

The training of deep neural network models on large data remains a difficult problem, despite progress towards scalable techniques. In particular, there is a mismatch between the random but predetermined order in which AI flows select training samples and the streaming I/O patterns for which traditional HPC data storage (e.g., parallel file systems) are designed. In addition, as more data are obtained, it is feasible neither simply to train learning models incrementally, due to catastrophic forgetting (i.e., bias towards new samples), nor to train frequently from scratch, due to prohibitive time and/or resource constraints. In this paper, we study data management techniques that combine caching and streaming with rehearsal support in order to enable efficient access to training samples in both offline training and continual learning. We revisit state-of-art streaming approaches based on data pipelines that transparently handle prefetching, caching, shuffling, and data augmentation, and discuss the challenges and opportunities that arise when combining these methods with data-parallel training techniques. We also report on preliminary experiments that evaluate the I/O overheads involved in accessing the training samples from a parallel file system (PFS) under several concurrency scenarios, highlighting the impact of the PFS on the design of the data pipelines.

data pipelines↗
DOE OSTI2025

The Design of a Multiphase CO2 Turbine Test Facility

As the energy market continues to evolve with increased renewables, such as solar and wind energy, the need to balance energy demand with its availability has become increasingly more challenging. The country’s aggressive decarbonization goals in the upcoming decades will increase renewable energy market penetration, thus exacerbating the disparity between energy demand and renewable resource availability. Long-duration energy storage technologies, such as pumped thermal energy storage (PTES), are potential solutions to this challenge with high potential round-trip efficiency (RTE), no geological or geographical constraints, and low safety risks. The charge mode of a PTES system operates a heat pump cycle, converting input power to thermal energy in hot and cold reservoirs. Fundamentally, heat pumps are commonly used in daily life, but the operating conditions required by high RTE PTES systems are outside the design experience of these systems. The low-pressure side of the cycle for a supercritical CO2 (sCO2) PTES operates just above the vapor-dome and potentially drives the turbine to expand into the dome, resulting in multiphase operation in the rear stages of the turbine. This paper presents the design of the test facility for an advanced multiphase-tolerant sCO2 turbine for the heat pump of a PTES system. Heat rejection and pressure loss estimations for the multiphase sections of the test loop presented unforeseen challenges.

25 ENERGY STORAGE↗
DOE OSTI2020

Analysis of the Shattered Pellet Injection Fragment Plumes Generated by Machine Specific Shatter Tube Designs

Shattered pellet injector systems have been installed on DIII-D, JET, and KSTAR and used to experimentally determine the effectiveness of the shattered pellet injection (SPI) process in mitigating the deleterious effects of a tokamak plasma disruption. Pellets are fired, and before entering the plasma, strike a bent tube known as a shatter tube causing the pellet to shatter. The process of pellet fragmentation is a chaotic process that can be described in terms of fragment size distribution through a statistical model that incorporates the effects of the pellet material and impact characteristics. In addition to the fragment size distribution, the shatter plume has other characteristics of interest, such as a fragment velocity distribution and temporal mass evolution. The fragment velocity distribution is important because it is needed to accurately model the spread and location of the ablation and the deposition of impurities in the plasma over time. The temporal mass evolution is necessary to determine the time-resolved delivery of mass to the plasma.Due to installation constraints, the shatter tube currently installed on JET has a unique geometry with a modest S-bend followed by a 20-deg bend at the end of the tube. The DIII-D and KSTAR shatter tube design is a simple tube bent through an angle of 20 deg followed by a straight section. The resulting shatter sprays from the JET shatter tube and a 20-deg miter bend shatter tube were experimentally characterized for various pellet materials and speeds. Laboratory testing of these shatter tubes allows for the use of fast cameras to capture the fragment spray traveling through a large vacuum chamber. These high-speed videos of the shatter plumes allow the fragment size distribution, temporal mass evolution, and velocity distribution of the fragments within the plume to be determined. Overall, this paper presents a comparison of the unique geometry of the JET shatter tube to the miter bend geometries used for shattering and some insight into the variables that may be adjusted to produce the optimal shatter spray. The impact of entrained propellant gas on the resulting shatter spray was examined during testing.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗