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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 OSTI2021

Spatio-Temporal Modeling of Field Surveyed Backsheet Degradation

Assessing photovoltaic module backsheet durability is critical to increasing module lifetime. Lab based accelerating testing has recently failed to predict large scale failures of widely adopted polymeric materials. Field surveyed data is critical to assess the performance of component lifetime. Using a documented field survey protocol, 13 field surveys where conducted. Each measurement is encoded with it's spatial location in respect to the other modules. By combining field survey data on degradation predictors with real time satellite weather data, data-driven predictive models of backsheet degradation were trained. LOESS models were constructed to investigate the spatial dependence of measurements. It was found that micro-climatic effects like tree-lines, ground surface changes, and elevation changes effected the magnitude and variance of the measurements. A GAM model was created to predict the value of degradation based on measured predictors. The model includes variables on the climate of the system and the location of each measurement in the PV mounting structure. The model performed well with an adj.R 2 of 0.95 for yellowness index prediction. The model was cross-validated using k-folds.

backsheet↗
DOE OSTI2021

Optimized Dispatch of Distributed Energy Resources for Resiliency and Power Quality Improvements at the Grid-Edge

Distributed Energy Resources (DERs) installed on low-voltage distribution systems, both utility-owned and nonutility owned may be employed to make improvements to system resiliency and power quality, in addition to simply serving load demand. By selectively dispatching active and reactive power from these existing DERs, improvements in voltage profiles and service availability during adverse events may be achieved. Further benefits can be gained by optimally choosing which DERs to dispatch power from, and the distribution of power from those DERs. For a given operating condition, using Linear Programming methods, optimal power dispatch values for individual DERs can be determined, while considering variables such as voltage gains, losses in the lines and the DERs, and DER reserve capacities. One such optimization technique is developed in this paper, and results from a real-time simulation study on a modified IEEE 13-bus distribution system with three DERs, are being presented. The operation of the optimized DER selection and dispatch algorithm is shown during normal operation of the transmission system when the DERs operate in grid-connected mode. Similar analyses can drive decision making during transmission system failure when the DERs operate in grid-forming or islanded mode.

Chowdhury, Prithwiraj Roy↗
DOE OSTI2022

Spatiotemporal Modeling of Real World Backsheets Field Survey Data: Hierarchical (Multilevel) Generalized Additive Models: Preprint

Assessing photovoltaic module backsheet durability is critical to increasing module lifetime. Lab based accelerating testing has recently failed to predict large scale failures of widely adopted polymeric materials. Field surveyed data is critical to assess the performance of component lifetime. Using a documented field survey protocol, 13 field surveys where conducted. Each measurement is encoded with it's spatial location in respect to the other modules. By combining field survey data on degradation predictors with real time satellite weather data, data-driven predictive models of backsheet degradation were trained. LOESS models were constructed to investigate the spatial dependence of measurements. It was found that micro-climatic effects like treelines, ground surface changes, and elevation changes effected the magnitude and variance of the measurements. A GAM model was created to predict the value of degradation based on measured predictors. The model includes variables on the climate of the system and the location of each measurement in the PV mounting structure. The model performed well with an adj:R2 of 0:95 for yellowness index prediction. The model was cross-validated using k-folds.

backsheet↗
DOE OSTI2026

Developing a Digital Twin for SRF Cavity Assembly at Fermilab

When assembling Superconducting Radio Frequency (SRF) Cavities, maintaining an environment devoid of particulates like dust and other small particles is essential. If a single spec of dust enters the cavity a significant degradation of performance can occur. To avoid a cavity failure Fermilab assembles the SRF cavities within a ISO-4 (Class 10) environment. This environment though is still susceptible to foreign contaminants when technicians enter and new components are added to the cleanroom. To reduce the risk even more Fermilab has introduced a cobot manipulator into the cleanroom environment to speed up the assembly time which will reduce the time that the technicians operate in the cleanroom. But, this still leaves the potential of contaminants to enter the cleanroom if new components need to be tested within the cleanroom. This project aims to lay the groundwork to develop a Digital Twin environment of the cleanroom to aid in manufacturing processes and testing. In its simplest form, a digital twin is a bidirectional link between a physical system and its digital counterpart or twin. NVIDIA Isaac Sim is used as the digital twin foundation for the digital representation of the cleanroom, specifically for the UR16e assembly area. A simulated UR16e was used to validate the performance of Isaac Sim as a testing environment by comparing the tool center points (TCP) positional data between the simulated and digital representation of the UR16e. Due to a new vision based robotic assembly process being introduced to the cleanroom a digital representation of the physical camera was tested and validated to ensure that it will produce close to the same outcome as the physical environment. The TCP comparison results showed a peak translational error of approximately 0.1mm and rotational errors of up to 8 between the simulated and digital UR16es. While the camera validation performed with high repeatability across multiple runs, it still requires minor tuning before it can accurately replicate a physical camera.

Imburgia, Joseph [Northern Illinois U.]↗
DOE OSTI2023

Startup process for a dual active bridge converter to prevent over-voltage failure and thermal run-away

A system and method for controlling a dual active bridge based DC/DC converter. A controller implements a startup control scheme and DC bus pre-charge routine to prevent damage to the converter upon startup. During startup of the converter, the startup control process can be used to prevent excessive phase-shift and the DC bus pre-charge routine adjusts the pulse width modulated duty cycle by increasing the dead time between signals, resulting in a decreased DC bus capacitor.

Singh, Braj K.↗
DOE OSTI2020

Impact of dual-layer solid-electrolyte interphase inhomogeneities on early-stage defect formation in Si electrodes

While intensive efforts have been devoted to studying the nature of the solid-electrolyte interphase (SEI), little attention has been paid to understanding its role in the mechanical failures of electrodes. Here we unveil the impact of SEI inhomogeneities on early-stage defect formation in Si electrodes. Buried under the SEI, these early-stage defects are inaccessible by most surface-probing techniques. With operando full field diffraction X-ray microscopy, we observe the formation of these defects in real time and connect their origin to a heterogeneous degree of lithiation. This heterogeneous lithiation is further correlated to inhomogeneities in topography and lithium-ion mobility in both the inner- and outer-SEI, thanks to a combination of operando atomic force microscopy, electrochemical strain microscopy and sputter-etched X-ray photoelectron spectroscopy. Our multi-modal study bridges observations across the multi-level interfaces (Si/LixSi/inner-SEI/outer-SEI), thus offering novel insights into the impact of SEI homogeneities on the structural stability of Si-based lithium-ion batteries. Severe structural deformation during (de)lithiation is the main factor limiting the stability of Si anodes in Li-ion batteries. Here, a multi-modal approach is used to visualize these deformations in their early-stage and link them to inhomogeneities in the dual-layer solid-electrolyte interphase.

25 ENERGY STORAGE↗
DOE OSTI2023

Hydrogen Equipment Enclosure Risk Reduction through Earlier Detection of Component Failures

Hydrogen component reliability and the hazard associated with failure rates is a critical area of research for the successful implementation and growth of hydrogen technology across the globe. The research team has partnered to quantify system risk reduction through earlier detection of hydrogen component failures. A model of hydrogen dispersion in a hydrogen equipment enclosure has been developed utilizing experimentally quantified hydrogen component leak rates as inputs. This model provides insight into the impact of hydrogen safety sensors and ventilation on the flammable mass within a hydrogen equipment enclosure. This model also demonstrates the change in safety sensor response time due to detector placement under various leak scenarios. The team looks to improve overall hydrogen system safety through an improved understanding of hydrogen component reliability and risk mitigation methods. This collaboration fits under the work program of IEA Hydrogen Task 43 Subtask E Hydrogen System Safety.

CFD↗
DOE OSTI2025

Quantitative insights for diagnosing performance bottlenecks in lithium–sulfur batteries

Lithium–sulfur (Li–S) batteries hold significant promise for electric vehicles and aviation due to their high energy density and cost-effectiveness. However, understanding the root causes of performance degradation remains a formidable challenge, as the interplay of multiple factors obscures key failure mechanisms. A major limitation has been the inability to quantify soluble sulfur species within practical detection limits accurately and to correlate electrochemical processes with associated physical inventory changes. Here, we introduce the high-performance liquid chromatography-ultraviolet spectroscopy and gas chromatography sequential characterization (HUGS) toolkit, capable of precisely quantifying seven distinct sulfur and polysulfide species at concentrations as low as 40 ppb. HUGS has been successfully applied to practical coin and pouch cells without requiring cell modification. Furthermore, our self-developed software, Dr HUGS, enhanced the data analysis speed by over 30 times, enabling multi-source data integration and delivering comprehensive analysis results within minutes. Using HUGS, we identify significant capacity losses from inactive lithium and sulfur during initial cycles and sulfide-rich solid–electrolyte interphase (SEI) formation on the anode during later cycles. Notably, our findings reveal that soluble polysulfides have minimal contributions to capacity loss, challenging long-standing assumptions. Moreover, HUGS demonstrates that constant-pressure setups in Li–S pouch cells improve compositional uniformity compared to constant-gap configurations. For sulfurized polyacrylonitrile (SPAN) cathodes, unique issues such as non-sulfide SEI formation and lithium pulverization are observed, which can be mitigated through localized high-concentration electrolytes to enhance lithium inventory retention. By enabling precise quantification of critical inventory components, HUGS provides transformative insights into failure mechanisms across various electrolytes and cathode chemistries, guiding rational design strategies for next-generation energy storage systems.

25 ENERGY STORAGE↗
DOE OSTI2021

Influence of alkali-silica reaction on the shear capacity of reinforced concrete beams with minimum transverse reinforcement

A growing number of critical concrete infrastructure are affected by alkali-silica reaction (ASR) damage such as the Seabrook Nuclear Power Plant in New Hampshire, Parker arch-gravity dam in Arizona, and several highway bridges in California and Texas. ASR causes expansion and cracking and degrades the concrete mechanical properties. Despite a wealth of material level studies there is still limited large-scale experimental data regarding the effects of ASR on reinforced concrete (RC) members. Due to the brittle nature of the shear failure in RC structures, this study focuses on the shear response of full-scale ASR damaged RC beams with minimum shear reinforcement. Six RC beams were built with different levels of ASR susceptibility and conditioned in different environments during which continuous expansion monitoring was performed. The beams all contained reactive fine aggregate (sand) and two of them had additional alkali, 1.25% by weight of cement, to accelerate ASR. The highest expansion rate of the beams happened during the first 150 days and the expansions stayed constant after 240 days and 330 days for beams conditioned in outdoor and laboratory conditions, respectively, until the last measurement at 575 days. The highest expansion, 0.4%, was seen in the beams with additional alkali and conditioned outside with regular water spray. Out of the six beams, three were selected at different levels of ASR damage and two shear tests were performed on the minimally reinforced spans close to the ends of each beam. Results indicated that beams gain shear strength from ongoing cement hydration in the presence of moisture for ASR expansions less than 0.2%. Compared to one of the beams with 0.2% ASR expansion, one of the other samples with 0.4% expansion lost 6% of its shear strength, 25% of its shear stiffness, and showed about two times larger shear cracks and shear deformations at peak load. Finally, the shear reinforcement yielded at 20% less load in the beam with 0.4% expansion compared to the beam with 0.2% expansion.

42 ENGINEERING↗
DOE OSTI2025

Temperature Evolution of the Activation Barriers Leads to Meyer−Neldel Rules for Structural Relaxation and Transport in Polymers

Understanding activation barriers controlling structural relaxation in glass-forming liquids, molecular transport, and ionic conductivity in amorphous polymers is a grand challenge of fundamental scientific and materials engineering interest across disciplines. Over decades, intriguing but puzzling empirical correlations between the elementary time scale of activated barrier crossing and the apparent Arrhenius activation energy, the so-called Meyer−Neldel (MN) rules, have been discovered in diverse liquids and glasses. Here, in this study, we formulate and successfully apply a new experimental analysis and an explicitly dynamical theoretical framework which provides an understanding of the origin, validity, and failure of such correlations, that bridge and unify the three fields of structural relaxation, molecular transport, and ionic conductivity in liquids and quenched glasses. Distinct quasi-universal laws are predicted in equilibrated liquids and nonequilibrium glasses, consistent with experiments. Our analysis reveals that even if the relaxation appears Arrhenius over a limited temperature range, the physical activation barrier is generally temperature-dependent in polymeric systems even below glass transition temperature. In addition, we show that the approximate validity of classical MN rules hinges on a linear temperature dependence of this barrier and the temperature range probed in experiments. Our findings are relevant for controlling the activation barrier in functional soft polymeric materials relevant to molecular separations, barrier coatings, and charge transport, and also provide new constraints on the theoretical understanding of the mechanism underlying slow activated dynamics in glass-forming condensed matter.

Meyer-Neldel rules↗
DOE OSTI2023

Production and testing of the powerboard for ATLAS ITk Strip barrel modules

The upgrade of the ATLAS ITk strips detector for HL-LHC will employ a custom PCB (powerboard) for on-module DC-DC conversion, HV switching, and monitoring. Production of about 14100 of such PCBs with high reliability is a big challenge. In this paper we will present the production procedure and quality control (QC) testing system for the powerboards to be installed on ITk Strip barrel modules. During production, about 150 powerboards will be produced every week. Each powerboard will need to pass QC tests before they are assembled to module. The QC tests include thermal cycling between -35 °C and 40 °C, soak test (continuous running of DC-DC converter at high load at 20 °C), and basic functionality and characterization electrical tests of the low voltage (LV), high voltage (HV), and monitoring functions of the powerboard. A custom QC test system is described, which is based on a reusable PCB (active board) with all testing circuits, a one-time powerboard carrier card, and a Z-turn SoC board which hosts and runs the testing program. The production procedure and QC test system has been tested with 400 powerboards during pre-production, and the system has been proven ready for production with the desired testing program, speed, safety, and cost. Performance and typical failures of powerboards observed during the QC test of pre-production powerboards is also presented.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Testing of In-Sodium Hydrogen Sensor

The goal of this project is to demonstrate diffusion-type in-sodium hydrogen meters (ISHMs) for real-time, in-situ monitoring of hydrogen concentration in molten sodium of a sodium-cooled fast reactor (SFR). The FY22 R&D efforts have been focused on (a) enhancement and fabrication of meshed ISHM prototype, (b) reconstruction of ISHM sodium test apparatus, (c) in-sodium test of meshed ISHM, and (d) ISHM performance and failure evaluations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Large Area Detection of Microstructural Defects with Multi-Mode Ultrasonic Signals

Cyclic loading or other stresses can lead to development of cracks and crack growth in mechanical structures, leading to eventual failure. While ultrasound imaging can be used for non-destructive testing of such structures, conventional ultrasound techniques are often limited by crack size, density, and areal coverage. An effective characterization of real-world, large-area structures is required at an early damage stage to prevent catastrophic failure and predict remaining life. In this study, a new nonlinear ultrasonic testing (NUT) method is proposed for large-area monitoring of practical structures with arbitrary complexity by using multiple-mode guided-wave ultrasonic signals. The proposed guided-wave NUT technique requires single-element transducers, simple electronics, and a mixed time-frequency domain signal processing. As a proof-of-concept demonstration, numerical simulations and experiments are performed on an A36 carbon steel beam assembly with previously formed microstructural defects that cause nonlinearities in ultrasonic response. The quadratic dependence of the nonlinear wave excitation on the input ultrasonic signal amplitude is shown by numerical simulations, and such a nonlinear ultrasonic response is experimentally observed in the zone with a high density of microstructural defects.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Optimizing the differential connection schemes for detecting 3D magnetic perturbations in DIII-D

Optimizing the differential pair connection scheme (i.e. the set of pairs) of a toroidal array of magnetic sensors dedicated to measuring slowly rotating asymmetric fields can enhance the mode number detection capability and failure-resilience. In this work the condition number obtained from singular value decomposition (SVD) of the design matrix is used as a metric to evaluate the quality of a connection scheme. A large number of possible pair connections are usually available, so evaluating all of them may require extensive use of computational resources and can be very time consuming. Alternative methods to reduce the number of pairs evaluated without losing the capabilities of toroidal mode detection are presented in this paper. Here, three examples of the applications of such analysis for the 3D magnetic diagnostic system of DIII-D are also presented: the addition of two new toroidal arrays with n > 3 detection capabilities, the modification of an existing toroidal array in the low field side of the machine to accommodate the addition of a helicon antenna, and the design of changes in several toroidal arrays in the high field side to accommodate the addition of a lower hybrid current drive antenna on the center post.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Abstract for CRADA between National Energy Technology Laboratory and Colonial Pipeline Company

The National Energy Technology Laboratory (NETL) and Colonial Pipeline Company (Participant) will collaborate in the field demonstration of optical fiber sensor systems developed at NETL on Participant’s fuel pipeline. The optical fiber sensor technologies are capable of distributed temperature and strain sensing, distributed acoustic sensing, and ultrasensitive acoustic sensing. Real-time monitoring of these parameters enables pipeline integrity monitoring, security monitoring, flow rate monitoring, etc. Successful demonstration on a real fuel pipeline at Participant’s facilities will validate the sensor technologies and installation methods at a real scale. This effort aligns with NETL’s mission in reliable and sustainable energy and reducing environmental effects due to pipeline failures.

42 ENGINEERING↗
DOE OSTI2024

Development of Readily Available & Robust High Heat Flux Gardon Gauges

Concentrated solar power (CSP) technologies deliver concentrated solar energy as a heat source to industrial processes, power generation cycles, and chemical cycles. CSP systems require accurate and reliable high flux measurements, and next generation CSP systems will require flux measurement up to 1000 W/cm2. Existing flux measurement devices do not comprehensively meet the flux rating, cycle life, cost, and lead-time needs of stakeholders, necessitating the development of an improved flux sensor. In this study, Sandia National Laboratories (SNL) partnered with Hukseflux Thermal Sensors to develop a low-cost, short lead-time, and robust flux sensor rated to 250 W/cm2. Three prototype circular foil gauge designs were assessed for performance at the National Solar Thermal Test Facility (NSTTF) at SNL. Each gauge design measured flux up to 250 W/cm2 with <5% measurement error. Following baseline error quantification, gauges were exposed to flux above 500 W/cm2 to assess gauge failure mechanisms. Gauges physically survived >500 W/cm2 flux exposure, but measurement error was found to increase after foil coatings reached 400 °C. The results of this study suggest that coating optical properties change at excessive temperatures and that foil coating temperature, rather than heat flux level, dictates the acceptable gauge measurement range.

McLaughlin, Luke (ORCID:0000000303711310)↗
DOE OSTI2025

Deconsolidation and Leach Burn Leach of Seven As Irradiated AGR 5/6/7 TRISO Fuel Compacts from Capsules 2, 3, 4, and 5

Seven as-irradiated Advanced Gas Reactor (AGR) 5/6/7 compacts underwent destructive post-irradiation examination via deconsolidation-leach-burn leach at Idaho National Laboratory (INL). The selection of the compacts extended the upper and lower limits of time-average volume-average (TAVA) temperature for compacts that had gone through deconsolidation-leach-burn leach so far. The measured inventories of fission products and actinides in the compact matrix and outer pyrolytic carbon were reported. Results indicated unexpectedly higher rates of fuel kernel leaching compared to compacts from AGR-1 and AGR-2. These failure rates were attributed to damage during post-irradiation sample handling, rather than irradiation itself. AGR-5/6/7 compacts have little or no matrix coverage for some particles at the top and bottom ends of cylindrical fuel compacts, making them more fragile. Sixty particles were randomly sampled from each compact, and the gamma results were reported. Three SiC shells from were identified, one of which showed signs of chemical attack in the high-irradiation temperature compact.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Performance of discontinuity-free components produced by additive turning computer aided manufacturing strategy

Computer aided manufacturing (CAM) techniques for directed energy deposition (DED) affect the material properties of the manufactured component based on the scan strategy used. In this study, we investigate the material characteristics of turning-style toolpath strategies to generate axisymmetric components with additive manufacturing (AM), referred to in this research as additive turning. This novel approach leverages existing CAM technology for turning, where the component rotates around a stationary cutting tool, to generate toolpath trajectories for DED with varying wall-thicknesses and controlled deposition angles. This strategy allows for entire components to be deposited in one continuous deposition, resulting in reduced cycle-time and improved material usage efficiency compared to conventional AM strategies where the beam is switched off at the end of every layer. Results from this study show that the use of additive turning can produce over 99 % dense components with less variation and anisotropy in texture and hardness, as well as a lower variation in elongation to failure when compared to conventional strategies. This research highlights that various CAM strategies could be deployed for AM to improve process efficiency or enable localized control over part performance.

36 MATERIALS SCIENCE↗