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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 829 records · Page 46
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Flexible positioning of a large area detector using an industrial robot

The DIAD beamline for Dual Imaging and Diffraction at Diamond Light Source has opted to use an industrial robot to position its Dectris Pilatus 2M CdTe diffraction detector. This setup was chosen to enable flexible positioning of the detector in a quarter-sphere around the sample position whilst reliably holding the large weight of 139 kg of detector, detector mount and cabling in a stable position. Metrology measurements showed that the detector can be positioned with a linear repeatability of <19.7 µm and a rotational repeatability of <16.3 µrad. The detector position stays stable for a 12 h period with <10.1 µm of movement for linear displacement and <3.8 µrad for rotational displacement. X-ray diffraction from calibration samples confirmed that the robot is sufficiently stable to resolve lattice d-spacings within the instrumental broadening given by detector position and beam divergence.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Assessment of the Distributed Ledger Technology for Energy Sector Industrial and Operational Applications Using the MITRE ATT&CK® ICS Matrix

In recent times, Distributed Ledger Technology (DLT) has gained significant attention for its potential application in the energy sector. Utilizing blockchain and DLT has demonstrated the ability to enhance the resilience of the electric infrastructure, which will support a more flexible infrastructure and advance grid modernization. However, the deployment of these technologies increases the overall attack surface. The MITRE ATT&CK® matrices have been developed to document an adversary’s tactics and techniques based on real-world observations. The MITRE ATT&CK® matrices provide a common taxonomy for offense and defense and have become a valuable conceptual tool across multiple cybersecurity disciplines for conveying threat intelligence, performing testing through red teaming or adversary emulation, and enhancing network and system defenses against intrusions. The MITRE ATT&CK® for Industrial Control Systems (ICS) matrix was created to provide knowledge about adversary behavior in the ICS technology domain. This study analyzes the relevance of various tactics and techniques across a seven-layer DLT engineering and cybersecurity stack, known as the DLT stack, designed by the Cybersecurity Taskforce under IEEE P2418.5 - Standard for Blockchain in Energy working group sponsored by Power and Energy Systems - Smart Buildings, Loads and Customer Systems (PES/SBLC) Technical Committee. Additionally, this paper identifies specific mitigation strategies tailored to the energy ICS environment

42 ENGINEERING↗
DOE OSTI2023

Strengthening Cybersecurity for Industrial Control Systems: Innovations in Protecting PLC-Based Infrastructure

In this paper, we propose two new approaches aimed at enhancing the security of industrial control systems (ICS) that utilize programmable logic controllers (PLCs) for the control of critical processes. The first approach involves the addition of a unique digital watermark to the PWM control that adjusts the motor speed to control the critical process. This enables efficient detection and identification of any unauthorized modifications to the sensor signals responsible for controlling the plant. The second approach focuses on monitoring the input current (i.e power) drawn by the PLC during the execution of critical process control tasks. Malicious intrusions to change the PLC parameters and/or unauthorized firmware updates can be rapidly detected. Both approaches demonstrate a substantial improvement in the security of ICS, effectively safeguarding against potential cyber-attacks. Experimental results from a laboratory scale water tank level controlled via PLC showcases rapid intrusion detection capabilities.

Huang, Peng-Hao↗
DOE OSTI2023

Deep Learning Based Workflow for Accelerated Industrial X-Ray Computed Tomography

X-ray computed tomography (XCT) is an important tool for high-resolution non-destructive characterization of additively-manufactured metal components. XCT reconstructions of metal components may have beam hardening artifacts such as cupping and streaking which makes reliable detection of flaws and defects challenging. Furthermore, traditional workflows based on using analytic reconstruction algorithms require a large number of projections for accurate characterization - leading to longer measurement times and hindering the adoption of XCT for in-line inspections. In this paper, we introduce a new workflow based on the use of two neural networks to obtain high-quality accelerated reconstructions from sparse-view XCT scans of single material metal parts. The first network, implemented using fully-connected layers, helps reduce the impact of BH in the projection data without the need of any calibration or knowledge of the component material. The second network, a convolutional neural network, maps a low-quality analytic 3D reconstruction to a high-quality reconstruction. Using experimental data, we demonstrate that our method robustly generalizes across several alloys, and for a range of sparsity levels without any need for retraining the networks thereby enabling accurate and fast industrial XCT inspections.

Rahman, Obaid↗
DOE OSTI2025

Federated Learning for Efficient Condition Monitoring and Anomaly Detection in Industrial Cyber-Physical Systems

Detecting and localizing anomalies in cyber-physical systems (CPS) has become increasingly challenging as systems grow in complexity, particularly due to varying sensor reliability and node failures in distributed environments. While federated learning (FL) offers a foundation for distributed model training, existing approaches lack mechanisms to handle these CPS-specific challenges. This paper presents an enhanced FL framework that introduces three key innovations: adaptive model aggregation based on sensor reliability, dynamic node selection for resource optimization, and Weibull-based checkpointing for fault tolerance. Our framework enables reliable condition monitoring while addressing the computational and reliability challenges of industrial CPS deployments. Experiments on NASA Bearing and Hydraulic System Datasets demonstrate superior performance over state-of-the-art FL methods, achieving 99.5% AUC-ROC in anomaly detection and maintaining accuracy under node failures. Statistical validation using Mann-Whitney (U) test confirms significant improvements (p < 0.05) in both detection accuracy and computational efficiency across diverse operational scenarios.1

Marfo, William [University of Texas at El Paso,Dep↗
DOE OSTI2024

Photovoltaic Cable Connectors: A Comparative Assessment of the Present State of the Industry

The consequences of failure for balance-of-systems components (such as photovoltaic (PV) cable connectors) include offline module string(s); low system voltage; arc, ground, insulation, and overtemperature faults; triggered fuse(s); system shutdown; and fire. The degradation modes for connectors are studied here through an industry survey and its subsequent examination, which are compared with field-degraded specimens. A total of 117 specimens were obtained from a variety of locations and climates or accelerated tests. A failure analysis for connectors from PV installations was developed (and applied to 54 specimens), including nondestructive examinations (photography, a custom resistance-current scan, and X-ray computed tomography) and destructive examinations (featuring milling of the external plastic, extraction of the internal convolute spring, and potting and polishing in cross section). Surface and through-thickness composition of the metal pins and springs was quantified using scanning electron microscopy with energy-dispersive X-ray spectroscopy. Fourier transform infrared spectroscopy was used to verify the base polymer materials and compare the chemical structure of the connector body, bushing, end nut, and o-ring. Thermogravimetric analysis and differential scanning calorimetry were used to further verify the degradation of the same polymeric components.

cable connectors↗
DOE OSTI2025

Privacy Preservation from High-Performance Computing to Autonomous Science [Industrial and Governmental Activities]

High-Performance Computing (HPC) and Leadership-Class Supercomputing are driving forces behind scientific advancements, enabling researchers to tackle complex challenges in physics, chemistry, biology, and engineering. These systems power vast simulations and data analyses, fueling discoveries in fields ranging from materials science to climate modeling. However, their use often involves processing sensitive data—such as proprietary industry simulations, biomedical records, and national security computations—posing significant privacy concerns. In conclusion, this issue is amplified in collaborative environments like Department of Energy (DOE) user facilities, where HPC resources are shared across institutions to foster innovation.

Kotevska, Olivera [Oak Ridge National Laboratory (↗
DOE OSTI2026

Integrated System Planning: Emerging Software Requirements in the Power Industry

Power system planning software remains fragmented across organizational boundaries, with specialized tools for capacity expansion, production cost modeling, power flow, and dynamic analysis operating on incompatible data models and assumptions. This article argues that the fragmentation is not merely a technical problem but a predictable consequence of Conway's law: software architectures mirror the departmental structures within which they are developed. Regulatory milestones like Federal Energy Regulatory Commission (FERC) Order 888 formalized these divisions, but the roots trace back to the distinct engineering disciplines-mechanical, chemical, and electrical-that staffed generation and transmission planning departments in vertically integrated utilities. As the industry moves toward integrated system planning (ISP) that coordinates generation, transmission, and distribution investment decisions, the software ecosystem must evolve accordingly. We identify five categories of software requirements to enable this transition: coherent data inputs decoupled from individual applications, unified and extensible data schemas, modular component representations that support multiple abstraction levels, lifecycle management of planning datasets, and well-defined application programming interface (API) contracts that separate data exchange from algorithmic control. We examine how these requirements interact with three common workflow patterns-serial gate clearing, sequential multiapplication, and convergence oriented-and discuss the interface design principles each demands. We then outline a vision for platform-based planning architectures where specialized analytical services compose through standardized interfaces and where artificial intelligence (AI)/machine learning (ML) tools augment decision support within a disciplined software infrastructure. The practices proposed here offer a path from today's siloed tool collections toward collaborative planning ecosystems capable of handling the complexity of modern power system transformation.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Design and Implementation of Full-Scale Industrial Control System Test Bed for Assessing Cyber-Security Defenses

In response to the increasing awareness of the Ethernet-based threat surface of industrial control systems (ICS), both the research and commercial communities are responding with ICS-specific security solutions. Unfortunately, many of the properties of ICS environments that contribute to the extent of this threat surface (e.g. age of devices, inability or unwillingness to patch, criticality of the system) similarly prevent the proper testing and evaluation of these security solutions. Production environments are often too fragile to introduce unvetted technology and most organizations lack test environments that are sufficiently consistent with production to yield actionable results. Cost and space requirements prevent the creation of mirrored physical environments leading many to look towards simulation or virtualization. Examples in literature provide various approaches to building ICS test beds, though most of these suffer from a lack of realism due to contrived scenarios, synthetic data and other compromises. In this paper, we provide a design methodology for building highly realistic ICS test beds for validating cybersecurity defenses. We then apply that methodology to the design and building of a specific test bed and describe the results and experimental use cases.

Gillen, Rob↗
DOE OSTI2020

Assessing Anomaly-Based Intrusion Detection Configurations for Industrial Control Systems

To reduce cost and ease maintenance, industrial control systems (ICS) have adopted Ethernetbased interconnections that integrate operational technology (OT) systems with information technology (IT) networks. This integration has made these critical systems vulnerable to attack. Security solutions tailored to ICS environments are an active area of research. Anomalybased network intrusion detection systems are well-suited for these environments. Often these systems must be optimized for their specific environment. In prior work, we introduced a method for assessing the impact of various anomaly-based network IDS settings on security. This paper reviews the experimental outcomes when we applied our method to a full-scale ICS test bed using actual attacks. Our method provides new and valuable data to operators enabling more informed decisions about IDS configurations.

Gillen, Rob↗
DOE OSTI2020

Retrospective analysis of biochemical limitations to photosynthesis in 49 species: C 4 crops appear still adapted to pre‐industrial atmospheric [ CO 2 ]

Abstract Leaf CO 2 uptake ( A ) in C 4 photosynthesis is limited by the maximum apparent rate of PEPc carboxylation ( V pmax ) at low intercellular [CO 2 ] ( c i ) with a sharp transition to a c i ‐saturated rate ( V max ) due to co‐limitation by ribulose‐1:5‐bisphosphate carboxylase/oxygenase (Rubisco) and regeneration of PEP. The response of A to c i has been widely used to determine these two parameters. V max and V pmax depend on different enzymes but draw on a shared pool of leaf resources, such that resource distribution is optimized, and A maximized, when V max and V pmax are co‐limiting. We collected published A / c i curves in 49 C 4 species and assessed variation in photosynthetic traits between phylogenetic groups, and as a function of atmospheric [CO 2 ]. The balance of V max ‐ V pmax varied among evolutionary lineages and C 4 subtypes. Operating A was strongly V max ‐limited, such that re‐allocation of resources from V pmax towards V max was predicted to improve A by 12% in C 4 crops. This would not require additional inputs but rather altered partitioning of existing leaf nutrients, resulting in increased water and nutrient‐use efficiency. Optimal partitioning was achieved only in plants grown at pre‐industrial atmospheric [CO 2 ], suggesting C 4 crops have not adjusted to the rapid increase in atmospheric [CO 2 ] of the past few decades.

Pignon, Charles P.↗
DOE OSTI2021

Economic, Exergy, and Environmental Analyses of the Energy Assessments for U.S. Industries

Abstract This paper highlights the expected versus actual outcomes of 152 energy assessments that were performed between 2011 and 2020. The 1317 energy-assessment recommendations (ARs) are grouped into eight categories. This study adopted four measures per each category of recommendations: annual electricity savings, annual gas savings, annual cost savings, and annual CO2 emission reduction. The first part of the analysis compares the expected to the actually implemented values of the measures applied to each recommendation’s category. It was found that the percentages of the actual to the expected electricity, gas, and cost savings are 26.6%, 11.4%, and 17.1%, respectively, while the percentage of the actual to the expected CO2 reduction is 22%. Moreover, the second part of the analysis presents each category's implementation rate and the reasons for rejecting the unimplemented ARs. Cash flow and expensive initial investment resulted in rejecting 25% of ARs. Furthermore, the study proposes techniques and strategies to increase ARs’ implementation rate and improve private energy services companies’ implementation rate. Finally, exergy analysis is added to show the improvement that energy assessment achieves regarding exergy and exergy efficiencies of different industrial applications.

Energy & Fuels↗
DOE OSTI2024

Understanding Environmental Barrier Coating Lifetimes and Performance for Industrial Gas Turbines

Hydrogen or hydrogen blend fuels are expected to replace natural gas in land-based industrial gas turbines (IGTs) to support a greener power economy. Silicon carbide (SiC) base ceramic matrix composites (CMCs) are considered for replacement of Ni-based superalloys to facilitate future efficiency improvements. SiC CMCs require environmental barrier coatings (EBCs) to mitigate volatilization from high-temperature steam, thus making the EBC lifetime critical information for identifying CMC component lifetimes. Here, the goal of this project is to determine the maximum bond coating temperature underneath the EBC for achieving an IGT component lifetime goal of 25,000 h, which is far greater than current CMC component lifetime requirements for aeroturbine applications. To provide data for the lifetime model, laboratory testing used atmospheric plasma-sprayed rare-earth silicate EBCs on monolithic SiC substrates with an intermediate Si bond coating. Specimens exposed to 1-h thermal cycles in flowing air–steam environments and reaction kinetics were assessed from 700 °C to 1350 °C by measuring the thickness of the thermally grown silica scales. The silica growth and phase transformation appear critical in predicting EBC lifetime and several strategies have been explored to reduce the oxide growth rate and improve EBC durability at elevated temperatures. Advanced characterization using Raman spectroscopy has helped clarify this system.

08 HYDROGEN↗
DOE OSTI2024

Resources, Training, and Education Under the Heliostat Consortium: Industry Gap Analysis and Building a Resource Database

Concentrating solar power is not a widely deployed or known technology area, and the heliostat workforce community in the United States is currently small, with knowledge and expertise not widely available. The resource, training, and education (RTE) topic within the Heliostat Consortium (HelioCon) was established to address this. RTE encompasses resources, practices, and programs to ensure that (1) newcomers to the heliostat development community have an adequate knowledge base and training to conduct R&D efforts, (2) outsiders to the field are provided with resources and opportunities to join the workforce, and (3) the workforce community is a productive, healthy, and fulfilling environment for all workers. In the first year of the project, a roadmap study was conducted, in which the major gaps in RTE were identified by consulting experts in the industry, with the top gap being the lack of public accessibility to concentrating solar-thermal power (CSP) knowledge. Here, to address this, the HelioCon team has been developing a centralized web-based resource database, containing a reference library, educational videos, lists of components suppliers and software/metrology tools, a power tower plant database, and information on existing standards/guidelines.

14 SOLAR ENERGY↗
DOE OSTI2024

Computational Study of Additively Manufactured Internally Cooled Airfoils for Industrial Gas Turbine Applications

Internal cooling features such as pin-fins, impingement jets, and rib-turbulators are necessary to keep turbine components cool, but if sufficiently advanced can potentially also eliminate the need for film cooling on turbine blades particularly in industrial gas turbines where temperatures are not extreme. Furthermore, by leveraging additive manufacturing, other advanced designs such as lattice and incremental impingement configurations are possible and have recently been experimentally tested. While the performance of such configurations has been quantified through means of overall cooling effectiveness, it is not as clear why certain designs were better than others, or what the mechanisms were behind the observed external cooling patterns. The purpose of this study was to computationally analyze different advanced turbine blade internal cooling designs previously tested by the National Energy Technology Laboratory.

CFD↗
DOE OSTI2024

Understanding EBC Lifetimes and Performance for Industrial Gas Turbines

Hydrogen or hydrogen blend fuels are expected to replace natural gas in land-based industrial gas turbines (IGTs) to support a greener power economy. Silicon carbide (SiC) base ceramic matrix composites (CMCs) are considered for replacement of Ni-based superalloys to facilitate future efficiency improvements. SiC CMCs require environmental barrier coatings (EBCs) to mitigate volatilization from high-temperature steam, thus making the EBC lifetime critical information for identifying CMC component lifetimes. The goal of this project is to determine the maximum bond coating temperature underneath the EBC for achieving an IGT component lifetime goal of 25,000 h, which is far greater than current CMC component lifetime requirements for aero-turbine applications. To provide data for the lifetime model, laboratory testing used plasma-sprayed rare-earth silicate EBCs on monolithic SiC substrates with an intermediate Si bond coating. Specimens exposed to 1-h thermal cycles in flowing air-steam environments and reaction kinetics were assessed from 700°-1350°C by measuring the thickness of the thermally grown silica scales. The silica growth and phase transformation appear critical in predicting EBC lifetime and several strategies have been explored to reduce the oxide growth rate and improve EBC durability at elevated temperatures. Advanced characterization using Raman spectroscopy has helped clarify this system.

Ridley, Mackenzie↗
DOE OSTI2024

Report on laser-induced fluorescence transitions relevant for the microelectronics industry and sustainability applications

A wide variety of feed gases are used to generate low-temperature plasmas for the microelectronics and sustainability applications. These plasmas often have a complex combination of reactive and nonreactive species which may have spatial and temporal variations in density, temperature, and energy. Accurate knowledge of these parameters and their variations is critically important for understanding and advancing these applications through validated and predictive modeling and the design of relevant devices. Laser-induced fluorescence (LIF) provides both spatial and temporally resolved information about the plasma-produced radicals, ions, and metastables. However, the use of this powerful diagnostic tool requires the knowledge of optical transitions including excitation and fluorescence wavelengths which may not be available or scattered through a huge literature domain. In this paper, we collected, analyzed, and compiled the available transitions for laser-induced fluorescence for more than 160 chemical species relevant to the microelectronics industry and the sustainability applications. A list of species with overlapping LIF excitations and fluorescence wavelengths have been identified. Finally, this summary is intended to serve as a data reference for LIF transitions and should be updated in the future.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

CRISPRi functional genomics in bacteria and its application to medical and industrial research

SUMMARY Functional genomics is the use of systematic gene perturbation approaches to determine the contributions of genes under conditions of interest. Although functional genomic strategies have been used in bacteria for decades, recent studies have taken advantage of CRISPR (clustered regularly interspaced short palindromic repeats) technologies, such as CRISPRi (CRISPR interference), that are capable of precisely modulating expression of all genes in the genome. Here, we discuss and review the use of CRISPRi and related technologies for bacterial functional genomics. We discuss the strengths and weaknesses of CRISPRi as well as design considerations for CRISPRi genetic screens. We also review examples of how CRISPRi screens have defined relevant genetic targets for medical and industrial applications. Finally, we outline a few of the many possible directions that could be pursued using CRISPR-based functional genomics in bacteria. Our view is that the most exciting screens and discoveries are yet to come.

Microbiology↗