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All sources NASA NTRS DOE OSTI

DOE OSTI2021

Mask Free OLED Fabrication Process for Non-Tunable and Tunable White OLED Panels

In this program we demonstrated a method for mask free fabrication of OLEDs. Conventional OLEDs use at least 2 shadowmasks during the fabrication process to define the deposition pattern for the organic layers and for the cathode layer. Although effective, the use of masks requires mask handling and mask change equipment which increases the cost of the OLED deposition system. New sets of masks are required for every new product design, and the mask sets require frequent cleaning as organic material builds up on the masks over time and can be a source of particle defects resulting in yield loss. The method investigated in this program uses laser removal of organic material to pattern the organic layers and define a moisture impermeable seal region. This method is digital and can be applied to any new panel design, avoiding the costs of new masks sets and associated yield loss. In addition, we developed a platform technology for producing white color tunable or dim-to-warm white OLEDs and demonstrated patterning of tunable white OLEDs using the low-cost mask free fabrication process.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Signature Analysis Utilizing a Dynamic Molten Salt Reactor Model for MC&A

Moving from traditional fixed fuel nuclear reactor systems to a mobile, dynamic fuel system that has dissolved special nuclear material in a molten salt is a paradigm shift in several respects. One major consideration is how to develop effective nuclear material controls and accounting for these novel reactor systems. The Molten Salt Reactor Experiment is one example of a critical molten salt system and provided a significant reference library based on the documented effort. But it was low thermal power that was not intended to reflect a commercial scale electricity production design. Therefore, to facilitate and assist vendors with domestic licensing considerations, research is underway to identify methods that could be used for domestic safeguards approaches for these novel reactor systems. This research presents the results of a signature analysis of data generated from three simulated scenarios using the molten salt demonstration reactor model defined in the Transient Simulation Framework of Reconfigurable Modules. Each scenario provides 1 hour isotope inventories over a 180 day period. The scenarios investigated provide test cases to examine if direct gamma-ray spectroscopy of the fuel can be used to identify changes comparing a base case (no reactivity control and fixed fission contribution) to an insertion of reactivity (10 pcm no change in fission composition) and a change in fission composition. The analysis demonstrates that monitoring the total count rate in a highly collimated high-resolution photon energy spectrum is sensitive to perturbations imposed into the reactor model. The total photon count rate changes ≈2% for the fission composition change and ≈4.5% for the reactivity insertion compared to the base case. However, both scenarios show an increase in the total photon count rate. The total photon count rate can be used to identify changes due to power (number of fissions) but not due to a change in the material undergoing fission. To distinguish between the two cases of increased power, the photon spectrum would require an intensive analysis technique. A photon peak count rate ratio analysis could be used to identify changes in the fissile material fission generation in the core through identification of a static peak that shows little variation to the source of fission and a highly varying peak. The photon peak strength will ultimately be determined by the isotope’s fission yield. A preliminary analysis investigating the coupling of the isotope’s fission yield and its concentration in the fuel salt derived from the modeling has been performed. A ratio analysis of the photon peak count rates of 140 La to 99 Mo demonstrated that the reactivity insertion creates a distinct difference in the ratio compared to the fission composition change scenario.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

AMS Thermal Cooling System (Final Report)

The Alpha Magnetic Spectrometer (AMS) is a U.S. Department of Energy-sponsored particle physics experiment on the International Space Station (ISS). AMS is exploring some of the most fundamental questions in physics such as understanding dark matter, antimatter, the origin of cosmic rays and their characteristics as well as searching for new physics phenomena in the universe. It has recorded more than 200 billion cosmic rays since its launch in May 2011. Over time, anomalies associated with the dedicated cooling system of the AMS Silicon Tracker system were observed, leading to the discovery of progressive deterioration in the functioning of the cooling system's four redundant pumps. The Tracker is crucial to the scientific mission of AMS, as it is the only subdetector that can distinguish matter from antimatter. This report details the successful program of work for the installation of the Upgraded Tracker Thermal Pump System (UTTPS) on AMS. This program included: identifying the root cause of deterioration in the original pumps; design, production, testing, and integration of the new UTTPS cooling system; launch of the UTTPS to ISS; installation of the UTTPS in AMS across a series of four complex extra-vehicular activities (EVAs); and establishment of a dedicated Flight Simulator Laboratory to test the performance of the UTTPS under various thermal conditions. This program was critical to the success of the AMS experiment, and its successful completion will enable AMS to continue taking data through 2030.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

Assessing the New Home Market Opportunity: Case Study and Cost Modeling for Solar and Storage in 2030

Residential solar and storage markets are growing in the United States. With approximately 1 million new homes constructed every year, this represents a significant opportunity for solar and storage installations. Some homebuilders have begun to build new homes with solar and storage included as a standard offering. It is not clear how solar and storage is incorporated into the new construction process and at what cost. Further, it is unclear what barriers or opportunities exist to scale this model nationwide. To fill this gap in the literature, this research conducts a case study of Mandalay Homes' new solar and storage community in Arizona to gather lessons learned. From this foundation, we further generate a set of pathways to reduce install costs and expand solar and storage market penetration in this sector. To model existing and 2030 solar and storage costs, we use the National Renewable Energy Laboratory's (NREL's) bottom-up cost model. This modeling is further informed by 12 interviews conducted with new home builders, solar contractors, and other subject matter expert organizations. Our case study analysis generated three key considerations for other homebuilders including: 1. Educating local permitting, inspection, and in some cases utility officials on solar and storage products, designs, and code compliant building practices may be required. The need for education may decline as more local governments and utilities review and approve solar and storage projects. 2. Incorporating solar and storage systems into the homebuilding process can add complexity and related coordination challenges. This does not need to result in home construction delays, but can result in costly contractor "dry runs" to construction sites. 3. Deploying solar and storage at the time of new construction has significant economies of scale, which can improve the value proposition of the systems. The case study, extant literature, and interviews were used to model both existing and future solar and storage installation costs at time of new construction. Here, we find three key cost reduction opportunities relating to solar and battery storage hardware, customer acquisition, and overhead. If future contractors can maximize the cost reduction opportunities outlined here, residential new construction costs could decline by 8 - 25% by 2030, depending on the modeled scenario. Though we expect costs to decline through 2030, it is unclear which of these scenarios may ultimately appear. Interviewees further identified a variety of barriers across each cost category that could temper the savings shown here. At the same time, interviewees described several pathways to scale the new construction solar and storage market, beyond installation cost savings. Interviewees confirmed that changes in finance, rate design, resilience policies, deployment mandates, and DER aggregation could all support more market adoption than seen today. These findings suggest that there are significant opportunities to expand new construction markets and this research can serve as a baseline to assess progress in this segment through 2030.

14 SOLAR ENERGY↗

DOE OSTI2022

Wind Turbine Drivetrain Reliability [Slides]

Pitch bearings, main bearings, and gearboxes in conventional wind turbine drivetrains often do not meet their 20-year minimum specified lifetime, resulting in turbine downtime as well as expensive, time-consuming repairs or replacements. The dominant failure modes of the drivetrain components and the conditions that lead to their failure are not fully accounted for during product design or routinely modeled for life management. Drivetrain reliability improvements and O&M cost reductions remain top priorities for both land-based and offshore wind turbines, especially as wind turbines continue to be deployed in increasingly remote and offshore locations, continue to increase in size, and are becoming expected to be in service beyond their original design life, all of which correspond to an increase in the impact of any reliability issues on O&M costs. This presentation summarizes the most recent activities by NREL and ANL on drivetrain reliability.

17 WIND ENERGY↗

DOE OSTI2022

Circular economy as a climate strategy: current knowledge and calls-to-action

Existing pledges and NDC targets, even if fully achieved, are still not sufficient to meet the Paris climate goals. Considerable additional strategies and actions are urgently needed to close the emission gap. Built environment, transport, food system, and clean energy are the most relevant sectors for circular economy strategies to deliver climate change mitigation benefits. Circular economy strategies can complement decarbonization measures to further reduce GHG emissions from material production, help lower emissions from operational energy use in the built environment and transport, and cut emissions from waste management. The largest potential GHG emissions reductions through circularity come from consumption side measures and product design measures. Circular economy strategies can support a sustainable clean energy transition, by helping relieve the mineral supply pressure, increasing supply chain resilience, preventing new waste challenges, accelerating the adoption of clean energy technologies, as well as maximizing their climate benefits. Furthermore, circular economy strategies can help enhance adaptation to climate change. Nine calls-to-action are put forward, for government, business, and civil society leaders to accelerate circular economy strategies with the highest potential for climate benefits, and for the research community to close critical knowledge gaps.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Activity Theory Literature Review

Complex challenges across Sandia National Laboratories' (SNL) mission areas underscore the need for systems level thinking, resulting in a better understanding of the organizational work systems and environments in which our hardware and software will be used. SNL researchers have successfully used Activity Theory (AT) as a framework to clarify work systems, informing product design, delivery, acceptance, and use. To increase familiarity with AT, a working group assembled to select key resources on the topic and generate an annotated bibliography. The resources in this bibliography are arranged in six categories: 1) An introduction to AT; 2) Advanced readings in AT; 3) AT and human computer interaction (HCI); 4) Methodological resources for practitioners; 5) Case studies; and 6) Related frameworks that have been used to study work systems. This annotated bibliography is expected to improve the reader's understanding of AT and enable more efficient and effective application of it.

42 ENGINEERING↗

DOE OSTI2023

Computed Tomography (CT) Analysis of 3D Printed Lattice Structures

LATTICE structures are increasingly used in product design across different industries, including the Department of Energy (DOE), due to their high strength and lightweight properties. These structures possess qualities such as high stiffness, energy absorption, large surface area, and structural support. To ensure lattice structures' quality and symmetry, it is crucial to have defect-free structures. However, in some cases, traditional non-destructive evaluation methods may not be practical due to encasing lattice structures in material. To analyze the lattice structures' quality, this project will employ CT imaging to gain access to the encased structures and perform a detailed analysis of each section. Three 3D printed complex lattice cubes were created, with two exposed and one encased in material, for this project. The CT X-ray cabinet will be used to scan all three cubes, and the data collected will be reconstructed and evaluated using complex interpretation software. This analysis will allow for a detailed examination of the structure's porosity, inclusions, cracks, wall thickness, and symmetry in each section.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Onset of Fluidization in MP-PIC Simulations using MFIX-Exa

Fluidized bed reactors are used across a variety of industries, including for energy processes like pyrolysis that result in low-cost energy products. Design and scale-up of fluidized beds is de-risked by modeling and simulation, utilizing tools like NETL’s MFIX-Exa High-Performance Computing (HPC) code for reacting multiphase flow. This report summarizes an investigation into the breadth of problems to which MFIX-Exa may be applied, specifically with regard to low fluid velocities and the onset of fluidization. A simple fluidization study is conducted both experimentally and numerically for particles of interest, then reactor simulations are compared to cold flow experiments for uniform distributor plates. Approaches for modeling bubble caps are also presented.

discrete particle method↗

DOE OSTI2020

The CYBER security – Competency Health and Maturity Progression (CYBER-CHAMP) model: Extending the National Initiative for Cybersecurity Education (NICE) Framework Across Organizational Security

Problem Statement: There is a pervasive talent deficit in the cybersecurity industry that prevents employers from being able to fill their open positions efficiently. A holistic approach to security is required to ensure organizations have adequate prevention and response capabilities in case of a cyberattack. Specifically, industrial control systems (ICS’s) and their operational technology (OT) components have become a constant target for cyberattacks. Research Questions: It is proposed that the NICE Framework should be extended in the following areas: 1) Include guidance regarding the job roles and competencies for both IT and OT professionals. 2) Offer step-by-step solutions, based on the work role mappings from the NICE Framework, to increase cybersecurity through employee training and education. 3) Provide a streamlined, lifecycle approach to building a cybersecurity program. Contribution: The CYBER security – Competency Health and Maturity Progression (CYBER-CHAMP©) model provides a customized solution for businesses to understand their education gaps in organizational security and target areas for improvement. Rationale: The Framework for Improving Critical Infrastructure Cybersecurity v1.1 addresses ICS but does not offer a measurement of cybersecurity maturity or clear methods to ascertain an organization’s current risk profile. In Phases 1 and 5 of the model, measurements are provided to help an organization build their current and target risk profiles. The NICE framework provides a structure for planning an IT cybersecurity workforce, but the OT aspects of cybersecurity are only briefly discussed. The model uses Phases 2-3 to examine the competencies of an organization’s workforce, which includes both IT and OT roles. Current frameworks do not offer next steps to increase an organization’s cybersecurity. During Phase 4, employees’ roles are mapped to training, education, and/or certifications from common vendors. Investigative Approach: The model provides measurements and metrics for both an organization’s status and continual improvement. This improvement methodology includes guidance for creating an overall strategic plan for security improvement via products designed to increase an organization’s operational readiness through workforce competency health. Lessons Learned: Depending on who was participating, there were contradicting answers given in Phase 1 due to different security cultures in the organization. This revelation has influenced the steps listed in the User’s Guide, where Phase 1’s first recommended step is to assemble a team that champions the facilitation and implementation of the model in the organization. During Phase 2, the discovery was made that organizations may be missing roles that are necessary to perform critical cybersecurity functions. By understanding the functional roles and competencies needed, they can contract or hire cybersecurity help to fill these gaps. Implications: Using the model, organizations can discuss quantitative measures for improvement as a business case for advancing their security program. Future research can validate and extend the present theory and model to a variety of environments. It is of interest to investigate additional security roles and knowledge domains that are used to build standardized cybersecurity curriculum.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Drivetrain Reliability Collaborative Update

bearing↗

DOE OSTI2021

Correlating Catalyst Design and Discharged Product to Reduce Overpotential in Li-CO 2 Batteries

Li-CO 2 batteries with dual efficacy for greenhouse gas CO 2 sequestration and high energy output have been regarded as a promising electrochemical energy storage technology. However, battery feasibility has been hampered by inferior electrochemical performance due to large overpotentials and low cyclability primarily caused by the difficult decomposition of ultra-stable Li 2 CO 3 during charge. The use of cathode catalysts has been highlighted as a promising solution and catalyst properties, as well as the nature of discharge products, are closely correlated with electrochemical performance. Here, the catalyst design strategies that include active site enrichment, electrical transport enhancement, and mass transfer improvement are summarized. Catalyst effects on product decomposition are then subsequently introduced, while product geometry and chemical composition will be explored, with an emphasis on the formation/decomposition of Li 2 C 2 O 4 instead of Li 2 CO 3 . Building on previous research, future directions that facilitate improvements in catalyst design are put forward to reinforce the fundamental development of Li-CO 2 batteries.

25 ENERGY STORAGE↗

DOE OSTI2024

Numerical Simulations in Support of a Long-Term Test of Gas Production From Hydrate Accumulations on the Alaska North Slope: Water Production and Associated Design and Management Issues

Here, we investigated numerical simulation strategies for a long-term test of depressurization-induced gas production from the B1 Sand of Unit B at the Hydrate-01 Stratigraphic Test Well. The main objective of this study was to estimate fluid production rates (with emphasis on water production) under a variety of conditions and production scenarios and contribute new insights to the design and management of the field test. In the first part of the study, we investigated the system response to a three-step depressurization process using two limiting sets of flow properties─the expected maximum and minimum intrinsic and effective permeabilities─for the very heterogeneous reservoir. In the second part, we investigated the effect of the production interval length and placement within the formation relative to the boundaries of the hydrate-bearing unit. The best performing well configuration was used in the third part of the study, which used the most representative subsurface flow properties to investigate the effect of the depressurization strategy on the production performance. The best overall performance (largest gas production with modest water production and a strong response at the observation wells) was obtained with a 10 m-long well situated 3 m below the top of the formation and a three-step depressurization scheme at 15-day intervals to a terminal bottomhole pressure of 2.8 MPa. The overall production performance was enhanced by a faster rate of depressurization. Estimated water production rates in all cases were limited and easily manageable. None of the tested well configurations or depressurization strategies significantly reduced water production without also severely reducing gas production. In all the investigated cases, 95% of the long-term fraction of produced water was replenished by inflows from the boundaries and could not be reduced. These substantial water inflows are an unavoidable feature of HU-B and cannot be easily mitigated by a hydraulic control.

02 PETROLEUM↗

DOE OSTI2025

Redefining Design for Remanufacturing: A Practical Methodology for Prioritizing Remanufacturing Design Rules

Products are often discarded when they fail or no longer meet user needs. These outcomes are frequently shaped by early design decisions. While remanufacturing offers a sustainable alternative by restoring products to like‐new condition, its potential is often limited by designs that do not consider remanufacturing from the outset. This research addresses that challenge by introducing a structured Design for Remanufacturing (DfRem) methodology and a CAD‐integrated tool to support real‐time design decisions. The DfRem framework introduces a new primary design function focused on preserving product functionality across its life cycle. It is supported by a fault tree that identifies failure modes that limit remanufacturing potential and a hierarchy of design principles including Prevent, Minimize, Relocate, Restore, and others. Each principle is linked to actionable design rules that help engineers reduce the need for remanufacturing or improve its efficiency when necessary. To operationalize this framework, we developed CAD plugins for Autodesk Inventor and PTC Creo. These tools use a state machine model to present prioritized design rules based on selected failure modes and user input. By embedding DfRem logic directly into widely used CAD environments, the tool enables engineers to make sustainability‐informed decisions without disrupting existing workflows. Furthermore, this approach highlights the critical role of design in enabling circular and resource‐efficient product development, making remanufacturing a more practical and accessible strategy during the early stages of product design.

CAD↗

DOE OSTI2023

Evaluation of a High-Power Target Design for Positron Production at CEBAF

A source for polarized positron beams at the Continuous Electron Beam Accelerator Facility (CEBAF) at Jefferson Lab is being designed. The Polarized Electrons for Polarized Positrons (PEPPo) concept is used to produce polarized e$^+$e$^-$-pairs from the bremsstrahlung radiation of a longitudinally polarized electron beam interacting within a high-Z conversion target. The scheme under consideration includes a 4 mm thick tungsten target that absorbs 17 kW deposited by a 1 mA continuous-wave electron beam with an energy of 120 MeV. The concept of a rotating tungsten rim mounted on a water-cooled copper disk was explored. The results of ANSYS thermal and mechanical analyses are discussed together with FLUKA evaluations of the radiation damages.

Ushakov, A.↗

DOE OSTI2023

Evaluation of a High-Power Target Design for Positron Production at CEBAF

Ushakov, A.↗

DOE OSTI2021

VFA Biorefinery Design for Informed Production of Ground and Aviation Fuels

The rising demand for low-carbon intensity fuel options requires evaluation of a system which can support their production economically and sustainably. Volatile fatty acids (VFAs) ranging from C2 to C8 can be derived in high yield from arrested anaerobic digestion of biomass. This talk provides an overview of our work in which we upgrade wet waste-derived VFAs using ketonization to elongate their carbon backbone to reach a range relevant to jet or diesel fuels. Kinetic models were used to predict ketone profiles from varying VFA profiles, thereby informing potential carbon flow to either (a) mixed paraffins for use in diesel or aviation fuel, or (b) ethers for use in diesel fuel. To do this, the anticipated products were screened for critical fuel characteristics using predictive tools. The criteria for neat and blended bioblendstocks were chosen based on conventional petrofuel requirements, and they were applied to inform fuel targets, identify limiting characteristics, and guide conversion development. While paraffins can serve as either diesel or aviation fuels, the latter has stringent criteria which include a precise distillation curve range tied to carbon distribution. Fuels which fall outside this range typically fail to meet other property metrics, and as such flashpoint and viscosity were identified as potentially limiting properties of this VFA aviation fuel. However, paraffin fractions which fall outside aviation criteria may meet diesel fuel requirements, which are looser except for the flashpoint minimum. Flashpoint was also a concern for smaller VFA diesel ethers, which posed an additional oxygenate risk of high water solubility. This fuel-informed conversion design process was demonstrated through production of paraffins with reduced sooting as compared to petrodiesel (~34%), and increased renewable aviation fuel blend levels (>70%). VFA-derived ethers improved petrodiesel by increasing fuel autoignition quality by 56% and reducing sooting by 86%. These VFA aviation and diesel fuels could enable greenhouse gas (GHG) reductions of over 165% and 50%, respectively, relative to their purely fossil-derived counterparts. Collectively, this work provides (i) an overview of how we leveraged the flexibility of VFAs for fuel production; and (ii) insight into the potential of a VFA biorefinery to accommodate varied feed and fuel applications, while also considering the merit of tailored fuel production pathways and GHG reduction potential.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Application of Box-Behnken design in optimizing product properties of supercritical methanol co -liquefaction of rice straw and linear low-density polyethylene

We report co-processing of plastic and biomass wastes to produce high-quality fuel has been attracting considerable interest in energy recovery. This work employed Box-Behnken Design (BBD) to optimize yield and properties of oil from supercritical methanol (scMeOH) co-liquefaction of rice straw (RS) and linear low-density polyethylene (LLDPE). Three independent variables of reaction temperature (270, 300, and 330°C), holding time (60, 90, and 120 mins), and RS/LLDPE mass ratio (0.15, 0.50, and 0.85) were selected for experiments. A maximum oil yield of 34.17 wt% was achieved at 303°C, 96 mins, and RS/LLDPE ratio of 0.59 according to BBD. Temperature and RS/LLDPE ratio dominated the oil yield and synergistic effects during co-liquefaction, whereas time was an insignificant factor. Optimum oil from co-liquefaction contained substantial hydrocarbons content of 32.91% compared to that from single RS-derived oil of 7.77%. Solid product obtained at the optimum condition could be used as solid fuel, due to its relatively high HHV of 43.08 MJ/kg compared to the other solid fuels (13.90–32.14 MJ/kg). This work provides a deep understanding of the co-processing of solid biomass and plastic wastes.

09 BIOMASS FUELS↗