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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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1,663 records · Page 5

The U.S. Fusion Materials Community Roadmap: Near-term research priorities for the development of plasma-facing and structural materials for fusion power plants

In response to the needs of a rapidly growing private fusion industry, the U.S. Fusion Materials Coordinating Committee (FMCC) and the broader U.S. fusion materials research community undertook an extensive effort to create a comprehensive roadmap for fusion materials development. The result of this effort was the U.S. Fusion Materials Community Roadmap (US-FMCR), which describes the steps needed to advance the technical maturity of leading candidates for plasma-facing materials and structural materials for fusion power plants from laboratory-scale experiments to a point of sufficient technological readiness for industrial adoption and implementation. However, researchers face significant resource constraints as well as very aggressive pilot plant development timelines. Thus, the research strategies detailed in the US-FMCR require further assessment to downselect the specific tasks that must be prioritized within the next two to three years, in order to make the most efficient use of funding, human resources, and experimental facilities. This paper presents an overview of the US-FMCR and its development process. We also present the subset of research objectives that the FMCC identified as the most urgent research priorities for the U.S. fusion materials research community. The state-of-the-art of materials research is also highlighted for each class of materials considered in the US-FMCR. The recommendations presented here integrate an extensive evaluation of the current status of fusion materials research with a broad cross-section of opinion from the wider U.S. fusion community.

Ferry, Sara [Massachusetts Institute of Technology

Technology & Design Innovations to Maximize the Reduction Effect on DCFC Unit Cost Economics (Max‐REDUCE)

With the high cost and reliability issues of DCFC infrastructure the project specifically addressed the needs of innovating on the AC to DC power conversion. We proved the integration of a new power module into existing charger units, and that theoretical educational work on single stage energy conversion is commercially viable, and a reduced cost compared to existing methods. Our A sample shown 3 PH 480VAC 60hz to 350VDC 8.5kW power transfer, and our software and simulation proved efficiency greater than 97% from 20kW to > 60kW, over the DC output voltage range 200 – 1200V. The project was stopped before we could implement B sample and execute full power testing, validation and integration into a demonstration charger (budget period 3).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Vehicle Technologies Program: Energy Storage R&D (2008 Annual Progress Report)

One of the primary objectives of the Energy Storage effort is the development of durable and affordable advanced batteries (and ultracapacitors) for use in a full range of vehicle applications, from start/stop to full-power HEVs, EVs, and PHEVs. The battery technology development activity spans three areas: system development of full battery systems; benchmark testing of emerging technologies in order to remain abreast of the latest industry developments; and Small Business Innovative Research (SBIR) to fund early-stage R&D for small businesses/entrepreneurs.

25 ENERGY STORAGE

Triggerable adhesives with infinite working life for large area application

Oak Ridge National Laboratory (ORNL) Manufacturing Demonstration Facility (MDF) entered a User Proposal with Perseus Materials in Knoxville, TN. By reinventing how composites are made, we unlock a new era of structural materials: faster to produce, easier to assemble, and strong enough for real-world scale. Perseus Materials was targeting the wind turbine industry to make large adhesive joints for composite turbine blades without the limitations of cure time and room temperature cure without the needs to have work times. The triggerable aspect would increase manufacturing rates for composite wind turbine blades.

36 MATERIALS SCIENCE

ER4047 Filler Wire Development - Initial Studies

This report describes the results of bead on pipe welding trials for the purpose of evaluating commercial off the shelf (COTS) 0.047” ER4047 filler material vendors for down selection of the of best candidate filler material for future Gas-metal Arc Welding (GMAW) development efforts. Four candidate COTS ER4047 filler wires were evaluated during this work - Astrolite, Alcotec, Hobart, and Lincoln. The storage condition of each of these filler wires was documented and visual inspection was performed.

36 MATERIALS SCIENCE

Assessment of Molybdate Based Corrosion Inhibitor for use at the Savannah River Tank Farm Cooling Water System

The Savannah River Site (SRS) has relied on 51 underground storage tanks, many dating back to the 1950s, to store radioactive liquid waste generated from nuclear processing and radionuclide production. These tanks use carbon steel cooling coils, cooled by soft, acidic water, to dissipate the decayed heat produced by radioactive waste. For decades, following historical industry practices, chromate has been added to the cooling water (~450 ppm at pH 9-11) to effectively inhibit corrosion, ensuring cooling coil longevity. Inspections of failed coils reveal that chromate-treated surfaces are generally well-preserved.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W

Converting Second‐Order Saddle Points to Transition States: New Principles for the Design of 4π Photoswitches

Abstract Molecular photoswitches have demonstrated potential for storing solar energy at the molecular level, with power densities comparable to commercial batteries and hydroelectric energy storage. However, development of efficient photoswitches is hindered by limitations in cyclability and optical properties of existing materials. We here demonstrate that certain limitations in photoswitches based on electrocyclizations stem from the issue of controlling competition between Woodward‐Hoffmann allowed and forbidden pathways. Our approach moves beyond the traditional view of activation barriers and reveals that second‐order saddle points are crucial in dictating the competition between disrotatory and conrotatory pathways. These insights suggest new opportunities to manipulate the competition between these pathways through geometric constraints, fundamentally altering the connectivity of the potential energy surface. Our study also emphasizes the necessity of multi‐reference methods and the need to conduct higher‐dimensional explorations for competing pathways beyond photoswitch design.

Chemistry

Testing and Validation of Wireless Communication Architecture for Heliostat Fields: SIPS Final Report

This work focuses on the development and testing of a low-cost wireless communication system for heliostat fields, enabling significant capital costs reductions for concentrating solar thermal systems. Outputs of this work include a working demonstration of a multi-node communication system, clear reporting of system performance, and technical documentation of system development and architecture for reproducibility. Through this process, an open-source repository was created for manufacturing hardware at ~$30/heliostat. The system includes software for cybersecurity, achieving sub-second communication latencies and derisking of hardware for eventual scale-up to tens of thousands of heliostats. While the system is not currently off-the-shelf ready, there is now a clearly defined pathway for scaling up and completing the commercial development process.

14 SOLAR ENERGY

Electrocatalytic grafting of polyvinyl chloride plastics

Polyvinyl chloride (PVC) plastics require high loadings of plasticizers and stabilizers to achieve commercially useful bulk properties. However, these non-covalent additives leach from PVC over time, resulting in the loss of their tailored functionality. This work details the electrocatalytic functionalization of PVC to covalently graft plasticizing additives directly onto the polymer backbone. Here, mechanistic insights guided the design of electrocatalysts capable of modifying C–Cl bonds of PVC under mild conditions with high selectivity while suppressing side reactions such as elimination and chain scission. Functional groups that mimic PVC plasticizers are covalently installed into the backbone of PVC to create new materials with distinct bulk properties from the original polymer. The degree of polymer grafting is easily controlled by simply changing the redox capacity that is passed during electrolysis. This strategy is employed to create chemically- and leach-resistant PVC materials by directly electrolyzing mixtures of consumer PVC products

Zackasee, Jordan L.S.

Enhanced Preparation for Intelligent Cybermanufacturing Systems (EPICS)

Opportunities exist for realizing transformative advances in productivity and reductions in energy footprint through ubiquitous sensing in manufacturing environments. Enhanced Preparation for Intelligent Cybermanufacturing Systems (EPICS) is a 21-month (4 academic semesters, plus one summer) experience for graduate students that focuses on scaling the knowledge, understanding and leadership skills in the cyber manufacturing area. Masters students (8/year, 32 total) complete 2-year projects on industrially-driven project topics, rotating to internships in summer semester to work on scoping and implementation at project partners. Students complete academic training in embedded systems, process modeling, data science, and cloud-based systems design. Their projects are targeted toward sensor retrofit, process monitoring, root cause analysis, and sensor fusion.

Advanced Manufacturing

A multiscale packed-bed reactor model for sustainable ethylene production via chemical looping oxidative coupling of methane

The rising global warming concerns and shale gas discovery have prompted research in the direction of greenhouse gas (GHG), such as methane, reduction and conversion. Oxidative coupling of methane (OCM) offers a pathway to low carbon-intense valorization of methane while producing ethylene, a chemical regarded as central to the petrochemical industry. Even after decades of OCM discovery, researchers keep understanding the process and underlying chemical reactions in a pursuit to achieve industrial viability for OCM. Here, in general, OCM suffers from low C 2 selectivity, yield and reactor temperature runaways due to highly exothermic nature of its reactions. Computational Fluid Dynamics (CFD) tools help analyze spatial gradients within the reactor to deeply understand the diffusion of species, mass and heat transfer phenomena. Furthermore, challenges associated with scaling up such as hot spot formation and parametric sensitivity can be addressed without having to expend on costly experiments. The current paper presents a multiscale packed-bed reactor CFD model coupled with a chemical kinetic model for the chemical looping OCM. The CFD model includes two scales i.e., macroscale for catalyst bed and microscale for individual pellets. Moreover, a chemical kinetic model based on 10 gas-phase reactions is integrated with the CFD model. An additional surface reaction for the formation of gas-phase oxygen from catalyst surface is added to account for the absence of feed oxygen. The model is calibrated against experimental results. The calibrated model captures trends in CH 4 conversion, C 2 selectivity and C 2 yield within a ± 4.35 % range across a temperature range of 700-900 °C. Moreover, model fidelity is evaluated by varying key computational parameters such as mesh resolution and time step size. The model is also verified by varying the inlet methane concentration and the gas hourly space velocity (GHSV) and comparing the results with literature. A sensitivity analysis and scale-up of the current model is undergoing.

Chemical looping

Robust and High Throughput Tools for Characterization of Wet Cellulosic Biogas Feedstocks and Co-Products: Cooperative Research and Development Final Report, CRADA Number CRD-21-21472

This project will develop standardized analytical procedures to support understanding of the chemical composition of wet manure feedstocks, and the digestate formed following anaerobic digestion of organic waste to produce renewable natural gas (RNG). The developed methods will be validated to improve component mass closure, eliminate ambiguities around key constituents, and document the precision and accuracy of the methods. Following validation of the analytical laboratory methods for characterization of wet organic waste feedstocks and digestate, NLR will use the same samples to build and validate near-infrared (NIR) models for high throughput analysis, potentially deployable at commercial facilities, enabling increased production of low carbon intensity RNG from wet organic wastes.

09 BIOMASS FUELS

Initial Feasibility Assessment and Broader Strategy Development for Fiber Integration via Advanced Manufacturing

Structural health monitoring is critical for ensuring the operational safety and cost-competitiveness of the developing advanced reactor designs. The extreme operational envelopes of these advanced architectures, having operating temperatures ranging 400°C–1,000°C and heightened displacement damage doses, render conventional commercially available piezoelectric transducers and resistive strain gauges unviable. Optical fiber sensors present an attractive solution for advanced radiation-hardened instrumentation due to their high thermal stability and distributed sensing capabilities. However, their deployment in embedded applications can be hindered by the severe thermomechanical strain driven by the coefficient of thermal expansion mismatch between fused silica glass and structural metal alloys like stainless steel (e.g., SS316L).

36 MATERIALS SCIENCE

Phase 1 Engagement Summary: Rural Alabama

An Alabama community coalition received technical assistance through the U.S. Department of Energy's Communities Local Energy Action Program (LEAP) to expand awareness of alternative transportation fuels through stakeholder engagement efforts. Phase 1 of the project centered on outreach, relationship-building, and the identification of community priorities. Through two workshops held in October and December 2024, the coalition engaged over 120 stakeholders - including county commissioners, school district representatives, and public and private fleet operators. These sessions included presentations from technical experts and industry partners, as well as a vehicle showcase and structured discussions to assess stakeholder needs and concerns. This report summarizes these efforts and identifies three key priority areas for Phase 2 of the project.

29 ENERGY PLANNING, POLICY, AND ECONOMY

3D Printing ofThermally Responsive Shape Memory LiquidCrystalline Epoxy Networks

Abstract A two-component liquid crystalline epoxy network (LCEN) with shape memory behavior was developed and evaluated as a candidate material for 3D printing. The cure kinetics of the uncured material and the shape memory properties of the cured LCEN were investigated by using parallel plate rheology and dynamic mechanical analysis, respectively. A commercially available fumed silica additive was introduced to the neat, uncured material to improve the rheological properties for 3D printing. The addition of fumed silica was found to increase the yield stress, shear-thinning behavior, and toughness of the uncured epoxy ink. Polarized light microscopy, differential scanning calorimetry, and wide-angle X-ray scattering measurements between the neat and additive-modified LCEN suggested a reduction in liquid crystalline alignment in the modified LCEN, owing to interactions between crystalline domains and fumed silica, which in turn influenced the mechanical behavior. Overall, the additive was found to be successful in preserving the shape memory properties of LCEN while improving its printability.

Chemistry

A fully light-driven approach to separate carbon dioxide from emission streams

Carbon capture from industrial point sources is an essential component of the global effort to mitigate climate risks. However, traditional approaches require significant energy input—often provided, counterproductively, by fossil fuel combustion. Using sunlight directly as the energy source would significantly improve the energy efficiency of carbon capture processes. Herein, we report the first fully visible-light-driven CO 2 separation system, in which carbon capture is achieved via the photoenolization/addition reaction of inexpensive 2-methylbenzophenone with CO 2 , and CO 2 release is realized through an intramolecular photodecarboxylation reaction. Finally, this system operates isothermally, works with natural sunlight, and facilitates CO 2 removal from natural gas flue emissions, providing a blueprint for other non-thermal chemical separations.

Ahmad, Bayu I. Z. [Cornell Univ., Ithaca, NY (Unit

Light–Material Interactions Using Laser and Flash Sources for Energy Conversion and Storage Applications

Abstract This review provides a comprehensive overview of the progress in light–material interactions (LMIs), focusing on lasers and flash lights for energy conversion and storage applications. We discuss intricate LMI parameters such as light sources, interaction time, and fluence to elucidate their importance in material processing. In addition, this study covers various light-induced photothermal and photochemical processes ranging from melting, crystallization, and ablation to doping and synthesis, which are essential for developing energy materials and devices. Finally, we present extensive energy conversion and storage applications demonstrated by LMI technologies, including energy harvesters, sensors, capacitors, and batteries. Despite the several challenges associated with LMIs, such as complex mechanisms, and high-degrees of freedom, we believe that substantial contributions and potential for the commercialization of future energy systems can be achieved by advancing optical technologies through comprehensive academic research and multidisciplinary collaborations.

Materials Science

Multi-Resolution UAV Path Replanning for Inspection of Tailings Dams

Autonomous inspection of large and complex structures with a commercial unmanned aerial vehicle (UAV) is a challenging problem that has been addressed in recent years. In this paper, we address the global motion planning problem of creating autonomous inspection missions for UAVs considering photogrammetry constraints. We focus on the inspection of large tailings dams, which are dam structures used to store waste byproducts of mining. Our method uses a prior sparse point cloud of the dam to generate a voxel grid, where paths satisfying photogrammetry constraints are tested for collisions. We then apply the A* algorithm as a local planner to avoid obstacles within the global mission. Moreover, we address the problem of changing routes online by using octree-based multi-resolution grids for efficient and fast pathfinding. Our results, obtained using tridimensional maps of an actual coal mine tailings dam, show that using octrees for multi-resolution motion planning is faster than using a fixed voxel grid in online missions while inspecting large structures.

42 ENGINEERING