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All sources NASA NTRS DOE OSTI

DOE OSTI2025

Surviving nanoscale interfacial stability in extreme thermal expansion contrast Zn(CN) 2 -epoxy resin matrix composites

Here, we report the remarkable stability at the nanoscale matrix-filler interface in a series of overall low coefficient of thermal expansion (CTE) zinc cyanide (ZC)/epoxy resin composites. These interfaces demonstrate the stability of highly contrasting materials. These composites are designed to optimize the properties of both materials: epoxy resins are valued for their high strength, superb chemical resistance, low dielectric properties, and adhesive abilities. ZC, a model flexible framework, exhibits negative thermal expansion (NTE) behavior and compensates for the epoxy resin’s detrimentally large thermal expansion values. Filled resins minimize the native 65 ppm/°C CTE values to 19 ppm/° C over a wide temperature range while maintaining linearity, yielding composites compatible with typical metal and ceramic substrates’—commonly bonded to the resin— 0–20 ppm/° C CTE values. Additionally, with significant intrinsic differences in the materials, we use wide-angle X-ray diffraction and atomic force microscopy to elucidate thermal movement. The ZC/epoxy interface is surprisingly resilient over 1,000 cycles between -55° C and 75° C, extremes typical to aerospace applications. Further, we show that the resin viscosity remains less than 21 Pa*s at up to 30 vol% ZC, an important consideration for workability. We also discuss settling distribution, glass transition temperature, flexural strength, and longevity. All results point favorably towards practical implementation in low thermal expansion application needs: filling the gap in component design.

42 ENGINEERING↗

DOE OSTI2023

Silver nanowire-indium zinc oxide composite flexible transparent conducting electrodes made by spin-coating and photonic curing

Flexible transparent conducting electrodes (TCE) play a critical role in modern technologies. Eliminating the high-temperature annealing of vacuum- or solution-deposited films will increase production throughput and lower the cost of the final products. Photonic curing uses intense pulses of broadband light to induce material transformations instead of heat. In this work, we combine solution deposition and photonic curing, replacing thermal annealing, to fabricate flexible composite TCE films on plastic polyethylene terephthalate (PET) substrates. The composite TCE films are composed of spin-coated silver nanowire-indium zinc oxide layers. Further, the TCE films’ electrical, optical, and morphological properties are investigated and compared to those of commercially available PET/TCE. A sheet resistance of 15 Ω/sq and an average transmittance from 400 – 700 nm of 77% are achieved with the spin-coated and photonic-cured composite flexible TCE films.

14 SOLAR ENERGY↗

DOE OSTI2023

THERMAL ANALYSIS AND DESIGN OF SELF-HEATING MOLDS USING LARGE-SCALE ADDITIVE MANUFACTURING FOR OUT-OF-AUTOCLAVE APPLICATIONS

Autoclave processing is a commonly used state-of-the-art fiber-reinforced composite manufacturing technology, albeit high capital cost, long cycle times and high energy consumption. Alternatively, out-of-autoclave processing reduces the initial and operating costs while producing composite structures with similar quality as that of autoclave parts. Additive Manufacturing (AM) the scaled-up molds for out-of-autoclave process using carbon fiber (CF) reinforced composite offers design flexibility, enhanced mechanical, and thermal properties in addition to reduction in weight and cost. However, heating of these molds using an oven is still expensive and necessitates an energy-efficient heating process. In this study, resistive heating through heating elements embedded within fiber reinforced composite molds is used as an efficient heating mechanism. The goal is to design wire embeddings and determine the optimal heat flux density to achieve a target uniform temperature of 1000C across the mold surface. To this end, numerical analyses were performed to evaluate the temperature distribution across the composite mold surface for a given wire placement and mold configuration. Constant thermal properties of the 20 wt.% short CF reinforced acrylonitrile butadiene styrene (ABS) were used in the thermal analysis. Time taken to reach the steady state temperature was also estimated. Design guidelines for wire embeddings were included to enable efficient manufacturing of fiber-reinforced composites through out-of-autoclave molds.

Pokkalla, Deepak↗

DOE OSTI2021

The Impacts of Distinct Flexibility Enhancements on the Value and Dynamics of Natural Gas Power Plant Operations

The rapid increase of renewable generation and its anticipated continued growth requires greater operational flexibility in modern power systems. Previous studies explored the addition of more flexible resources to improve system flexibility, but this may also be achieved at lower cost by enhancing existing power plants via flexibility retrofits. Potential flexibility upgrades to existing thermal plants include modifications that enable faster ramp rates, increase maximum load levels, decrease minimum load levels, and provide faster and lower cost startup operations. In this paper, we focus on improvements to existing natural gas combined cycle generators, and apply a unit commitment model to analyze the impact that each specific upgrade has on their operational dynamics and profitability from both the system perspective and from the asset owner perspective. We show that the value of each type of flexibility improvement varies depending on the capacity factor and usage pattern of the generator before the upgrade, and that the relative benefit of each type of flexibility varies. We demonstrate diminishing returns to increased flexibility when upgrading multiple generators simultaneously. Sensitivity tests for several shares of renewable generation, different generation mixes and different net load realizations confirm the generality of the results shown.

03 NATURAL GAS↗

DOE OSTI2024

Field Performance of Commercial Building Load Flexibility Using Model Predictive Control

Model Predictive Control (MPC) applied to buildings is starting to see some commercial adoption by companies. However, it is hard to estimate if relative energy cost savings are enough to justify the cost of MPC implementation with few reported demonstrations. In small commercial and residential buildings, a one size-fits-all solution can help reduce implementation costs, while in very large buildings or districts the potential energy cost savings magnitude can cover more tailored solutions. This estimation becomes harder for medium to large commercial buildings, where a one-size-fits-all solution cannot be adopted and potential energy cost savings might not be sufficient to cover a tailored solution. Therefore, value propositions in addition to energy efficiency alone can make MPC technology more attractive through additional energy cost savings. One such value proposition is load shifting in response to dynamic electricity prices. On this aspect, MPC is a key technology to unlock building thermal mass for energy flexibility in response to electric grid conditions. This study shows the experimental results of MPC control of an office building in Berkeley, where different dynamic electricity price profiles were used in the MPC objective function to shift the building load and to calculate hypothetical electricity costs. Results show potential 50% cost savings with respect to the existing controller with the dynamic price scenario.

Zanetti, Ettore↗

DOE OSTI2024

Energy Storage Improves Power Plant Flexibility and Economic Performance

Most existing coal-fired power plants were designed for sustained operation at full load to maximize efficiency, reliability, and revenue, as well as to operate air pollution control devices at design conditions. Depending on plant type and design, these plants can adjust output within a fixed range in response to plant operating or market conditions. The need for flexibility driven by increased penetration of variable and non-dispatchable power generation, such as wind and solar, is shifting the traditional mission profile of thermoelectric power plants in three ways: more frequent shutdowns when market or grid conditions warrant, more aggressive load ramp rates (rate of output change), and a lower minimum sustainable load, which provides a wider operating range and helps avoid costly plant shutdowns. Recent studies have shown that the flexibility of a coal-fired power plant can be improved by energy storage. The objective of this work was to analyze a set of energy storage options and determine their impact on the flexibility and economics of a representative coal-fired power plant. The effect of three energy storage systems integrated with a coal power plant on plant flexibility and economics was investigated. The results obtained in this project show that energy storage systems integrated with a thermal power plant improve plant flexibility and participation in the energy and ancillary services markets, which improves plant financial performance.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Self‐Assembled Metal–Dielectric Hybrid Metamaterials in Vertically Aligned Nanocomposite Form with Tailorable Optical Properties and Coupled Multifunctionalities

Metal–dielectric hybrid metamaterials have attracted increasing research interest in recent years because of their novel optical properties and promising applications in the fields of electronic and photonic devices. Dielectric permittivity is a key parameter that strongly influences the optical properties of materials. By self‐assembling the metallic and dielectric components in a pillar‐in‐matrix structure, a strong anisotropic structure forms and results in opposite signs of permittivity components (i.e., ε || > 0 and ε ⊥ < 0, or vice versa) and exotic optical responses including hyperbolic dispersion in the visible to near‐infrared region. Herein, the main approaches of tuning the permittivity in self‐assembled metal–dielectric vertically aligned nanocomposite (VAN) thin films are reviewed, including tuning the metal pillar density and geometry, film strain state and background pressure during growth, and seeking other metal‐free and complex structure designs. Future research directions are also proposed, including unique approaches to improve their thermal stability, integrate on flexible substrates toward wearable device fabrication, and explore real‐time tunable metamaterials.

Zhang, Di↗

DOE OSTI2021

Lithium substituted poly(amic acid) as a water-soluble anode binder for high-temperature pre-lithiation

Multifunctional binders hold great promise in advanced electrode designs for both fundamental research and practical utilization of lithium-ion batteries (LIBs). The reactions between Si/SiO x -dominated anodes with lithium are expected to be exothermic in principle, while the thermal tolerance along with the volume change makes high-temperature binders attractive for large scale roll-to-roll manufacturing. For instance, if a high temperature binder is also water soluble, it can be compatible with the current graphite-based anode manufacturing process. In this work, we present a water-soluble poly(amic acid)-based binder, which can withstand high temperature for industrial pre-lithiation process and effectively hold active materials together during repeated charge and discharge cycles. This lithium substituted poly(amic acid) binder (denoted as Li-Pa) can serve as a drop-in replacement for environmentally friendly electrode fabrication in large scale by providing aqueous solubility, exceptional thermal stability and mechanical flexibility.

25 ENERGY STORAGE↗

DOE OSTI2026

A robust alloy design (RAD) strategy for next-generation (IV) nuclear fission reactors

Next-generation nuclear reactors demand structural materials capable of withstanding extreme conditions, including high temperatures, intense neutron flux, and corrosive environments. Multi-Principal Element Alloys (MPEAs) have emerged as promising candidates due to their exceptional radiation tolerance, thermal stability, and compositional flexibility. This study introduces a versatile and customizable Robust Alloy Design (RAD) strategy for systematically designing MPEAs for GEN-IV reactor fuel cladding. The RAD framework integrates nuclear-relevant selection criteria, empirical parameter assessments, and high-throughput CALPHAD simulations to efficiently narrow compositional space and identify stable alloys. A unified RAD score developed for the first time, combines key performance metrics, including fuel-clad chemical interaction (FCCI), neutron absorption cross-section (NAC), valence electron configuration (VEC), and melting point factor (MPF), into a flexible ranking system adaptable to reactor-specific priorities. Among 724 candidates, V555(5Al–5Cr–5Fe–85V) emerged as the top alloy, validated experimentally with a homogeneous single-phase BCC microstructure and superior mechanical properties (nano-indentation: 3.389 ± 0.258 GPa; Vickers hardness: 240 ± 6.7 HV), significantly outperforming Zircaloy-4 and V-4Cr-4Ti. Importantly, the RAD strategy is not limited to nuclear applications; its customizable weighting system enables scalability to other extreme environments. This adaptability positions RAD strategy as a versatile tool for advanced materials design across multiple industries.

Alloy design↗

DOE OSTI2023

On the flow-stress model of Preston, Tonks, and Wallace - Observations, parameter constraints, and implementations (Rev. 1)

A detailed discussion about the PTW flow-stress model has been presented, including theoretical considerations, model calibrations to experimental data, and model implementations in LANL ASC hydro-codes. The main findings are: In order to reproduce the intended behavior of the PTW model at high strain rates, the following conditions on the model parameters need to be valid: y 1 ≥ s 0 and y 2 ≥ β ; When the conditions above are not satisfied, PTW and PTW_Mod1 have slightly different behavior in the phonon-drag regime, and should be treated as different models. PTW exhibits a discontinuity above the critical strain rate. PTW_Mod1 does not show such a discontinuity but implies a different strain-rate dependence at high strain rates. Examples of this behavior include older calibrations for stainless steel and depleted uranium; In the thermal-activation regime, some flexibility was introduced in the original PTW model to allow for different rate-dependent behaviors at intermediate strain rates. Example: copper. However, many material calibrations do not require this extra flexibility, and the complexity and ambiguity of the intended behavior can be partially blamed for the inconsistent model implementations across ASC codes; The limit for the material constant p going to zero is well defined and leads to a simplified flow-stress equation, discontinuity free; Modern calibrations of the PTW parameters are done using Impala. Constraints on the PTW parameters are enforced; Implementation of the PTW model in LANL ASC hydro-codes suffered of several shortcom ings. At the time of writing, FLAG and xRAGE contain consistent and correct implemen tations of the PTW and PTW_Mod1 models. Corresponding changes to Pagosa have been suggested.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Quantifying and Optimizing the Energy Benefits of Mass Timber Construction

The International Mass Timber Alliance (IMTA) is a global organization of industry leaders, engineers, scientists, and associations dedicated to advancing mass timber construction. Its mission is to generate and disseminate scientific data supporting the development of standardized construction and energy efficient practices that promote the adoption of mass timber worldwide. IMTA collaborated with Oak Ridge National Laboratory (ORNL) to leverage ORNL’s expertise in building envelope modeling and testing to evaluate how mass timber construction can reduce peak heating and cooling demand, lower overall energy use, and improve resilience during power outages. A previous study of 80 mass timber buildings in Finland found measured energy use up to 50% lower than predicted by simulation. This project aimed to validate and extend those findings for U.S. buildings through analytical modeling, laboratory testing, and full-scale building evaluations. The research focused on the thermal performance of low-embodied-energy wall assemblies, such as cross-laminated timber (CLT) panels and log walls, with particular attention to the effects of thermal inertia on indoor comfort and energy performance. While mass timber’s structural and fire-resistance properties are well documented, its whole-building thermal behavior has received limited attention. Field data, simulation results, and resilience testing from this study will inform future modeling practices, design guidelines, and construction practices by quantifying the unique thermal and demand-flexibility benefits of mass timber construction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Risks and Benefits of Pressurized Water Reactor Coupling to Energy Storage and Water Desalination

This research explored potential options to improve nuclear pressurized water reactors’ (PWRs) operational flexibility through integration with thermal energy storage (TES) and water desalination technologies. Benefits and challenges of TES technologies were reviewed, which includes sensible heat storage systems, latent heat storage systems, and thermochemical storage systems. Water desalination technologies were reviewed and compared, which includes multi-stage flash, reverse osmosis, and multi-effect distillation. The multi-effect distillation technology was selected to be coupled with a generic PWR. Risk of this cogeneration was quantified using the probabilistic risk assessment (PRA) methodology. Results suggest that nuclear-desalination cogeneration can be done safely because the additional risk to the PWR is trivial, and even in certain cases the PWR risk is decreased. This cogeneration operation is expected to improve efficiency of thermal utilization and the nuclear plant’s revenues. In summary, this study supports the potential of nuclear-desalination cogeneration systems to address water scarcity while optimizing nuclear energy use and managing safety.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Hybrid Cooling and Water Treatment for Resilient, Water-Self-Sufficient Data Centers

The continued growth of data center infrastructure is intensifying demand for freshwater resources, particularly in water-stressed regions, and is increasingly limiting sustainable capacity expansion. This work investigates a conceptual hybrid system that integrates freeze desalination with ultrasonic-assisted ice separation to enable on-site production of pure water from diverse sources, including seawater, brackish groundwater, and reclaimed industrial or agricultural wastewater. Simultaneously, the system produces low-temperature cooling streams that enhance heat removal in high power density computing environments. A process-level thermodynamic analysis is performed across a range of boundary and operating conditions, including variations in feed concentration, freezing temperature, and mass flow rate. The results are presented as performance curves relating feedwater concentration and target purified water output to the corresponding intake flow requirements, enabling estimation of source water demand per unit of Information Technology Equipment (ITE) energy consumption (kWh) across varying data center scales and operational scenarios. The corresponding electrical energy consumption for integrated cooling and water treatment is also evaluated as a function of system operating parameters and target water production levels. These results provide a basis for evaluating system feasibility across different conditions and for identifying parameter ranges in which integrated water treatment and cooling improve resource efficiency, thermal performance, and operational flexibility in data centers.

Elhefny, Aly [ORNL] (ORCID:0000000284907923)↗

DOE OSTI2020

Thermal Analysis of Large Area Additive Manufacturing Resistance Heating Composites for Out of Oven/Autoclave Applications

Additive Manufacturing (AM) of carbon fiber (CF) reinforced composite has received growing attention because of the design flexibility, superior mechanical properties, improved thermal properties, and weight reduction. Autoclave tooling was proven to be a successful application for large scale AM technology. The capital cost, and cost associated with heating, and cycle time in a conventional autoclave process is relatively high. Thus, an innovative design of AM mold with an efficient heating scheme is essential. This study represents an innovative method of the resistive heating of composite molds which does not require a room size oven for heating during the curing processing. Therefore, it has the potential to reduce the operating cost drastically. For the design validation and feasibility study, we performed a numerical analysis of the wire embedded and AM mold parts. The goal of this study is to determine and optimize the thermal behavior of the printed mold with embedded wire technology. It is anticipated that the larger distance between the embedded wires along the printing direction (z-direction) increase the cold spot, on the other hand, a close distance of the wire can create the unwanted localize heating, thus melting. Constant thermal properties of the 20 wt.% short CF reinforced acrylonitrile butadiene styrene (ABS) was used for the simulation purpose. Thermal characterization was set to 100°C to avoid the thermal deformation or bulging on the part surface.

billah, Kazi↗

DOE OSTI2020

Thermal Analysis of Large Area Additive Manufacturing Resistance Heating Composites for Out of Oven/Autoclave Applications

billah, Kazi↗

DOE OSTI2020

Thermal Analysis of Large Area Additive Manufacturing Resistance Heating Composites for Out of Oven/Autoclave Applications

billah, Kazi↗

DOE OSTI2023

Design and experimental testing of a 150 kWh thermal battery using thermosiphons embedded in a concrete matrix for power plant flexible operation

One of the options for achieving the global temperature limitation of 1.5 °C target, for the mitigation of global warming, is based on the better penetration of renewables into the electrical grid. This has imposed a burden to fossil fuel fired power plants since they are required to operate away from their baseload mode to compensate for the inherent intermittence of the renewable power. Integrating energy storage with fossil plants is an option to achieve their needed flexibility. A cost competitive energy storage option for the solution is based on storing sensible heat in concrete. Here, this paper reports research results and development of a thermal battery cell (TBC) capable of operating at temperatures up to 425 °C. A novel concept consisting of a concrete matrix for sensible heat storage, engineered to provide enhanced thermal and mechanical properties, and twenty-two thermosiphon elements, engineered for dual action were designed and fabricated into a single thermal energy storage (TES) module. Research for the development of the components for the TBC was performed in the laboratory. Efficient heat transfer, to/from the storage media, was demonstrated under several charging and discharging conditions with a thermal storage capacity of 150 kWh th and a rapid discharge, making the TBC suitable for fast ramping when integrated with a fossil fuel fired power plant. Efficient radial heat transfer to the concrete was observed due to the well designed spacing and location of thermosiphons in the radial direction. A minimal temperature difference of 2 °C, between the thermosiphons bottom and top was obtained, demonstrating the isothermicity of those elements. An overall end-to-end TBC energy-to-energy round trip efficiency of 70% was achieved.

25 ENERGY STORAGE↗

DOE OSTI2023

Techno-Economic and Deployment Analysis of Fossil Fuel-Based Power Generation with Integrated Energy Storage

Most existing coal-fired power plants were designed for sustained operation at full load to maximize efficiency, reliability, and revenues. Depending on plant type and design, these plants can adjust output within a fixed range in response to plant or market conditions. The need for flexibility driven by increased penetration of variable and non-dispatchable power generation such as wind and solar is shifting traditional mission profile of thermoelectric power plants in three ways: more frequent shutdowns when market or grid conditions warrant, more aggressive load ramp rates (rate of output change), and lower minimum sustainable load, which provides a wider operating range and helps avoid costly plant shutdowns. The recent studies have shown that flexibility of a coal-fired power plant can be improved by the energy storage. The objective of this project was to analyze a set of energy storage options (technologies) and determine their impact on flexibility and economics of a representative coal-fired power plant. The effect of five Energy Storage Systems (ESSs) integrated with a coal power plant on plant flexibility and economics was investigated in this study. The results obtained in this project and presented in this report showed that ESS integrated with a thermal power plant improves plant flexibility and participation in the Energy and Ancillary Services markets and also improves plant financial performance.

20 FOSSIL-FUELED POWER PLANTS↗