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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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DOE OSTI2026

Measuring labor productivity dynamics in U.S. industrial and electric power sectors: a case study (2014–2023)

This study proposes a subsystem methodology for measuring labor productivity in the U.S. industrial and electric power sectors by leveraging public data available between 2014 and 2023. Building on Pasinetti’s framework and subsequent developments, the approach employs Vertically Integrated Sectors (VIS) to account for both direct and indirect productivity effects. The novelty of this work is twofold. First, it enables the estimation of productivity trends over time, providing a robust foundation for empirical analysis. Second, it applies the methodology to a case study of the electric generation sector, highlighting its practical relevance. Using data from the Bureau of Economic Analysis, the Bureau of Labor Statistics, and the Impact Analysis for Planning (IMPLAN) tool, the study reveals significant discrepancies between conventional productivity measures and those derived from the VIS approach. Furthermore, the proposed method aligns with the principles of Integrated Energy Systems by capturing the interrelations among generation, distribution, storage, and consumption. This alignment underscores its utility and applications for energy-related policy and planning. Overall, the findings contribute to more precise labor productivity assessments, supporting informed decision-making and future research. Additionally, the method highlights the importance of considering the whole supply chain, providing interrelated metrics for labor productivity which includes both, direct and indirect effects on the final labor productivity metric. By incorporating intersectoral dependencies, this method offers a more comprehensive and accurate measure of labor productivity compared to traditional metrics.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Blockchain Research and Development Activities Sponsored by the U.S. Department of Energy and Utility Sector

This article provides an in-depth analysis of blockchain research in the energy sector, focusing on projects funded by the U.S. Department of Energy (DOE) and comparing them with industry-funded initiatives. A total of 110 funded activities within the U.S. power industry were successfully tracked and mapped into a newly developed categorization framework. This framework is designed to help research agencies to systematically understand their funded portfolio. Such characterization is expected to help them make effective investments, identify research gaps, measure impact, and advance technological progress to meet national goals. In line with this need, the proposed framework proposes a 2-D categorization matrix to systematically classify blockchain efforts within the energy sector.Under the proposed framework, the Energy System Domain serves as the primary classification dimension, categorizing use cases into 30 distinct applications. The second dimension, Blockchain Properties, captures the specific needs and functionalities provided by Blockchain technology. The aim was to capture blockchain’s applicability and functionality: where and why blockchain? Principles behind the selection of the viewpoint dimensions were carefully defined based on consensus obtained through the Blockchain for Optimized Security and Energy Management (BLOSEM) project. The mapped results show that activities within the Grid Automation, Coordination, and Control (31.8%), Marketplaces and Trading (25.5%), Foundational Blockchain Research (19.1%), and Supply Chain Management (17.3%) domains have been actively pursued to date. The three leading specific use case applications were identified as Transactive Energy Management for Marketplaces and Trading, Asset Management for Supply Chain Management, and Fundamental Blockchain for Foundational Blockchain Research. The Marketplaces and Trading and Retail Services Enablement domains stood out as being favored by industry by a factor greater than 2 (2.3 and 2.6, respectively), yet there seemed to be little to zero investment from DOE. Approximately 76% of the total projects prioritized Immutability, Identity Management, and Decentralization and/or Disintermediation compared to Asset Digitization and/or Tokenization, Automation, and Privacy and/or Anonymity. The greatest discrepancies between DOE and industry were in Asset Digitization and/or Tokenization and Automation. The industry efforts (36% in Asset Digitization/Tokenization and 22% in Automation) was 14 times and 2.4 times, respectively, more intensive than the DOE-sponsored efforts, indicating a significant discrepancy in industry versus government priorities. Overall, quantifying DOE-sponsored projects and industry activities through mapping provides clarity on portfolio investments and opportunities for future research.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

BOTTLE 2 - Analysis

The use of analysis is foundational to BOTTLE. In particular, we conduct techno-economic analysis (TEA), life cycle assessment (LCA), and supply chain modeling for each new BOTTLE innovation, spanning new deconstruction and upcycling technologies to redesigned polymers. These critical analysis tools are used in parallel with laboratory research to ensure that BOTTLE technologies can ultimately meet our key metrics. The BOTTLE team used analysis early in the current 3-year project cycle to identify research priorities from a scale, energy, and economics perspective (Nicholson et al., Joule 2021), and recently we presented a comprehensive framework for comparing new circularity-focused approaches to linear, incumbent practices (Nicholson et al., Ann. Rev. Chem. Biomolec. Eng. 2022). This presentation will also review case studies in analysis for closed-loop PET recycling across a range of recycling methods, baseline studies that we have conducted for plastics pyrolysis and gasification as another comparator for BOTTLE technologies, and a comprehensive study of existing closed-loop recycling technologies from a full suite of environmental impacts and feedstock quality metrics. We have undertaken studies of circular polymers being developed in the Redesign task, and we will present an exemplary case for a bio-based acrylic polymer that can replace polymethyl methacrylate. Overall, analysis is critical to enable the BOTTLE Consortium to focus on impactful, realistic technologies.

BIOMASS FUELS↗
DOE OSTI2014

3D high-content screening for the identification of compounds that target cells in dormant tumor spheroid regions

Cancer cells in poorly vascularized tumor regions need to adapt to an unfavorable metabolic microenvironment. As distance from supplying blood vessels increases, oxygen and nutrient concentrations decrease and cancer cells react by stopping cell cycle progression and becoming dormant. As cytostatic drugs mainly target proliferating cells, cancer cell dormancy is considered as a major resistance mechanism to this class of anti-cancer drugs. Therefore, substances that target cancer cells in poorly vascularized tumor regions have the potential to enhance cytostatic-based chemotherapy of solid tumors. With three-dimensional growth conditions, multicellular tumor spheroids (MCTS) reproduce several parameters of the tumor microenvironment, including oxygen and nutrient gradients as well as the development of dormant tumor regions. We here report the setup of a 3D cell culture compatible high-content screening system and the identification of nine substances from two commercially available drug libraries that specifically target cells in inner MCTS core regions, while cells in outer MCTS regions or in 2D cell culture remain unaffected. We elucidated the mode of action of the identified compounds as inhibitors of the respiratory chain and show that induction of cell death in inner MCTS core regions critically depends on extracellular glucose concentrations. Finally, combinational treatment with cytostatics showed increased induction of cell death in MCTS. The data presented here shows for the first time a high-content based screening setup on 3D tumor spheroids for the identification of substances that specifically induce cell death in inner tumor spheroid core regions. This validates the approach to use 3D cell culture screening systems to identify substances that would not be detectable by 2D based screening in otherwise similar culture conditions. - Highlights: • Establishment of a novel method for 3D cell culture based high-content screening. • First reported high-content screen for the identification of compounds that target cells in dormant tumor spheroid regions. • Metabolite profiling by NMR spectroscopy on 3D tumor spheroids. • Identification of respiratory chain inhibitors to specifically induce cell death in inner tumor spheroid regions. • Respiratory chain inhibitors enhance cytostatic based therapy in vitro.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

IEA Bioenergy Task 40 Sustainable International Bioenergy Trade: Securing Supply and Demand (Country Report 2014—United States)

Logistical barrier are tied to feedstock harvesting, collection, storage and distribution. Current crop harvesting machinery is unable to selectively harvest preferred components of cellulosic biomass while maintaining acceptable levels of soil carbon and minimizing erosion. Actively managing biomass variability imposes additional functional requirements on biomass harvesting equipment. A physiological variation in biomass arises from differences in genetics, degree of crop maturity, geographical location, climatic events, and harvest methods. This variability presents significant cost and performance risks for bioenergy systems. Currently, processing standards and specifications for cellulosic feedstocks are not as well-developed as for mature commodities. Biomass that is stored with high moisture content or exposed to moisture during storage is susceptible to spoilage, rotting, spontaneous combustion, and odor problems. Appropriate storage methods and strategies are needed to better define storage requirements to preserve the volume and quality of harvested biomass over time and maintain its conversion yield. Raw herbaceous biomass is costly to collect, handle, and transport because of its low density and fibrous nature. Existing conventional, bale-based handling equipment and facilities cannot cost-effectively deliver and store high volumes of biomass, even with improved handling techniques. Current handling and transportation systems designed for moving woodchips can be inefficient for bioenergy processes due to the costs and challenges of transporting, storing, and drying high-moisture biomass. The infrastructure for feedstock logistics has not been defined for the potential variety of locations, climates, feedstocks, storage methods, processing alternatives, etc., which will occur at a national scale. When setting up biomass fuel supply chains, for large-scale biomass systems, logistics are a pivotal part in the system. Various studies have shown that long-distance international transport by ship is feasible in terms of energy use and transportation costs, but availability of suitable vessels and meteorological conditions (e.g., winter time in Scandinavia and Russia) need to be considered. However, local transportation by truck (both in biomass exporting and importing countries) may be a high-cost factor, which can influence the overall energy balance and total biomass costs.

09 BIOMASS FUELS↗
DOE OSTI2021

CCE and Resilience Strategies

Consequence-driven Cyber-informed Engineering (CCE) is a methodology focused on securing the nation’s critical infrastructure systems. Developed at Idaho National Laboratory, CCE starts with the assumption that if a critical infrastructure system is targeted by a skilled and determined adversary, the targeted network can and will be penetrated. This think like the adversary approach provides critical infrastructure owners, operators, vendors and manufacturers with a disciplined methodology to: evaluate complex systems; determine what must be fully safeguarded; and apply proven engineering strategies to isolate and protect an industry’s most critical assets.

42 ENGINEERING↗
DOE OSTI2025

Development of the Well-to-Wake Life Cycle Assessment Model for Marine Fuels in R&D GREET 2025

The Marine analysis capabilities in the 2025 Research and Development Greenhouse gases, Regulated Emissions, and Energy use in Technologies (R&D GREET) have been updated to incorporate the latest findings from the Fourth International Maritime Organization (IMO) GHG Study.1 To support these updates and enhance user flexibility, the former single marine module used in previous R&D GREET versions has been split into two workbook tabs: The Marine_Fuel tab, which covers the fuel-cycle, and the Marine_Trip tab, which covers the trip-cycle. In the Marine_Fuel tab, fuel cycle results for 39 marine fuels are available—assuming a slow speed diesel engine—and can be seen in Appendix A. However, there are options for changing feedstocks for multiple fuels, ability to view results with or without pilot fuels for fuels such as methanol and ammonia, and carbon capture options. All these combinations make the number of total possible pathways over one hundred. For each pathway, life cycle emission results are divided into feedstock, conversion, and combustion categories, along with pilot fuel supply chain emissions for fuels used in dual fuel engines. In the newly created Marine_Trip tab, users can view the life cycle emissions of using these fuels from a trip perspective. Compared to R&D GREET 2024, 16 new types of vessels are added in R&D GREET 2025. Examples of results assuming the default size for each vessel type are available in Appendix A. Additional information categories on vessels are included such as vessel size, main propulsion type, engine power rating, combustion cycle, etc. based on the Fourth IMO GHG Study. Operational mode of the trip, fuel consumption, and load calculation were updated based on the report. The fuel consumption calculation also incorporates low-load adjustment, speed–power correction, weather correction, and fouling correction factors. Furthermore, fuel consumption in boilers or steam turbines is also added for the first time, besides fuel use in main propulsion engines and auxiliary engines. This effort makes the R&D GREET Marine capabilities more robust than before. Users will be able to estimate fuel consumption more accurately for more diverse choices of vessel categories, vessel sizes, and energy converters.

09 BIOMASS FUELS↗
DOE OSTI2018

Assessing I 2 S-LWR economic competitiveness using systematic differential capital cost evaluation methodology

One of the major factors impeding nuclear power plant (NPP) construction is their economics. In this study, a systematic differential economics evaluation approach was developed through the use of the Code of Accounts guidelines to assess the costs of nuclear power plants. The methodology, entirely based on publicly available data, may serve as a template to evaluate direct costs for reactors of any size and design at any stage of developments. In particular, this approach was used to assess the costs of the Integral Inherently Safe Light Water Reactor (I 2 S-LWR). The I 2 S-LWR is a design concept of a large (~1000 MWe) light water reactor. One of its key design features promoting inherent safety is implementation of an integral primary circuit configuration, which however necessitates a compact design of the core and primary circuit components. Through the methodology here presented, a representative loop PWR design was taken as a reference and the differential cost was estimated for each individual account based on the design difference, or similarity. Cost scaling techniques were applied to the accounts representing systems that differ from the ones of the reference PWR. Cost estimating techniques were used to evaluate cost of innovative components that are not part of standard PWR designs. By evaluating the cost difference of the I 2 S-LWR from the standard PWR, rather than the absolute cost, the uncertainty in the estimate is reduced. A similar approach was used by ORNL to estimate the cost of a Fluoride-salt High-temperature Reactor (FHR). A traditional four-loop PWR plant with a core thermal power of 3417 MWth (1144 MWe) was selected as the reference. Costs for that plant were prepared in 1978 by the Department of Energy (DOE) Energy Economics Data Base (EEDB), averaging actual cost incurred in the construction of several nuclear power plants (NPP), itemized with a great level of detail according to the Code of Accounts. This best estimate costs are denoted PWR12-BE. For each account, the cost of equipment, site labor and site material is provided. Industry experts at Westinghouse Electric Company performed a “sanity check” of the cost items, adjusting the cost of several items to match the current market and supply chain data. The detailed cost assessment of I 2 S-LWR was performed, systematically analyzing cost for each account, and applying the differential economics approach. First, Relative importance of each account, i.e., its contribution to the total cost was established, to help focus analysis on the most significant contributors. Moreover, the accounts describing components that are different than that of the PWR12-BE were identified. The integral configuration of the reactor has important implications on the cost of the reactor plant equipment (accounts 22x). Turbine generator equipment (Accounts 23x) is not believed to be much different than that of the reference design. I 2 S-LWR structures (Accounts 21x) mainly differ from that of a standard LWR as several buildings (containment building, shield building, annex building, waste processing building, fuel storage building) are integrated into a single building (nuclear island). Yardwork has a higher cost for the I 2 S-LWR, as the NI is partially below grade. On the other hand, due to its compact Nuclear Island footprint, I 2 S-LWR facilitates (and includes in its reference version) the use of seismic isolators, which contribute to reducing the direct cost. The total capital investment cost (TCIC), on the $/kW basis, of I 2 S-LWR is 5.84% lower than that of PWR12-BE, in spite of the lower power output of I 2 S-LWR. However, for the Western US (0.7 g), benefits of the seismic isolation are more pronounced, and the I 2 S-LWR total capital investment cost is 13.02% lower than that of PWR12-BE. If the I 2 S-LWR is compared to a PWR10-BE (traditional loop design, but scaled to the same power level as I 2 S-LWR), the savings are even higher, in the range 11.12%–17.89%. The analysis indicates that I 2 S-LWR has potential to offer an economically attractive design, with TCIC lower than that of a nuclear power plant based on a traditional loop PWR design. In other words, I 2 S-LWR design offers significantly enhanced safety, while at the same time improving economics. The differential economics approach developed in this paper can be used in identifying changes in cost of key components in order to improve the economics of a nuclear reactor design. The method can also help compare the economics of advanced Generation IV reactors and innovative water-cooled SMR (Small Modular Reactors) with respect to standard LWR technologies. In summary, the differential economics approach and can be used as a tool capable of helping stakeholder decisions.

Economic↗
DOE OSTI2020

RADIANCE Cybersecurity Plan: Generic Version

Under its Grid Modernization Initiative, the U.S. Department of Energy (DOE), in collaboration with energy industry stakeholders developed a multi-year research plan to support modernizing the electric grid. One of the foundational projects for accelerating modernization efforts is information and communications technology interoperability. A key element of this project has been the development of a methodology for engaging ecosystems related to grid integration to create roadmaps that advance the ease of integration of related smart technology. This document is the product of activities undertaken in 2017 through 2019. It provides a Cybersecurity Plan describing the technology to be adopted in the project with details as per the GMLC Call document.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Efficient Silicon Carbide (SiC) Fiber Manufacture: Continuous Processing of Novel Precursors via Modified Material Handling

General Atomics Electromagnetic Systems (GA-EMS) together with The Nonwovens Institute (NWI) and Harper International have executed on a development project to improve the production efficiency and reduce the production cost of silicon carbide (SiC) fiber – a critical material that advances US energy security and aerospace leadership. In the first budget period (BP1), the modified tow throughput (MTT) apparatus was developed, enabling fiber spinning in the form of loose coils rather than tightly packed spools (Figure 1) for batch processing of SiC fiber. This coil-based approach was proven to be capable of uniform fiber crosslinking and ceramic conversion, as well as demonstrating key process efficiencies while meeting the program fiber property targets.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

The significance of biomass densification in biological-based biorefineries: A critical review

Replacing fossil fuels with renewable biofuels derived from lignocellulosic biomass is an important aspect of addressing environmental challenges and developing a sustainable industrial society. Densification overcomes the problems of low bulk density and poor flowability of biomass and has been commercialized for producing solid biofuels, but the overall impact of densification on biological-based biorefineries that primarily target liquid fuels (e.g., ethanol) is still under investigation. Herein, this review provides a thorough summary of the application of densified biomass in biological-based biorefineries. First, the effects of densification parameters as well as variables of biomass materials on the densified products’ quality are reviewed, and different commonly used densification technologies are also discussed and compared. Then, the discussion focuses on the physiochemical modifications of biomass caused by densification that may influence further pretreatment and/or enzymatic hydrolysis in biorefineries. Industrial pelleting has been generally shown to exhibit positive/neutral effects on the enzymatic hydrolysis of multiple biomass feedstocks after pretreatments, indicating the viability of using pellets as starting feedstocks in biorefineries. Densification causes structural disruption of biomass, which may facilitate further biochemical conversions. Integrating biomass densification in the feedstock supply chain is feasible for large-scale biorefineries to overcome the techno-economic barriers and become profitable. Suggestions are presented for the efficiency enhancement and cost reduction in densification-based biorefineries. To enable wider applications, it is now the time to employ more demo and full-scale activities in different regions of the world pushing the research and innovation of densification integrated within biorefining.

09 BIOMASS FUELS↗
NASA NTRS2000

Models of the Protocellular Structures, Functions and Evolution

In the absence of extinct or extant record of protocells, the most direct way to test our understanding of the origin of cellular life is to construct laboratory models that capture important features of protocellular systems. Such efforts are currently underway in a collaborative project between NASA-Ames, Harvard medical School and University of California. They are accompanied by computational studies aimed at explaining self-organization of simple molecules into ordered structures. The centerpiece of this project is a method for the in vitro evolution of protein enzymes toward arbitrary catalytic targets. A similar approach has already been developed for nucleic acids: First, a very large population of candidate molecules is generated using a random synthetic approach. Next, the small numbers of molecules that can accomplish the desired task are selected. These molecules are next vastly multiplied using the polymerase chain reaction. A mutagenic approach, in which the sequences of selected molecules are randomly altered, can yield further improvements in performance or alterations of specificities. Unfortunately, the catalytic potential of nucleic acids is rather limited. Proteins are more catalytically capable but cannot be directly amplified. In the new technique, this problem is circumvented by covalently linking each protein of the initial, diverse, pool to the RNA sequence that codes for it. Then, selection is performed on the proteins, but the nucleic acids are replicated. To date, we have obtained "a proof of concept" by evolving simple, novel proteins capable of selectively binding adenosine tri-phosphate (ATP). Our next goal is to create an enzyme that can phosphorylate amino acids and another to catalyze the formation of peptide bonds in the absence of nucleic acid templates. This latter reaction does not take place in contemporary cells. once developed, these enzymes will be encapsulated in liposomes so that they will function in a simulated cellular environment. To provide a continuous energy supply, usually needed to activate the substrates, an energy transduction complex which generates ATP from adenosine diphosphate, inorganic phosphate and light will be used. This system, consisting of two modern proteins, ATP synthase and bacteriorhodopsin, has already been built and shown to work efficiently. By coupling chemical synthesis to such a system, it will be possible to drive chemical reactions by light if only the substrates for these reactions are supplied.

Pohorille, Andrew↗
DOE OSTI2017

Twistact techno-economic analysis for wind turbine applications.

This report is the final deliverable for a techno-economic analysis of the Sandia National Laboratories-developed Twistact rotary electrical conductor. The U.S. Department of Energy Wind Energy Technologies Office supported a team of researchers at Sandia National Laboratories and the National Renewable Energy Laboratory to evaluate the potential of the Twistact technology to serve as a viable replacement to rare-earth materials used in permanent-magnet direct-drive wind turbine generators. This report compares three detailed generator models, two as baseline technologies and a third incorporating the Twistact technology. These models are then used to calculate the levelized cost of energy (LCOE) for three comparable offshore wind plants using the three generator topologies. The National Renewable Energy Laboratory s techno-economic analysis indicates that Twistact technology can be used to design low-maintenance, brush-free, and wire-wound (instead of rare-earth-element (REE) permanent-magnet), direct-drive wind turbine generators without a significant change in LCOE and generation efficiency. Twistact technology acts as a hedge against sources of uncertain costs for direct-drive generators. On the one hand, for permanent-magnet direct-drive (PMDD) generators, the long-term price of REEs may increase due to increases in future demand, from electric vehicles and other technologies, whereas the supply remains limited and geographically concentrated. The potential higher prices in the future adversely affect the cost competitiveness of PMDD generators and may thwart industry investment in the development of the technology for wind turbine applications. Twistact technology can eliminate industry risk around the uncertainty of REE price and availability. Traditional wire-wound direct-drive generators experience reliability issues and higher maintenance costs because of the wear on the contact brushes necessary for field excitation. The brushes experience significant wear and require regular replacement over the lifetime of operation (on the order of a year or potentially less time). For offshore wind applications, the focus of this study, maintenance costs are higher than typical land-based systems due to the added time it often requires to access the site for repairs. Thus, eliminating the need for regular brush replacements reduces the uncertain costs and energy production losses associated with maintenance and replacement of contact brushes. Further, Twistact has a relatively negligible impact on LCOE but hedges risks associated with the current dominant designs for direct-drive generators for PMDD REE price volatility and wire-wound generator contact brush reliability. A final section looks at the overall supply chain of REEs considering the supply-side and demand-side drivers that encourage the risk of depending on these materials to support future deployment of not only wind energy but other industries as well.

17 WIND ENERGY↗
DOE OSTI2026

Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology

Refrigerator technology has advanced significantly over the last couple of decades. Today’s refrigerators use only about 25% of the energy that was required to power models built in 1975. Even as they continually improve efficiency to meet standards, refrigerators have increased in size by almost 20%, added energy-consuming features such as through-the-door ice, and provide more benefits than ever before. However, a few challenges and technology gaps are preventing further improvement of the demand responsiveness and efficiency of the refrigerators. One of the major technology gaps in existing refrigerators is their outdated de-icing process. When the evaporator generates frost, an old-fashioned resistive heating element melts the ice. Most refrigerators have a timed defrost cycle, rather than an active system that could monitor the state of the frost. In these systems, not only is the precious electricity used at its least efficient form of conversion (direct conversion of electricity to heat), but also all the latent heat associated with the ice is wasted during the melting process. On top of that, the refrigerator needs to work harder to pull the temperature down after defrosting, and, last but not least, the food quality is severely impacted by the temperature swings during the defrost cycle. According to a study, the EU alone wastes 89 million tons of food in the supply chain every year. Any temperature swing during defrosting (about 6F according to Emerson for low-temperature cases) can negatively impact the shelf life of meat and other products for multiple days. All these issues can happen during the peak demand time of the electric grid. Unlike the conventional systems, the proposed novel advanced micro-vibrational deicing process uses no heat for defrosting. Instead, it uses the micro vibrations generated by a piezoelectric or vibration-generating module to mechanically break ice from the heat exchanger almost instantaneously. The project titled “Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology, performed by Ultrasonic Technology Solutions, LLC (UTS) of Knoxville, TN, in collaboration with Emerson (now Copeland), represents the final phase of a multi-year effort funded under the U.S. Department of Energy’s Building Technologies Office (BTO) BENEFIT FOA 2020. Initiated on October 1, 2021, and completed after a nine-month no-cost extension ending September 30, 2025, this project aimed to develop and validate a novel micro-vibrational mechanical defrosting system, achieving more than 25% improvement in defrosting energy efficiency over conventional baseline defrosting technologies. Over sixteen quarters, the project advanced from fundamental ice-mechanical characterization and prototype development to full-scale system integration and validation. Initial efforts established project management infrastructure and characterized ice adhesion properties, followed by the design and fabrication of early aluminum-based prototypes for resonance frequency testing. Subsequent quarters saw rapid technical progression, including the identification of optimal piezoelectric and motor-based vibration mechanisms, the demonstration of effective de-icing over 6x6-inch aluminum surfaces. The team achieved its Go/No-Go milestone by exceeding the 25% energy-efficiency improvement target—reaching up to 3,340% under optimized conditions—and later confirmed that motor-driven systems offered superior performance and energy efficiency compared to piezoelectric alternatives. Continued refinement led to the development of amplifier systems on printed circuit boards, improved control and instrumentation hardware, and integration into full-scale heat exchanger (HX) prototypes at both UTS and Copeland facilities. Multiple vibration-mounting studies and frost-growth experiments guided mechanical optimization and noise-mitigation strategies, achieving a 17.5 dB reduction in sound pressure level and verifying robust mechanical performance. Advanced analyses, including modal and harmonic simulations, established a quantitative understanding of vibrational behavior and de-icing efficiency across >1000 cm² systems. The final project phase successfully demonstrated scalable integration within reach-in and chest freezer prototypes, confirmed >25% efficiency improvements in large-area systems, and completed a comprehensive business model and scale-up strategy identifying electric defrost systems as the primary beachhead market. The culmination of this DOE-supported effort establishes micro-vibrational defrosting as a viable, high-efficiency, low-noise, and demand-flexible de-icing technology, paving the way for commercial deployment and broader application in next-generation refrigeration systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

On the Path to SunShot. Emerging Opportunities and Challenges in U.S. Solar Manufacturing

This report provides insights into photovoltaic (PV) and concentrating solar power (CSP) manufacturing in the context of the U.S. Department of Energy's SunShot Initiative. Although global PV price reductions and deployment have been strong recently, PV manufacturing faces challenges. Slowing rates of manufacturing cost reductions, combined with the relatively low price of incumbent electricity generating sources in most large global PV markets, may constrain profit opportunities for firms and poses a potential challenge to the sustainable operation and growth of the global PV manufacturing base. In the United States, manufacturers also face a factors-of-production cost disadvantage compared with competing nations. However, the United States is one of the world's most competitive and innovative countries as well as one of the best locations for PV manufacturing. In conjunction with strong projected PV demand in the United States and across the Americas, these advantages could increase the share of PV technologies produced by U.S. manufacturers as the importance of innovation-driven PV cost reductions increases. Compared with PV, CSP systems are much more complex and require a much larger minimum effective scale, resulting in much higher total CAPEX requirements for system construction, lengthier development cycles, and ultimately higher costs of energy produced. The global lack of consistent CSP project development creates challenges for companies that manufacture specialty CSP components, and the potential lack of a near-term U.S. market could hinder domestic CSP manufacturers. However, global and U.S. CSP deployment is expected to expand beyond 2020, and U.S. CSP manufacturers could benefit from U.S. innovation advantages similar to those associated with PV. Expansion of PV and CSP manufacturing also presents U.S. job-growth opportunities.

14 SOLAR ENERGY↗
DOE OSTI2024

Connecting radiation-driven changes in structural, thermal, and mechanical properties in several medical device polymers

Stemming from security threats and shortages in supply, a recent push has emerged to develop alternatives to radioisotope Cobalt-60 gamma radiation for sterilization of polymeric medical products, including electron beam (e-beam) and X-ray machine-based sources. However, before large-scale implementation, the effects of these non-isotope-based methods must be thoroughly investigated from several perspectives, involving their potential detrimental effects on the structural, thermal, and mechanical properties of polymers in medical devices. This paper investigates such effects in commonly used medical device polymers, including polypropylene homopolymer (PPH), polyolefin elastomer (POE), low-density polyethylene (LDPE), acrylonitrile butadiene styrene (ABS), and chlorobutyl rubber (CIIR). To connect radiation-driven changes in polymer structural and thermal properties and corresponding changes in mechanical properties, several characterization techniques were utilized, including gel permeation chromatography (GPC), Fourier transform infrared spectroscopy (FTIR), dynamic mechanical analysis (DMA) and differential scanning calorimetry (DSC). We found that the tensile strength of X-ray irradiated PPH, as well as X-ray, e-beam, and gamma irradiated CIIR decreases due to chain scission, which is corroborated by GPC and DMA. The GPC results of LDPE suggest chain scission, but interestingly without a corresponding decline in tensile strength. By comparison, POE and ABS appear to undergo further crosslinking with increasing irradiation dose, which generally strengthens them. Importantly, in the vast majority of the cases, there were small to no changes in properties upon changing radiation technologies (at a given dose), i.e., no radiation source dependence. However, in a few specific cases, radiation method dependencies did arise, for instance, in terms of the molecular weight of PPH being significantly increased upon X-ray irradiation, while the melting temperature, glass transition temperature, and elongation at break reduced compared to gamma. Overall, this study provides valuable insight into radiation-driven chemical and structural changes in polymers that produce changes in physical and functional properties.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Scale-Up of Lithium Iron & Aluminum Nickelate Advanced Cathode and Fabrication of A Battery Pack Comprising The Same

Global battery manufacturers are increasingly worried about the serious supply chain constraint caused by rapid fluctuations in cobalt prices over the years. We present a novel cobalt-free, nickel-rich layered cathode material called NFA class (LiNixFeyAlzO2) to tackle this challenge. Spherical NFA(OH)2 precursors were successfully synthesized by incorporating Ni, Fe, and Al elements using a co-precipitation reaction in a continuous stirred tank reactor. The LiNFAO2 cathode, composed of LiNi0.85Fe0.05Al0.1O2, was synthesized and analyzed using X-Ray diffraction, Mössbauer spectroscopy, and scanning electron microscopy (SEM). The material's electrochemical behavior was evaluated through various techniques at different lithiation/delithiation states in two voltage ranges. The cobalt-free material exhibits a high capacity of 190 mAh/g at 0.1C within the voltage range of 3V-4.5V, as demonstrated by electrochemical performance evaluations. Rate and cycling evaluations showed good rate capability and cycling stability, with 88% capacity retention after 100 cycles at C/3 within the voltage range of 3V-4.3V. Our research shows the great potential of cobalt-free NFA cathodes as a feasible option for developing cost-effective lithium-ion batteries.

25 ENERGY STORAGE↗