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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Copper–Carbon Nanotube Composites Enabled by Brush Coating for Advanced Conductors

There is a growing demand for advanced conductors with enhanced electrical properties to increase the energy efficiency in various applications. A promising strategy to achieve this involves the use of ultraconductive copper (UCC) composites that incorporate highly conductive carbon materials, such as carbon nanotubes (CNTs), into the copper matrix. In this study, we present a scalable brush coating technique to incorporate CNTs onto Cu substrates to produce Cu–CNT–Cu composites. The process involves brush coating the CNT solution on Cu tape substrates, followed by vacuum-assisted thermal removal of organic moieties (e.g., surfactant/polymer). This step ensures the creation of a uniformly distributed CNT network within the Cu matrix. By addition of a thin film Cu overlayer, the fabricated Cu–CNT–Cu composite architecture demonstrates similar electrical conductivity, increased current carrying capacity, and enhanced mechanical properties compared to pure Cu reference tapes. Finally, the performance characteristics of these UCC tapes along with the scalability of the brush coating approach hold great promise for the fabrication of advanced conductors for wide-ranging energy applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Structure of Iridium Oxides and Their Oxygen Evolution Electrocatalysis in Acidic Media

Proton exchange membrane water electrolyzers (PEMWEs) have emerged as one of the most promising technologies for the large-scale production of clean hydrogen. Gigawatt scale deployment of PEMWEs requires substantial reduction in the loading of iridium (Ir), which is one of the most expensive and rarest elements. Substantial reduction in Ir loading calls for the development of innovative Ir-based anodes, which requires a clear understanding of how iridium oxides accelerate the sluggish oxygen evolution reaction (OER) in acidic media. Herein, we studied the structure and OER electrocatalysis of three representative iridium oxides ─ hydrous, amorphous, and rutile ─ by employing a combination of physicochemical and electrochemical characterization. Additionally, we found that the hydrous iridium oxide had a different local structure of IrO 6 octahedra and a superior OER intrinsic activity compared with the other two, and that the OER activities of all three types decreased with decreasing pH of acidic solution. We proposed that the OER process of these iridium oxides is limited by water nucleophilic attack on the OER intermediate oxygenated adsorbates. Based on this mechanism, we attributed the superior OER activity of hydrous iridium oxides to their longer Ir–O bonds and the pH-dependent OER activity of iridium oxides to the pH-dependent oxidation of Ir.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Growth of Nanocrystal Superlattices from Liquid Crystals

The growth of superlattices (SLs) made from self-assembled nanocrystals (NCs) is a powerful method for creating new materials and gaining insight into fundamental molecular dynamics. Previous explorations of NCSL syntheses have mostly compared them to crystallization. However, NCSL synthesis has not broadly shown cooling crystallization from saturated solutions as a reversible crystallization–dissolution process. We demonstrate the reversible growth of NCSLs by dispersing NCs in liquid crystal (LC) “smart solvents,” and harnessing the transitions between the isotropic and nematic phases of the LCs. The growth mode and morphology can be tuned. Furthernore, this process is a model platform for studying crystallization and demonstrates great potential in manufacturing NCSLs as colloidal crystals through liquid-phase epitaxy or colloidal synthesis.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2025

High-efficiency frost and ice control via sensing-assisted nanovibrational slippery surfaces

Frost and ice accretions on surfaces pose persistent challenges across numerous industrial, residential and transportation systems. While various removal strategies exist, they often suffer from limited effectiveness or high energy consumption, such as frosting delay, ice crack generation, and Joule heating. Here, in this work, we report a novel integrated approach combining vibrational quasi-liquid surface (QLS) and capacitive sensing for efficient condensate, frost, and ice management. Compared to Joule heating, our approach does not rely on complete melting and evaporation for removal, resulting in 68% and 95% energy savings for frost and ice removal, respectively. Our QLS coating significantly reduces surface retention forces, achieving 91% and 87% less residual mass compared to hydrophilic surfaces for frost and ice removal through surface nanovibration, respectively. The integrated capacitive sensor provides real-time detection of different phase states, enabling on-demand removal in precise timeframes. This sensor-assisted approach showed 3.8 times lower energy consumption compared to conventional Joule heating for defrosting. This synergistic integration of surface engineering, nanovibration, and intelligent sensing represents a significant advancement in phase change processes, offering an energy-efficient solution for frost and ice mitigation in energy-intensive systems.

Shen, Yuchen [Univ. of Texas at Dallas, Richardson↗
DOE OSTI2023

Deuterium supersaturated surface layer in tungsten: ion energy dependence

Abstract Properties of deuterium (D) supersaturated surface layers (DSSLs) formed in tungsten (W), such as thickness, internal microstructures, and D retention, are experimentally investigated as a function of the incident ion energy, E i . W samples were exposed to D plasmas in the PISCES-A linear plasma device in a range of E i ∼ 45–175 eV, while other plasma exposure parameters were fixed: sample temperature, T s , ∼423 K, ion flux, Γ i , ∼1.2 × 10 21 m −2 s −1 , and fluence, Φ i , ∼3.0 × 10 24 m −2 . High-resolution, cross-sectional, transmission electron microscopy observations confirm that (1) a DSSL forms even at the lowest E i ∼ 45 eV, (2) the DSSL thickness, Δ t DSSL , is found to decrease with decreasing E i from ∼11–12 nm at E i ∼ 175 eV to ∼5–6 nm at ∼45 eV, and to agree with approximately the maximum implantation depth calculated using SDTrimSP, and (3) high-density D nanobubbles with a diameter of ∼1 nm or less exist inside the DSSL, which is deemed to validate a theory-predicted vacancy stabilization process due to trapping of a solute D atom(s). Utilizing a D areal density of ∼4.2 × 10 19 m −2 in the first 14 nm from the surface at E i ∼ 75 eV from nuclear reaction analysis and the measured E i dependence of Δ t DSSL , our previous laser-induced breakdown spectroscopy data is updated: both dynamic and static D retention increase with decreasing E i , and the D/W atomic fraction during plasma exposure reaches ∼0.3 at E i ∼ 45 eV. A possible DSSL formation mechanism is proposed.

Physics↗
DOE OSTI2025

Low-phase-noise surface-acoustic-wave oscillator using an edge mode of a phononic band gap

Low-phase-noise microwave-frequency integrated oscillators provide compact solutions for various applications in signal processing, communications, and sensing. Surface acoustic waves (SAWs), featuring orders-of-magnitude shorter wavelength than electromagnetic waves at the same frequency, enable integrated microwave-frequency systems with much smaller footprint on chip. SAW devices also allow higher-quality (Q) factors than electronic components at room temperature. Here, we demonstrate a low-phase-noise gigahertz-frequency SAW oscillator on 128°Y-cut lithium niobate, where the SAW resonator occupies a footprint of 0.05 mm 2 . Leveraging phononic crystal band-gap-edge modes to balance between Q factors and insertion losses, our 1-GHz SAW oscillator features a low phase noise of -132.5 dBc/Hz at a 10-kHz offset frequency and an overlapping Hadamard deviation of 6.5 × 10 -10 at an analysis time of 64 ms. The SAW resonator-based oscillator holds high potential in developing low-noise sensors and acousto-optic integrated circuits.

42 ENGINEERING↗
DOE OSTI2025

Nonsingular black holes as dark matter

It is commonly assumed that low-mass primordial black holes cannot constitute a significant fraction of the dark matter in our universe due to their predicted short lifetimes from the conventional Hawking radiation and evaporation process. Assuming physical black holes are nonsingular—likely due to quantum gravity or other high-energy physics—we demonstrate that a large class of nonsingular black holes have finite evaporation temperatures. This can lead to slowly evaporating low-mass black holes or to remnant mass states that circumvent traditional evaporation constraints. As a proof of concept, we explore the limiting curvature hypothesis and the evaporation process of a nonsingular black hole solution in two-dimensional dilaton gravity. We identify generic features of the radiation profile and compare them with known regular black holes, such as the Bardeen solution in four dimensions. Remnant masses are proportional to the fundamental length scale, and we argue that slowly evaporating low-mass nonsingular black holes, or remnants, are viable dark matter candidates. Published by the American Physical Society 2025

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

In situ synchrotron X-ray total scattering measurements and analysis of colloidal CsPbX 3 nanocrystals during flow synthesis

In situ X-ray scattering measurements of CsPbX 3 (X = Cl, Br, I) nanocrystal formation and halide exchange at NSLS-II beamlines were performed in an automated flow reactor. Total scattering measurements were performed at the 28-ID-2 (XPD) beamline and small-angle X-ray scattering at the 16-ID (LiX) beamline. Nanocrystal structural parameters of interest, including size, size distribution and atomic structure, were extracted from modeling the total scattering data. The results highlight the potential of these beamlines and the measurement protocols described in this study for studying dynamic processes of colloidal nanocrystal synthesis in solution with timescales on the order of seconds.

nucleation↗
DOE OSTI2025

Early Fault Detection in Nuclear Systems: A Digital Engineering Approach

Nuclear energy systems present unique challenges in terms of ensuring safety, reliability, and efficiency during their design and operation. Early fault detection is critical for mitigating risks and fostering system resilience. However, current methods often fall short at identifying faults during early stages, potentially leading to costly delays and safety risks. The present work proposes a comprehensive digital engineering approach that leverages digital twins, digital threads, model-based systems engineering, artificial intelligence, and immersive extended reality to support early fault detection in nuclear systems. Through a series of case studies, we highlight specific gaps in the fault detection mechanisms of traditional nuclear design and operation processes, then demonstrate a suite of solutions we are working to implement to address these shortcomings in similar projects. Our findings suggest that a digital engineering approach to design and operation can significantly improve fault detection, ultimately leading to reductions in risk.

42 - ENGINEERING↗
DOE OSTI2023

Practical considerations in using a binary pseudorandom array for instrument transfer function calibration

Binary pseudo-random array (BPRA) artifacts are useful devices for calibrating the instrument transfer function (ITF) of interferometric microscopes and other optical and non-optical surface and wavefront measurement instruments. The intrinsic white noise character of the power spectral density function of the artifact simplifies the deconvolution of the ITF from the measured power spectral density (PSD). However, resampling of the BPRA intrinsic artifact features with the measurement tool's specific sampling pattern modifies the white noise character of the intrinsic spectrum and needs to be accounted for in the ITF-based data deconvolution process. We have developed an analytic solution to the spectrum of a resampled one- and two- dimensional BPRA. The resultant nominal PSD function is a simple twoparameter cosine function with a period equal to the resampled pixel width. A transfer function model for interferometric microscopes that incorporates this function, along with an ITF that includes aliasing effects and variable numerical aperture (NA), wavelength, and obscuration factor, is used to fit to the BPRA PSDs measured by an interference microscope for a range of objective and zoom lens magnification combinations.

Takacs, PZ↗
DOE OSTI2023

Ultrafast dense DNA functionalization of quantum dots and rods for scalable 2D array fabrication with nanoscale precision

Scalable fabrication of two-dimensional (2D) arrays of quantum dots (QDs) and quantum rods (QRs) with nanoscale precision is required for numerous device applications. However, self-assembly–based fabrication of such arrays using DNA origami typically suffers from low yield due to inefficient QD and QR DNA functionalization. In addition, it is challenging to organize solution-assembled DNA origami arrays on 2D device substrates while maintaining their structural fidelity. Here, we reduced manufacturing time from a few days to a few minutes by preparing high-density DNA-conjugated QDs/QRs from organic solution using a dehydration and rehydration process. We used a surface-assisted large-scale assembly (SALSA) method to construct 2D origami lattices directly on solid substrates to template QD and QR 2D arrays with orientational control, with overall loading yields exceeding 90%. Our fabrication approach enables the scalable, high fidelity manufacturing of 2D addressable QDs and QRs with nanoscale orientational and spacing control for functional 2D photonic devices.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2022

Homomorphic Encryption for Machine Learning and Artificial Intelligence Applications

Third-party and expert analysis is a cost-effective solution for solving specialized problems or processing large datasets related to reactor structural health monitoring and nondestructive evaluation. However, when handling proprietary information, third-party and expert analysts pose a privacy risk. To address this challenge, Homomorphic Encryption (HE) permits arithmetic operations on encrypted data without exposing the underlying data. Implementations of Machine Learning (ML) and Artificial Intelligence (AI) algorithms using HE greatly enhances the capabilities of third-party analysts while maintaining a low security risk. This paper details current success in applying Principal Component Analysis (PCA) and Fully Connected Neural Networks (NN) using the Microsoft SEAL implementation of the popular CKKS Fully Homomorphic Encryption (FHE) algorithm. The MNIST Handwritten Dataset is analyzed as a proof-of-concept demonstration of the implementations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Verification and Validation of the STAT7 Code

This document presents the verification and validation of the STAT7 Version 1.1 code, which has been developed to perform the steady-state thermal hydraulics (TH) safety calculations required to support conversion of the Massachusetts Institute of Technology Research Reactor from highly enriched uranium fuel to low- enriched uranium fuel. The key capabilities of the code, including statistical processing, water property generation, and TH solution, are verified independently. While the first two capabilities are checked using statistical tests and NIST data tables, each component of the TH solution is verified using simple geometry test problems. The comparison between results obtained by the code and by hand calculations on these problems shows that each of these components works correctly. Additionally, a comprehensive comparison between STAT7 Version 1.1 and PLTEMP/ANL Version 4.3 Revision 162 calculations is performed for the validation. Good agreement is achieved between the results obtained with the two codes for all TH parameters belonging to the fuel core region.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

The Effect of Acceleration on the Separation Force in Constrained-Surface Stereolithography

Constrained-surface-based stereolithography has recently attracted much attention from both academic and industrial communities. Despite numerous experimental, numerical and theoretical efforts, the fundamental need to reduce the separation force between the newly cured part and constrained surface has not yet been completely solved. In this paper, we develop a fluid dynamics approach, proposed in our previous work, to theoretically model the separation force in 3D printing of a cylindrical part for flat and patterned windows. We demonstrate the possibility of separation force reduction with an accelerated movement of the printing platform. In particular, we investigate behaviors of transient parameter, its reduction rate, and separation force reduction with respect to elevation speed and time. The proposed approach involves deceleration and acceleration stages and allows to achieve the force reduction for the entire printing process. Finally, we provide implicit analytical solutions for time moments when switching between the stages can be done without noticeable increase of separation force and explicit expression for separation force in case of patterned window.

Gritsenko, Dmitry (ORCID:0000000248181512)↗
DOE OSTI2024

Transitioning from Simulation to Reality: Applying Chatter Detection Models to Real-World Machining Data

Chatter, a self-excited vibration phenomenon, is a critical challenge in high-speed machining operations, affecting tool life, product surface quality, and overall process efficiency. While machine learning models trained on simulated data have shown promise in detecting chatter, their real-world applicability remains uncertain due to discrepancies between simulated and actual machining environments. The primary goal of this study is to bridge the gap between simulation-based machine learning models and real-world applications by developing and validating a Random Forest-based chatter detection system. This research focuses on improving manufacturing efficiency through reliable chatter detection by integrating Operational Modal Analysis (OMA), Receptance Coupling Substructure Analysis (RCSA), and Transfer Learning (TL). The study applies a Random Forest classification model trained on over 140,000 simulated machining datasets, incorporating techniques like Operational Modal Analysis (OMA), Receptance Coupling Substructure Analysis (RCSA), and Transfer Learning (TL) to adapt the model for real-world operational data. The model is validated against 1600 real-world machining datasets, achieving an accuracy of 86.1%, with strong precision and recall scores. The results demonstrate the model’s robustness and potential for practical implementation in industrial settings, highlighting challenges such as sensor noise and variability in machining conditions. This work advances the use of predictive analytics in machining processes, offering a data-driven solution to improve manufacturing efficiency through more reliable chatter detection.

42 ENGINEERING↗
DOE OSTI2022

Integrating Embodied Carbon Knowledge for Design Decisions: Preprint

Measuring energy consumption of buildings is well established, and techniques to evaluate the carbon associated with operating buildings are improving. Embodied carbon of buildings is more complex as it considers the release of carbon throughout the building material supply chain and building material end of life fate. Decisions made early during the design and construction of the building can influence and potentially reduce the embodied carbon of buildings. The design and construction communities are uniquely positioned to make decisions that reduce embodied carbon. The objective of this project is to understand barriers to low carbon design and delivery and to point the design and construction communities to useful resources that will result in decisions that reduce embodied carbon. The outcomes of this work include educational resources that familiarize designers and contractors with embodied carbon and life cycle assessments (LCA), case studies that focus on design changes from LCA results, an overview of LCA tools, and examples of readily available, cost-effective design and construction steps to lower embodied carbon. We present an evaluation of existing resources, organized in a decision tree guidance, and identify gaps for further resource development. Through this evaluation process we investigated ways to streamline the process of identifying barriers to implementing solutions quickly.

design professional decisions↗
DOE OSTI2021

From casting to 3D printing geopolymers: A proof of concept

The objective of this paper is to define a mix design strategy allowing the implementation of geopolymer in powder bed 3D printing. In a selective binder approach, an aluminosilicate powder bed is activated through the deposit of an alkaline silicate solution. We first show that, in comparison to casting, this technology requires mastering the spreading of the liquid into the powder bed to ensure that the reaction takes place where it is needed. A series of experiments at the drop level, mimicking the 3D printing process, were performed to determine the printing solution composition for a given powder bed packing. We then highlight the relationship between the compressive strength of the printed geopolymer and the powder bed saturation, controlled by the printing parameters. Finally, SEM/EDX analysis confirm the formation of geopolymer with desired Si/Al and Na/Al ratios in the resulting printed material.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cations impact radical reaction dynamics in concentrated multicomponent aqueous solutions

Ultraviolet (UV) photolysis of nitrite ions (NO 2 – ) in aqueous solutions produces a suite of radicals, viz., NO · , O – , · OH, and · NO 2 . The O – and NO · radicals are initially formed from the dissociation of photoexcited NO 2 – . The O – radical undergoes reversible proton transfer with water to generate · OH. Both · OH and O – oxidize the NO 2 – to · NO 2 radicals. The reactions of · OH occur at solution diffusion limits, which are influenced by the nature of the dissolved cations and anions. Here, we systematically varied the alkali metal cation, spanning the range from strongly to weakly hydrating ions, and measured the production of NO · , · OH, and · NO 2 radicals during UV photolysis of alkaline nitrite solutions using electron paramagnetic resonance spectroscopy with nitromethane spin trapping. Comparing the data for the different alkali cations revealed that the nature of the cation had a significant effect on production of all three radical species. Radical production was inhibited in solutions with high charge density cations, e.g., lithium, and promoted in solutions containing low charge density cations, e.g., cesium. Through complementary investigations with multinuclear single pulse direct excitation nuclear magnetic resonance (NMR) spectroscopy and pulsed field gradient NMR diffusometry, cation-controlled solution structures and extent of NO 2 – solvation were determined to alter the initial yields of · NO and · OH radicals as well as alter the reactivity of NO 2 – toward · OH, impacting the production of · NO 2 . The implications of these results for the retrieval and processing of low-water, highly alkaline solutions that comprise legacy radioactive waste are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗