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DOE OSTI2024

High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP): Design Guidelines and Specifications for DC Distribution-Based Charging Hub

Managed under U.S. Department of Energy (DOE)-funded EVs@Scale Consortium, High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project aims to design and develop a high-power, interoperable charging experimental platform to research, develop, and demonstrate the integration and control approaches for a DC distribution-based high-power charging (HPC) system. The eCHIP project addresses the crucial need to design and validate efficient, low-cost, reliable, and interoperable solutions for DC-coupled charging hub ('DC hub' for short). This report explains the design, development, and implementation process of the experimental platform for the DC hub. The utilization of DC distribution holds significant potential for enhancing the operation of an HPC station architecture. However, there are challenges establishing the DC hub, including interoperability, commoditization, distributed energy resource integration, stability, DC protection, and lack of common system level controllers. To address these challenges, a testing setup is required that accommodates commercial off-the-shelf (COTS) products as well as novel, in-house designed solutions to evaluate different use cases at rated power and voltage levels.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Supervisory Control and Data Acquisition for Electrochemical Separation Experimentation

The Python-based program is a laboratory automation tool designed to control and monitor electrochemical systems. The tool was developed for capacitive deionization (CDI) experiments, but it can be used for any system that requires controlled voltage or current segments and multi-parameter monitoring. The program integrates hardware components to run user-defined experimental parameters, providing operational control of a programmable power supply, peristaltic pump, and data acquisition devices. Currently, the program is structured with a workflow that includes an initialization (or pre-run) phase, a main loop, and a post-experiment stabilization (or post-run) phase. The initialization phase prepares and stabilizes the cell, ensuring that the electrodes and solution reach a baseline state before the experiment begins. The main loop consists of multiple voltage segments that repeat, controlling the experiment while recording key parameters such as time, voltage, current, pH, and conductivity. Finally, the post-experiment stabilization phase allows the system to stabilize after the experiment, returning the cell and solution to equilibrium conditions before ending the sequence. The program is designed with four variations, each tailored to different experimental needs. All variations include both the initialization and post-experiment stabilization stages, which run for a set amount of time, voltage, current, and flow rate before and after the main experiment block. The main loop runs for a set number of cycles, as defined by the user input, and each cycle is composed of 2 or 4 segments. The 4 program variations are described as follows: Program 1: The main program includes 2 segments. Each segment is defined to have a set duration, flow rate, voltage, and current. This program measures conductivity, flow rate, voltage, and current. Program 2: The main program expands Program 1 to include 4 segments. Each segment has a specified duration, flow rate, voltage, and current. Like Program 1, it measures conductivity, flow rate, voltage, and current. Program 3: The main program consists of 2 segments, each defined by time, flow rate, voltage, and current. In addition to conductivity, flow rate, voltage, and current, Program 3 collects pH and temperature data through a 4-channel data acquisition device. Program 4: This program independently controls two channels of a multi-channel power supply simultaneously. While conductivity can only be measured for one cell at a time, the dual-channel control makes it possible to operate two cells simultaneously under different voltage/current conditions. The main program includes 2 segments.For each program, all measurements are automatically logged and integrated into a single Excel output file. Data are displayed in numerical format and plotted, both in real time, to track system performance. A key feature of the program is its ability to synchronize all outputs so that every measurement shares a single timestamp, ensuring accurate alignment of voltage, current, pH, conductivity, and pH data.By combining hardware control, real-time monitoring, and unified data collection, this program significantly reduces manual workload and minimizes errors, making it a reliable platform for researchers, engineers, and laboratory technicians conducting CDI experiments, among other electrochemical tests.

Valentino, Lauren [Argonne National Laboratory (AN↗

DOE OSTI2021

Discrete-Time Causal Control of a Wave Energy Converter With Finite Stroke in Stochastic Waves

We consider feedback control design for a wave energy converter (WEC) for which the power takeoff (PTO) system has a finite stroke limit. Stationary stochastic wave loading is assumed, with a known spectrum, and the plant dynamics are assumed to be linear. We develop a technique for the design of a discrete-time controller, which has three design stages. In the first stage, a linear controller is optimized while imposing a relaxation of the maximum stroke constraint on the design. In the second stage, a tandem nonlinear feedback loop is designed for the purpose of stroke protection. In the third stage, the two designs (linear and nonlinear) are fused in a manner that preserves the stability of the overall system. The technique is demonstrated in a simulation of a simple cylindrical buoy. We show that the controller may be tuned through the adjustment of scalar design parameters, which adjust the tradeoff between the mean generated power and the force levels required to protect the stroke.

16 TIDAL AND WAVE POWER↗

NASA NTRS1990

Indexing system for optical beam steering

This paper describes the design and testing of an indexing system for optical-beam steering. The cryogenic beam-steering mechanism is a 360-degree rotation device capable of discrete, high-precision alignment positions. It uses low-precision components for its rough alignment and kinematic design to meet its stringent repeatability and stability requirements (of about 5 arcsec). The principal advantages of this design include a decoupling of the low-precision, large angular motion from the high-precision alignment, and a power-off alignment position that potentially extends the life or hold time of cryogenic systems. An alternate design, which takes advantage of these attributes while reducing overall motion, is also presented. Preliminary test results show the kinematic mount capable of sub-arc second repeatability.

Sullivan, Mark T.↗

DOE OSTI2025

PID-Regulated Heating System for PIP-II Reference Line

The Proton Improvement Project-2 centers on building a new superconducting linear particle accelerator (Linac) at Fermilab. At the heart of the accelerator is the reference line, a critical system that defines the ideal path for the particle beam as it passes through magnets, RF cavities, and other beamline elements. Temperature stability is crucial for the reliable operation of RF components, such as mixers and filters. Fluctuations affect key performance parameters like conversion loss, isolation, and linearity. To mitigate any drift caused by ambient temperature changes, a heating plate assembly is utilized to maintain key components at a controlled temperature of 40°C. The system utilizes an aluminum 36”x36”x0.5” heat plate powered by a MOSFET-based control circuit, delivering approximately 460 W of thermal energy through a resistor array. Real-time temperature feedback is provided by a PT100 Resistance Temperature Detector (RTD), which interfaces with a Proportional–Integral–Derivative (PID) control algorithm to maintain closed-loop temperature regulation. The control signal actively modulates the gate voltage of an N channel MOSFET, dynamically adjusting power delivery in response to deviations from the temperature setpoint. Simulations and LTspice models validate the functionality and responsiveness of the circuit under varying conditions. The prototype has successfully demonstrated stable thermal control, paving the way for integration into the PIP-II infrastructure. The final design will feature an expanded resistor array, as well as communication with a PLC for continuous data acquisition and diagnostics. This work directly supports Fermilab’s broader mission by contributing to the stability and reliability of core accelerator systems, enhancing the precision of particle beam delivery for future physics experiments.

Mosher, Alexander [Fermilab]↗

NASA NTRS1979

Gravitational redshift space-probe experiment

A Scout D rocket was launched from Wallops Island, Virginia, carrying an atomic hydrogen maser oscillator system as the payload. The frequency of signals from the oscillator was monitored on the ground at Merritt Island, Florida, by using two hydrogen masers as comparison oscillators. The first-order Doppler shift in the signals was eliminated by a go-return transponder link to the payload, and the resulting data, representing the relativistic shifts, were recovered and recorded. The objective was to measure directly the effect of gravitational potential on the frequency of an atomic hydrogen maser assuming it to be a 'proper' clock. A gravitational effect amounting to some 4.5 parts in 10 to the 10th power was measured with an oscillator having a stability better than 1 part in 10 to the 14th power. Therefore, to make the best possible use of the oscillator, all frequency shifts at the 2 to 5 X 10 to the -15 power level in delta f/f in the system must be accounted for. This includes all the phase variations that can cause such a shift to appear. The experiment, the data available and the manner in which they were processed, and the results are described.

Vessot, R. F. C.↗

DOE OSTI2024

EVs@Scale Lab Consortium High-Power Charging Pillar Deep-Dive Technical Meeting

Managed under the the U.S. Department of Energy (DOE)-funded EVs@Scale Consortium, the High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project aims to create an experimental platform for integration and control approaches in a direct current (DC), distribution-based high-power charging (HPC) system. The eCHIP project addresses the crucial need to design and validate efficient, low-cost, reliable, and interoperable solutions for a DC-coupled charging hub ("DC hub" for short). This report explains the design, development, and implementation process of an experimental platform for the DC hub. DC distribution holds significant potential for enhancing the operation of an HPC station architecture. However, there are challenges in establishing a DC hub, including interoperability, commoditization, distributed energy resource integration, stability, DC protection, and a lack of common system-level controllers. To address these challenges, a testing setup is required that accommodates commercial off-the-shelf (COTS) products, as well as novel, in-house designed solutions, to evaluate different use cases at rated power and voltage levels. The developed proof-of-concept charging platform and open-source SEMS allow the development and testing of various controllers and chargers from different vendors. The DC hub platform integrated EVs, an ESS, a PV system, and building load to demonstrate the flexibility of the platform. The open-source SEMS controlled the devices within the hub using a rule-based implementation, realizing available standards.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Experimental Analysis of Salt Hydrate Latent Heat Thermal Energy Storage System With Porous Aluminum Fabric and Salt Hydrate as Phase Change Material With Enhanced Stability and Supercooling

Phase change materials (PCMs), especially salt hydrates possess high volumetric energy storage capacity in their transition temperature range. These materials are used in applications where it is necessary to store thermal energy due to temporary load shift between demand and availability. Thus, possible applications are HVAC, recovery of waste heat, and defense thermal management. Despite salt hydrates potential, the practical feasibility of latent heat storage with salt hydrates is limited due to low power rating, supercooling, phase segregation, and long-term stability. Its low power rating and long-term stability limits its application in most applications. This work experimentally validates the stability and thermal performance of a compact heat exchanger charged with salt hydrate during melting and freezing. The compact heat exchanger was designed with fins on both the heat transfer fluid (HTF) and salt hydrate PCM side. The thermal performance of the latent heat thermal energy storage system (LHTESS) was evaluated for various operating conditions. The results show that LHTESS could achieve an average heat transfer coefficient of 124 and 87 W/(m2 K) during melting and solidification, respectively. The stability of the system in suppressing supercooling was validated over 800 cycles with nucleating agent and active homogenous nucleation techniques. The supercooling was reduced to 3 °C with zinc hydroxyl nitrate as nucleating agent and less than 1 °C with the active homogenous nucleation technique. The LHTESS showed less than 6% degradation in energy storage capacity over 800 cycles.

42 ENGINEERING↗

NASA NTRS1997

HARV ANSER Flight Test Data Retrieval and Processing Procedures

Under the NASA High-Alpha Technology Program the High Alpha Research Vehicle (HARV) was used to conduct flight tests of advanced control effectors, advanced control laws, and high-alpha design guidelines for future super-maneuverable fighters. The High-Alpha Research Vehicle is a pre-production F/A-18 airplane modified with a multi-axis thrust-vectoring system for augmented pitch and yaw control power and Actuated Nose Strakes for Enhanced Rolling (ANSER) to augment body-axis yaw control power. Flight testing at the Dryden Flight Research Center (DFRC) began in July 1995 and continued until May 1996. Flight data will be utilized to evaluate control law performance and aircraft dynamics, determine aircraft control and stability derivatives using parameter identification techniques, and validate design guidelines. To accomplish these purposes, essential flight data parameters were retrieved from the DFRC data system and stored on the Dynamics and Control Branch (DCB) computer complex at Langley. This report describes the multi-step task used to retrieve and process this data and documents the results of these tasks. Documentation includes software listings, flight information, maneuver information, time intervals for which data were retrieved, lists of data parameters and definitions, and example data plots.

Yeager, Jessie C.↗

DOE OSTI2020

Energetic Control of Redox-Active Polymers toward Safe Organic Bioelectronic Materials

Avoiding faradaic side reactions during the operation of electrochemical devices is important to enhance the device stability, to achieve low power consumption, and to prevent the formation of reactive side-products. This is particularly important for bioelectronic devices, which are designed to operate in biological systems. While redox-active materials based on conducting and semiconducting polymers represent an exciting class of materials for bioelectronic devices, they are susceptible to electrochemical side-reactions with molecular oxygen during device operation. In this work, electrochemical side reactions with molecular oxygen are shown to occur during organic electrochemical transistor (OECT) operation using high-performance, state-of-the-art OECT materials. Depending on the choice of the active material, such reactions yield hydrogen peroxide (H 2 O 2 ), a reactive side-product, which may be harmful to the local biological environment and may also accelerate device degradation. A design strategy is reported for the development of redox-active organic semiconductors based on donor–acceptor copolymers that prevents the formation of H 2 O 2 during device operation. This study elucidates the previously overlooked side-reactions between redox-active conjugated polymers and molecular oxygen in electrochemical devices for bioelectronics, which is critical for the operation of electrolyte-gated devices in application-relevant environments.

36 MATERIALS SCIENCE↗

DOE OSTI2024

First considerations on the supporting structures of FCC-ee booster and collider in the arc regions

In 2022, the FCC Feasibility Study management mandated a working group to analyse the best configuration of the FCC-ee tunnel in the arc regions, in view of the construction of a mock-up of the arc half-cell. One of the main and most challenging goals of the study, named FCC-ee Arc Half-Cell Mock-up Project, was to perform a preliminary investigation on the principles of supporting the Short-Straight Sections and dipoles of the half-cells, both for the booster and for the collider machines. This is an important input needed for the choice of the best configuration of the relative placement of the booster with respect to the collider. The structural stiffness, mass and stability of the supporting structures must be optimized to minimize the vibrations transmitted/transferred to the magnetic system of the accelerators by elements such as pumps, water cooling system, beam thermomechanical stresses, powering elements, etc. To perform the study, tools such as CAD software, FEM and analytical techniques were employed. This paper summarizes the preliminary design concepts and the results of the simulations performed.

Accelerator Subsystems and Technologies↗

DOE OSTI2024

Computational design of high entropy alloy coating for hydrogen turbine applications

This project aims to develop novel high entropy alloy (HEA)-based coatings to protect critical components in hydrogen-fueled turbine power system. The HEA-coatings will demonstrate superior performance in hydrogen combustion environment to commercial NiCoCrAlY coating in current natural gas turbine system. The HEA coating facilitates the formation of a protective scale of alpha-alumina to slow down the inward diffusion of oxidizing species and the outward diffusion of metal elements, and possesses ultrahigh corrosion and spallation resistance to prolong the service lifetime of critical components in hydrogen turbine power system. Aimed to accelerate the discovery of novel HEA coating compositions, high throughput computational modeling including CALPHAD and density functional theory and machine learning are performed to predict phase stability, oxygen permeability, oxidation rate constant, coefficient of thermal expansion, and mechanical properties. Based on the modeling and machine learning prediction, experimental validation is performed. Preliminary results will be presented and approaches to minimize oxidation will be discussed.

alloy design↗

NASA NTRS1976

Recent developments in NASA's Supersonic Cruise Aircraft Research /SCAR/ Program

The paper reviews the SCAR program with emphasis on research in the areas of propulsion system, structures and materials, aerodynamic performance, stratospheric emissions, and stability and controls. Specific results relate to multicycle engine progress, coannular jet noise relief, blended wing-body configuration progress, powered-lift progress, and progress in structural design methodology.

Mascitti, V. R.↗

NASA NTRS1986

Thermal aging effects in refractory metal alloys

The alloys of niobium and tantalum are attractive from a strength and compatibility viewpoint for high operating temperatures required in materials for fuel cladding, liquid metal transfer, and heat pipe applications in space power systems that will supply from 100 kWe to multi-megawatts for advanced space systems. To meet the system requirements, operating temperatures ranging from 1100 to 1600 K have been proposed. Expected lives of these space power systems are from 7 to 10 yr. A program is conducted at NASA Lewis to determine the effects of long-term, high-temperature exposure on the microstructural stability of several commercial tantalum and niobium alloys. Variables studied in the investigation include alloy composition, pre-age annealing temperature, aging time, temperature, and environment (lithium or vacuum), welding, and hydrogen doping. Alloys are investigated by means of cryogenic bend tests and tensile tests. Results show that the combination of tungsten and hafnium or zirconium found in commercial alloys such as T-111 and Cb-752 can lead to aging embrittlement and increased susceptibility to hydrogen embrittlement of ternary and more complex alloys. Modification of alloy composition helps to eliminate the embrittlement problem.

Stephens, J. R.↗

NASA NTRS1987

Thermal aging effects in refractory metal alloys

Stephens, Joseph R.↗

NASA NTRS1995

Improved Microwave Fiber-Optic Link

High power output and narrow linewidth of Nd:YAG laser and external modulator combination enable higher stability and higher dynamic range fiber-optic transmission of microwave signals over longer distances. System prototype to test concept of high fidelity transmission of received microwave signals over fiber-optic cables, without need to downconvert microwave signals for transmission. Useful in distribution of future, more stable, frequency reference signals, phased array radar systems, and aircraft landing systems using bistatic radar.

Logan, Ronald T.↗

NASA NTRS2008

WRATS Integrated Data Acquisition System

The Wing and Rotor Aeroelastic Test System (WRATS) data acquisition system (DAS) is a 64-channel data acquisition display and analysis system specifically designed for use with the WRATS 1/5-scale V-22 tiltrotor model of the Bell Osprey. It is the primary data acquisition system for experimental aeroelastic testing of the WRATS model for the purpose of characterizing the aeromechanical and aeroelastic stability of prototype tiltrotor configurations. The WRATS DAS was also used during aeroelastic testing of Bell Helicopter Textron s Quad-Tiltrotor (QTR) design concept, a test which received international attention. The LabVIEW-based design is portable and capable of powering and conditioning over 64 channels of dynamic data at sampling rates up to 1,000 Hz. The system includes a 60-second circular data archive, an integrated model swashplate excitation system, a moving block damping application for calculation of whirl flutter mode subcritical damping, a loads and safety monitor, a pilot-control console display, data analysis capabilities, and instrumentation calibration functions. Three networked computers running custom-designed LabVIEW software acquire data through National Instruments data acquisition hardware. The aeroelastic model (see figure) was tested with the DAS at two facilities at NASA Langley, the Transonic Dynamics Tunnel (TDT) and the Rotorcraft Hover Test Facility (RHTF). Because of the need for seamless transition between testing at these facilities, DAS is portable. The software is capable of harmonic analysis of periodic time history data, Fast Fourier Transform calculations, power spectral density calculations, and on-line calibration of test instrumentation. DAS has a circular buffer archive to ensure critical data is not lost in event of model failure/incident, as well as a sample-and-hold capability for phase-correct time history data.

Piatak, David J.↗

NASA NTRS2010

A Broad Bank Lidar for Precise Atmospheric CO2 Column Absorption Measurement from Space

Accurate global measurement of carbon dioxide column with the aim of discovering and quantifying unknown sources and sinks has been a high priority for the last decade. In order to uncover the "missing sink" that is responsible for the large discrepancies in the budget the critical precision for a measurement from space needs to be on the order of 1 ppm. To better understand the CO2 budget and to evaluate its impact on global warming the National Research Council (NRC) in its recent decadal survey report (NACP) to NASA recommended a laser based total CO2 mapping mission in the near future. That's the goal of Active Sensing of CO2 Emissions over Nights, Days, and Seasons (ASCENDS) mission - to significantly enhance the understanding of the role of CO2 in the global carbon cycle. Our current goal is to develop an ultra precise, inexpensive new lidar system for column measurements of CO2 changes in the lower atmosphere that uses a Fabry-Perot interferometer based system as the detector portion of the instrument and replaces the narrow band laser commonly used in lidars with a high power broadband source. This approach reduces the number of individual lasers used in the system and considerably reduces the risk of failure. It also tremendously reduces the requirement for wavelength stability in the source putting this responsibility instead on the Fabry- Perot subsystem.

Georgieva, E. M.↗