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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

Recommended Actions to Improve Adapter Safety

With the rapid advancement and acceleration in the electric vehicle (EV) industry within the United States, major automakers and EV charging companies are increasingly adopting the North American Charging Standard (NACS) connector style, now officially known as J3400. This shift is expected to enhance charging infrastructure, providing a better customer experience by making it easier for all EV drivers to access a wider network of direct-current (DC) fast chargers (DCFCs). However, the adoption of the J3400 standard presents challenges for many EVs already on the roads and some currently coming off production lines that are equipped with the Combined Charging System (CCS) connector, which this report will refer to as the North American standard, CCS1. These vehicles will need adapters to use new or existing J3400 infrastructure. During this transition, several issues have emerged. Firstly, there is a need to standardize the new connector type to ensure it is interoperable, safe, and reliable. Second, existing CCS EV drivers need a way to access the J3400 network, which will require electric vehicle supply equipment (EVSE) or sites with both connector types, driver-provided adapters to physically convert from CCS to J3400, or EVSE with retained adapters designed for use with the EVSE. Third, adapter standards will need to be written to specify how they will be designed and what evaluations will be needed to ensure safe and reliable performance. To address these challenges, adapters that support different types of charging connectors will be essential. These adapters will play a crucial role in supporting the transition and ensuring continued service for legacy EVs with CCS inlets as the J3400 standard becomes the predominant one in the United States. Consequently, the National Charging Experience (ChargeX) Consortium has investigated and performed a teardown analysis on the different adapter versions on the market. The aim is to create a failure mode and effects analysis (FMEA) on what are expected to be the most common adapter types used in this transition. In order to support this work, we executed an FMEA exercise with the main goal of identifying gaps in the existing adapters' performance and conformance to the most common safety requirements of high-power and high-voltage devices. This effort focused on adapters provided by the driver, as these may present the highest safety and reliability risks. The recommendations made here apply to both retained and driver-provided adapters.

25 ENERGY STORAGE↗
DOE OSTI2020

Energy Frontier Research in Extreme Environments (EFree)

The mission of EFree has been to accelerate the discovery and synthesis of new energy materials using extreme conditions. EFree has addressed specific knowledge gaps in the discovery of paradigm-shifting, transformative energy materials. The Center targeted three focus areas, Revolutionary Energy Transport Materials, Advanced Structural Materials and Novel Energy Conversion Materials using a system of Center-wide Projects that fall within each of these focus areas. EFree scientists studied materials under extreme conditions to deepen the understanding of materials behavior, enabling new materials to be discovered and ultimately produced by design for practical use at ambient conditions. In addition, EFree supported a range of exploratory projects as feasibility studies for Center-wide projects as well as technical developments that supported these scientific efforts. Over the period of performance, the Center made significant advancements across all three focus areas. This report summarizes key results from the Center and highlights the most important accomplishments including the discovery of near-room-temperature superconductivity, novel diamond-like carbon nanothread materials and new ‘exotic’ semiconductors.

08 HYDROGEN↗
DOE OSTI2022

GridDS: Data Science Toolkit for Energy Grid Data

According to the U.S. Energy Information Administration (EIA), the demand for energy is expected to increase 50% by the year 20501. While energy standards, such as the Institute of Electrical and Electronics Engineers (IEEE) Standard 1547, (Basso 2015) and monitoring with wide area management systems (WAMS) (Liu 2017, Zhou 2016) have enabled large scale data collection and storage, the application of this data in mitigating costs associated with increased consumer demand is an ongoing focus for energy research. This ubiquitous data collection presents a promising opportunity for machine learning and data science to improve efficiency of distributed energy resources (DERs). The GridDS software toolkit is designed to leverage advanced metering infrastructure (AMI), outage management systems data (OMS), Supervisory control Data Acquisition (SCADA), and geographic information systems (GIS) to forecast future energy demands and detect incipient grid failures. GridDS is a python software library designed to be modular and generalizable to data recorded by DERs. In adapting to disparate datasets recorded by various WAMS, GridDS provides a range of unique functionality not presently implemented in current WAMS which have highly specific software infrastructure by design. GridDS functionality ranges from data specification and preparation, to training and validation for state of the art machine learning, to interactive data visualization. For data intake, GridDS combines: Pandera: a library for creating data specifications. TimeScaleDB: a postgresSQL database infrastructure for efficient storage of timeseries data. Dataset class: A custom dataset class / interface that ensures modularity between a range of synthetic and live recorded datasets. Is

Ladd, Alexander↗
DOE OSTI2020

Performance testing of a Compton suppressed coincidence measurements using the Advanced Radionuclide Gamma-spectrOmeter

A Compton-suppressed multidimensional gamma-spectrometer is being developed within the Shallow Underground Laboratory (SUL) at Pacific Northwest National Laboratory (PNNL, USA). This Advanced Radionuclide Gamma-spectrOmeter (ARGO) system consists of two Broad Energy Germanium (BEGe) detectors, surrounded by a 12-detector sodium iodide (NaI) Compton suppression shield, situated inside a low-background lead and copper shield, fitted with a cosmic veto background reduction system. The detector has advanced functionality, including operation in single or combined detector mode, coincidence mode and Compton suppressed coincidence mode. Validation experiments measuring a neutron irradiated natural uranium sample, have demonstrated order of magnitude improvements in gamma detection sensitivity compared to conventional gamma-spectrometry techniques. Importantly this research demonstrates the feasibility of processing and analysing high-multiplicity datasets and the potential for high-sensitivity radionuclide measurements.

ARGO↗
DOE OSTI2023

Integrated Optimization of Powertrain Energy Management and Vehicle Motion Control for Autonomous Hybrid Electric Vehicles

Hybrid Electric Vehicles (HEVs) and autonomous vehicles have been widely studied recently for on-road transportation. In the study of autonomous HEVs, the control of the vehicle's external dynamics and powertrain dynamics are often treated separately. Optimizing these two problems together can significantly improve fuel economy. In this paper, an autonomous HEV following a leader is considered. First, the augmented model to integrate the abovementioned dynamics is presented. Second, the optimization problem is defined to find the optimum fuel consumption of the follower in pursuit of a leader in a drive cycle. A customized control strategy based on Approximate Dynamic Programming (ADP) is then explored in which the optimal cost-to-go at each time step is approximated using neural networks. Also, the accuracy of the optimization solution is enhanced by applying the concept of the reachable sets. At last, three case studies show that the examined integrated control strategy outperforms the one with the separated optimization method by an additional 7.4%, 4.6%, and 11.8% improvement in fuel consumption, respectively.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

New Mobility Technology Assessment - Benefits, Risks, and Safety

The age of vehicle automation is upon us. The fundamental perception and control technology is maturing as we speak (and write) with robo-taxis proliferating in select US cities. The news cycle is no longer filled with technological skepticism, but rather societal commentary on our collective response and use of the technology. This maturing of the technology is also accompanied by a renaissance in new types of urban movement technology to more effectively link people with goods, services, and employment, particularly in dense development areas where vehicle congestion (even automated vehicles) prevents high quality mobility. The National Renewable Energy Laboratory, through the DOE Clean Energy to Communities (C2C) program has worked with two jurisdictions to assess the benefits, risks, and safety concerns for a new product offering based on suspended cable technology which is fully automated and proposes an aerial network of self-propelled gondolas. The recognized need, independent of the technology, is to fairly assess the benefits of the proposed transportation system, assess its technical maturity, as well as risks and safety concerns. Using this new technology as an example, a technology represented by Swyft Cities, NREL developed a succession of mini-studies that characterized the technical maturity level, assessed the proposed benefits for Greenville, SC, examined the risks involved in moving forward with an emerging mobility technology, and determined the governing safety protocols and standards that are applicable to the space. These mini-case studies, though centered on Swyft Cities aerial automated gondola technology, are highly transferable to any type of new mobility technology and lays out a repeatable process for assessing new technology within an city or community context.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Joint optimal scheduling for electric vehicle battery swapping-charging system based on wind farms

Insufficiencies in charging facilities limit the broad application of electric vehicles (EVs). In addition, EV can hardly represent a green option if its electricity primarily depends on fossil energy. Considering these two problems, this paper studies a battery swapping-charging system based on wind farms (hereinafter referred to as W-BSCS). In a W-BSCS, the wind farms not only supply electricity to the power grid but also cooperate with a centralized charge station (CCS), which can centrally charge EV batteries and then distribute them to multiple battery swapping stations (BSSs). The operational framework of the W-BSCS is analyzed, and some preprocessing technologies are developed to reduce complexity in modeling. Then, a joint optimal scheduling model involving a wind power generation plan, battery swapping demand, battery charging and discharging, and a vehicle routing problem (VRP) is established. Then a heuristic method based on the exhaustive search and the Genetic Algorithm is employed to solve the formulated NP-hard problem. Numerical results verify the effectiveness of the joint optimal scheduling model, and they also show that the W-BSCS has great potential to promote EVs and wind power.

17 WIND ENERGY↗
DOE OSTI2026

EVs@Scale: NextGen Profiles EVSE Characterization 2025

As part of the U.S. DOE EVs@Scale consortium, the Next-Generation Profiles (NextGen Profiles [NGP]) project presents analysis and results from the characterization of high-power conductive and wireless charging infrastructure. High Power Charging equipment is capable of recharging electric vehicle traction batteries at power levels of 200KW and above. Electric Vehicle Service Equipment (EVSE) characterization involves testing over a wide range of DC charging currents and voltages during nominal and off-nominal conditions. This testing allows for a better understanding of the impact that high-power charging will have on the electric grid. A common set of standard test plans, procedures, and data requirements were applied to the characterization in this document with minor updates and improvements. This report covers all conductive characterization activities performed between October 2024 and September 2025 on the Delta Electronics 350KW Electric Vehicle Charging System, consisting of power cabinet model EIDN-U350KTA01 and dispenser model EIDD-U350SSUUAEG-350.Key Findings include: Output regulation, Efficiency and power factor, Load management, Grid Resilience, Smart Charge Management (SCM) performance, Thermal control system performance, Multi-port simultaneous charging performance, and Selected performance comparisons with other EVSEs characterized in the NextGen Profiles project. Hot and cold temperature testing was not conducted on the Delta 350KW due to laboratory limitations. Future research could include continued testing the Delta hardware under off-nominal temperature conditions including multi-port/multi-session simultaneous charge testing, in addition to collecting data on other high-power conductive chargers to augment.

25 ENERGY STORAGE↗
NASA NTRS1980

Energy efficient engine: Flight propulsion system preliminary analysis and design

The characteristics of an advanced flight propulsion system (FPS), suitable for introduction in the late 1980's to early 1990's, was more fully defined. It was determined that all goals for efficiency, environmental considerations, and economics could be met or exceeded with the possible exception of NOx emission. In evaluating the FPS, all aspects were considered including component design, performance, weight, initial cost, maintenance cost, engine system integration (including nacelle), and aircraft integration considerations. The current FPS installed specific fuel consumption was reduced 14.2% from that of the CF6-50C reference engine. When integrated into an advanced, subsonic, study transport, the FPS produced a fuel burn savings of 15 to 23% and a direct operating cost reduction of 5 to 12% depending on the mission and study aircraft characteristics relative to the reference engine.

Johnston, R. P.↗
NASA NTRS1979

Energy efficient engine. Flight propulsion system preliminary analysis and design

The characteristics of an advanced Flight Propulsion System (FPS) suitable for introduction in the late 1980's to early 1990's, were defined. It was determined that NASA goals for efficiency, environmental considerations, and economics could be met or exceeded with the possible exception of NOx emission. In evaluating the FPS, all aspects were considered including component design, performance, weight, initial cost, maintenance cost, engine-system integration (including nacelle), and aircraft integration considerations. In terms of the NASA goals, the current FPS installed specific fuel consumption was reduced 14.2% from that of the CF6-50C reference engine. When integrated into an advanced, subsonic, study transport, the FPS produced a fuel-burn savings of 15 to 23% and a direct operating cost reduction of 5 to 12% depending on the mission and study-aircraft characteristics relative to the reference engine.

Johnston, R. P.↗
DOE OSTI2026

Commercial integration of advanced nuclear energy with Artificial Intelligence (AI): Possible implications

The integration of advanced nuclear technologies (both fission and fusion) with artificial intelligence (AI) presents unprecedented national security challenges and opportunities. As fusion energy approaches commercial viability alongside advanced Small Modular Reactors (SMRs), their integration with AI and Artificial General Intelligence (AGI) systems could fundamentally transform the global energy and AI landscapes — two pillars of national security. This document briefly examines how AI could accelerate nuclear energy development and deployment while altering existing power structures, a lot could be done to deepen the discussions. Simultaneously, it observes how nuclear-powered AI may expedite advances toward AGI and beyond. These issues are deeply interconnected and thus need to be examined as a whole and more comprehensively than what’s being summarized here. For instance, AI-powered autonomous operation of nuclear facilities could reduce human error but introduce new cybersecurity vulnerabilities and uncertainties. Further investigation would also address how AI-enhanced nuclear technologies might complicate proliferation concerns through advanced fuel cycle management, nuclear materials production and safeguard. The strategic advantage gained by first entities achieving successful AI-nuclear integration could reshape global and national security framework. Timely analysis of these implications may be crucial for policymakers seeking to harness these technologies' benefits while effectively mitigating their potential risks.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2015

Design, Qualification and Integration Testing of the High-Temperature Resistance Temperature Device for Stirling Power System

The Advanced Stirling Radioisotope Generator (ASRG), developed from 2006 to 2013 under the joint sponsorship of the United States Department of Energy (DOE) and National Aeronautics and Space Administration (NASA) to provide a high-efficiency power system for future deep space missions, employed Sunpower Incorporated's Advanced Stirling Convertors (ASCs) with operating temperature up to 840 C. High-temperature operation was made possible by advanced heater head materials developed to increase reliability and thermal-to-mechanical conversion efficiency. During a mission, it is desirable to monitor the Stirling hot-end temperature as a measure of convertor health status and assist in making appropriate operating parameter adjustments to maintain the desired hot-end temperature as the radioisotope fuel decays. To facilitate these operations, a Resistance Temperature Device (RTD) that is capable of high-temperature, continuous long-life service was designed, developed and qualified for use in the ASRG. A thermal bridge was also implemented to reduce the RTD temperature exposure while still allowing an accurate projection of the ASC hot-end temperature. NASA integrated two flight-design RTDs on the ASCs and assembled into the high-fidelity Engineering Unit, the ASRG EU2, at Glenn Research Center (GRC) for extended operation and system characterization. This paper presents the design implementation and qualification of the RTD, and its performance characteristics and calibration in the ASRG EU2 testing.

Deep Space↗
DOE OSTI2026

Electric-vehicle battery second-life and recycling pathways: How economics depend on chemistry, processing, and application

We assess the economics of repurposing and recycling electric vehicle (EV) batteries by estimating the maximum acquisition price repurposers and recyclers could pay for used EV packs across cathode chemistries, first-life conditions, second-life applications, and recycling processes. We develop a novel open-source process-based cost model of a UL-1974-certified repurposing facility and leverage battery degradation models to estimate the maximum acquisition price repurposers could pay for used EV batteries while producing second-life battery energy storage systems with life-adjusted costs equivalent to new systems. We compare these maximum price estimates to maximum prices for recyclers based on cost and revenue estimates from the EverBatt model. We find that repurposing is more economical than recycling for lithium iron phosphate (LFP) batteries, due to their relatively long life and low value materials; recycling is generally more economical than repurposing for lithium nickel cobalt aluminum oxide (NCA) batteries, due to their shorter life and higher value materials; and the economics for lithium nickel manganese cobalt oxide (NMC) batteries depend more heavily on first life retirement conditions and second life application intensity. These results suggest an overall strategy: reuse LFP, recycle NCA, and sort NMC into recycling or repurposing pathways based on state of health and second-life application.

25 ENERGY STORAGE↗
DOE OSTI2020

Cummins Electric Truck with Range-Extending Engine (ETREE) Project (Final Technical Report)

The Cummins Electric Truck with Range Extending Engine (ETREE) program designed, developed, and demonstrated a range extending electric vehicle that employs an electrified propulsion system installed in a class 6 commercial vehicle (Peterbilt 220). This project was relevant to industry and the greater public because at the time of the project there were two keys to widespread electrified commercial vehicle adoption yet to be realize: 1) For pure electrified vehicle adoption, battery improvements are needed: Cost must decrease, and energy density must increase. 2) Electric vehicles must overcome fleet operator risks such as: operations in cold climates, hilly terrain, or where majority of conventional trucks are replaced with electrified vehicles. In the near to medium term these adoption hurdles were address by the objectives of this project. A plug-in hybrid vehicle that could be operated in all electric mode for most of its workday optimizing the use of grid energy with the ability to supplement energy demand with the onboard range extending engine. This project’s architecture provided ability to match a conventional class 6 commercial vehicle range and performance characteristics prior to the ubiquitous adoption of battery electric vehicle charging infrastructure as well. Additionally, the vehicles produced as part of this project can be considered a prototype for a commercially viable heavily electrified commercial vehicle because most of the physical hardware used for the project is commercially available in the market today. The ETREE program met its main objectives and demonstrated 65% fuel consumption reduction as compared to a conventional class 6 vehicle while meeting performance and range expectations. This was achieved by drawing upon the strengths of the assembled team: Cummins, PACCAR, the Ohio State University, Argonne National Laboratory and the National Renewable Energy Laboratory.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2026

Mobility Energy Productivity (MEP) Metric: Partnerships, Applications, and Key Enhancements

The Mobility Energy Productivity (MEP) metric is a holistic measure of transportation systems performance that quantifies the ability of individuals to reach destinations in a cost-efficient and energy-efficient manner. This presentation highlights recent partnerships that have advanced the adoption of MEP as a decision-support tool by various agencies, stakeholders, and researchers. Applications include evaluating multimodal accessibility, comparing system-level energy impacts, and informing infrastructure investment strategies. Key enhancements to the metric - such as expanded regional applications and incorporation of emerging technologies - are also discussed. Together, these efforts highlight the potential of MEP to inform data-driven decisions that shape future transportation systems.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Numerical and experimental analysis of mechanically induced failure in electric vehicle battery modules

Mitigating thermal runaway and cell-to-cell propagation is essential for improving the safety of electric and hybrid vehicles. Enhancing digital twin capabilities to predict battery mechanical abuse is particularly critical for automotive and aerospace applications, where crashworthiness is a key concern. Understanding failure conditions and propagation in battery modules during mechanical abuse is complex due to interactions between structural deformation, heat transfer, electrochemical processes, exothermic reactions and mechanical fracture. While prior studies have focused on modeling cell-level behavior, extending these models to module or pack level is necessary for a system level understating of electric vehicle safety. This study develops coupled large deformation finite element models that simultaneously solve for electrochemistry, material failure, internal short circuit and thermal runaway propagation. The models account for mechanical and thermal interactions between lithium-ion cells and other battery components while the contact interfaces are evolving with time. Model-predicted voltage, temperature and force responses are compared with experimental data for validation. The results demonstrate that the approach captures key failure mechanisms, including thermal propagation through heat transfer, electrical propagation from short circuits in parallel-connected cells, and mechanical propagation via penetration and crack formation. These findings show that computational models are valuable tools for understanding battery module failure and providing insight that can reduce the need for extensive experimental testing.

25 ENERGY STORAGE↗
DOE OSTI2024

Perspectives on Potential Advanced Construction Technologies for Nuclear Energy

Advanced reactor technologies have attracted considerable financial support, catalyzing innovation in the nuclear energy landscape. These next generation reactors are designed with enhanced passive safety systems and the potential for cost reductions. As these advanced reactors approach technological maturity, their commercial success also requires focused examination and essential support. Economic assessments in the nuclear energy sector often emphasize construction costs and the risk of scheduling delays as primary contributors to deployment expenditures. Traditionally, vital elements of nuclear energy deployment including civil/structural engineering, design sophistication and automation have been either undervalued or postponed in the development cycles. Additionally, the nuclear industry’s collective experience in nuclear project execution has diminished over the past several decades due to the infrequency of new plant constructions. Hence, the National Reactor Innovation Center’s (NRIC) Advanced Construction Technology Initiative (ACTI) aims to reduce cost overruns and schedule slippages that have plagued the construction of nuclear power plant projects. With this initiative, NRIC is facilitating the development of advanced nuclear plant construction technologies and approaches through partnerships that would provide game-changing benefits to the construction of advanced nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

ADVANCED CONSTRUCTION TECHNOLOGY INITIATIVE (ACTI)

Advanced reactor technologies have attracted considerable financial support, catalyzing innovation in the nuclear energy landscape. These next generation reactors are designed with enhanced passive safety systems and the potential for cost reductions. As these advanced reactors approach technological maturity, their commercial success also requires focused examination and essential support. Economic assessments in the nuclear energy sector often emphasize construction costs and the risk of scheduling delays as primary contributors to deployment expenditures. Traditionally, vital elements of nuclear energy deployment including civil/structural engineering, design sophistication and automation have been either undervalued or postponed in the development cycles. Additionally, the nuclear industry’s collective experience in nuclear project execution has diminished over the past several decades due to the infrequency of new plant constructions. Hence, The National Reactor Innovation Center’s (NRIC) Advanced Construction Technology Initiative (ACTI) program aims to reduce cost overruns and schedule slippages that have plagued the construction of nuclear power plant projects. With this initiative, NRIC is facilitating the development of advanced nuclear plant construction technologies and approaches through partnerships that would provide game-changing benefits to the construction of advanced nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗