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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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At least 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Redefining Design for Remanufacturing: A Practical Methodology for Prioritizing Remanufacturing Design Rules

Products are often discarded when they fail or no longer meet user needs. These outcomes are frequently shaped by early design decisions. While remanufacturing offers a sustainable alternative by restoring products to like‐new condition, its potential is often limited by designs that do not consider remanufacturing from the outset. This research addresses that challenge by introducing a structured Design for Remanufacturing (DfRem) methodology and a CAD‐integrated tool to support real‐time design decisions. The DfRem framework introduces a new primary design function focused on preserving product functionality across its life cycle. It is supported by a fault tree that identifies failure modes that limit remanufacturing potential and a hierarchy of design principles including Prevent, Minimize, Relocate, Restore, and others. Each principle is linked to actionable design rules that help engineers reduce the need for remanufacturing or improve its efficiency when necessary. To operationalize this framework, we developed CAD plugins for Autodesk Inventor and PTC Creo. These tools use a state machine model to present prioritized design rules based on selected failure modes and user input. By embedding DfRem logic directly into widely used CAD environments, the tool enables engineers to make sustainability‐informed decisions without disrupting existing workflows. Furthermore, this approach highlights the critical role of design in enabling circular and resource‐efficient product development, making remanufacturing a more practical and accessible strategy during the early stages of product design.

CAD↗
DOE OSTI2020

Predicting a Sharp Decline in Selectivity for Catalytic Esterification of Alcohols from van der Waals Interactions

Controlling the selectivity of catalytic reactions is a critical aspect of improving energy efficiency in the chemical industry; thus, predictive models are of key importance. Herein the performance of a heterogeneous, nanoporous Au catalyst is predicted for the complex catalytic self-coupling of the series of C 2 -C 4 alkyl alcohols, based solely on the known kinetics of the elementary steps of the catalytic cycle for methanol coupling, using scaling methods augmented by density functional theory. Notably, a sharp decrease in selectivity for ester formation with increasing molecular weight to favor the aldehyde due to van der Waals interactions of reaction intermediates with the surface was predicted and subsequently verified quantitatively by experiment. Furthermore, the agreement between theory and experiment clearly demonstrates the efficacy of this approach for building a predictive model of catalytic behavior for a homologous set of reactants using a small set of experimental information.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Predicting a Sharp Decline in Selectivity for Catalytic Esterification of Alcohols from van der Waals Interactions

Controlling the selectivity of catalytic reactions is a critical aspect of improving energy efficiency in the chemical industry; thus, predictive models are of key importance. Herein the performance of a heterogeneous, nanoporous Au catalyst is predicted for the complex catalytic self-coupling of the series of C 2 –C 4 alkyl alcohols, based solely on the known kinetics of the elementary steps of the catalytic cycle for methanol coupling, using scaling methods augmented by density functional theory. Notably, a sharp decrease in selectivity for ester formation with increasing molecular weight to favor the aldehyde due to van der Waals interactions of reaction intermediates with the surface was predicted and subsequently verified quantitatively by experiment. Further, the agreement between theory and experiment clearly demonstrates the efficacy of this approach for building a predictive model of catalytic behavior for a homologous set of reactants using a small set of experimental information.

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

Balancing Doses of EL222 and Light Improves Optogenetic Induction of Protein Production in Komagataella phaffii

ABSTRACT Komagataella phaffii, also known asPichia pastoris, is a powerful host for recombinant protein production, in part due to its exceptionally strong and tightly controlled P AOX1 promoter. MostK. phaffiibioprocesses for recombinant protein production rely on P AOX1 to achieve dynamic control in two‐phase processes. Cells are first grown under conditions that repress P AOX1 (growth phase), followed by methanol‐induced recombinant protein expression (production phase). In this study, we propose a methanol‐free approach for dynamic metabolic control inK. phaffiiusing optogenetics, which can help enhance input tunability and flexibility in process optimization and control. The light‐responsive transcription factor EL222 fromErythrobacter litoralisis used to regulate protein production from the P C120 promoter inK. phaffiiwith blue light. We used two system designs to explore the advantages and disadvantages of coupling or decoupling EL222 integration with that of the gene of interest. We investigate the relationship between EL222 gene copy number and light dosage to improve production efficiency for intracellular and secreted proteins. Experiments in lab‐scale bioreactors demonstrate the feasibility of the outlined optogenetic systems as potential alternatives to conventional methanol‐inducible bioprocesses usingK. phaffii.

Biotechnology & Applied Microbiology↗
DOE OSTI2022

Elucidating Instabilities Contributing to Capacity Fade in Bipyridine‐Based Materials for Non‐aqueous Flow Batteries

Abstract Metal‐based non‐aqueous redox flow batteries have the potential for long‐term energy storage if stability requirements can be achieved. One such stability issue in metal coordination complexes arises from ligand shedding in the anolyte upon reduction. Recognizing that the free ligands are relatively more stable than the metal coordination complex under highly reducing conditions, we evaluated a family of metal‐free bipyridinium materials as flow battery anolytes with the corresponding iron coordination complex as the catholyte. Bipyridinium compounds were functionalized for increased electrochemical stability, cycled in flow cells to understand efficiencies, and analyzed for degradation products. Methylation of the bipyridine nitrogens increased electrochemical stability yet left the reduced molecule susceptible to radical‐induced bond cleavage. Subsequent functionalization of bipyridine with carbomethoxy groups resulted in good battery performance with 96 % Coulombic and 90 % voltage efficiency, and improved cycling stability over a methoxy‐substituted anolyte with 14 % vs 36 % capacity fade in the first charge‐discharge cycle.

Kolesnichenko, Claudina X.↗
DOE OSTI2022

Enabling power measurement and control on Astra: The first petascale Arm supercomputer

Astra, deployed in 2018, was the first petascale supercomputer to utilize processors based on the ARM instruction set. The system was also the first under Sandia's Vanguard program which seeks to provide an evaluation vehicle for novel technologies that with refinement could be utilized in demanding, large-scale HPC environments. In addition to ARM, several other important first-of-a-kind developments were used in the machine, including new approaches to cooling the datacenter and machine. Here we document our experiences building a power measurement and control infrastructure for Astra. While this is often beyond the control of users today, the accurate measurement, cataloging, and evaluation of power, as our experiences show, is critical to the successful deployment of a large-scale platform. While such systems exist in part for other architectures, Astra required new development to support the novel Marvell ThunderX2 processor used in compute nodes. In addition to documenting the measurement of power during system bring up and for subsequent on-going routine use, we present results associated with controlling the power usage of the processor, an area which is becoming of progressively greater interest as data centers and supercomputing sites look to improve compute/energy efficiency and find additional sources for full system optimization.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Tailoring Chemical Absorption-Precipitation to Lower the Regeneration Energy of a CO 2 Capture Solvent

Solvent-based CO 2 capture consumes significant amounts of energy for solvent regeneration. To improve energy efficiency, this study investigates CO 2 fixation in a solid form through solvation, followed by ionic self-assembly-aided precipitation. Based on the hypothesis that CO 3 2- ions may bind with monovalent metal ions, we introduced Na + into an aqueous hexane-1,6-diamine solution where CO 2 forms carbamate and bicarbonate. Then, Na + ions in the solvent act as a seed for ionic self-assembly with diamine carbamate to form an intermediate ionic complex. The recurring chemical reactions lead to the formation of an ionic solid from a mixture of organic carbamate/carbonate and inorganic sodium bicarbonate (NaHCO 3 ), which can be easily removed from the aqueous solvent through sedimentation or centrifugation and heated to release the captured CO 2 . Mild-temperature heating of the solids at 80–150 °C causes decomposition of the solid CO 2 -diamine-Na molecular aggregates and discharge of CO 2 . This sorbent regeneration process requires 6.5–8.6 GJ/t CO 2 . It was also found that the organic carbamate/carbonate solid, without NaHCO 3 , contains a significant amount of CO 2 , up to 6.2 mmol CO 2 /g-sorbent, requiring as low as 2.9–5.8 GJ/t CO 2 . In conclusion, molecular dynamic simulations support the hypothesis of using Na + to form relatively less stable, yet sufficiently solid, complexes for the least energy-intensive recovery of diamine solvents compared to bivalent carbonate–forming ions.

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

A semi–automatic analytical methodology for characterizing the energy consumption of MRI systems using load duration curves

Background and purpose: Magnetic resonance imaging (MRI) scanners are a major contributor to greenhouse gas emissions from the healthcare sector, and efforts to improve energy efficiency and reduce energy consumption rely on quantification of the characteristics of energy consumption. The purpose of this work was to develop a semi-automatic analytical methodology for the characterization of the energy consumption of MRI systems using only the load duration curve (LDC). LDCs are a fundamental tool used across various fields to analyze and understand the behavior of loads over time. Methods: An electric current transformer sensor and data logger were installed on two 3T MRI scanners from two vendors, termed M1 (outpatient scanner) and M2 (inpatient/emergency scanner). Data was collected for 1 month (7/11/2023 to 8/11/2023). Active power was calculated, assuming a balanced three-phase system, using the average current measured across all three phases, a 480 V reference voltage for both machines, and vendor-provided power factors. An LDC was constructed for each system by sorting the active power values in descending order and computing the cumulative time (in units of percentage) for each data point. The first derivative of the LDC was then computed (LDC’), smoothed by convolution with a window function (sLDC’), and used to detect transitions between different system modes including (in descending power levels): scan, prepared-to-scan, idle, low-power, and off. The final, segmented LDC was used to measure time (% total time), total energy (kWh), and mean power (kW) for each system mode on both scanners. The method was validated by comparing mean power values, computed using the segmented 1-month LDC, for each nonproductive system mode (i.e., prepared-to-scan, idle, lower-power, and off) against power levels measured after a deliberate system shutdown was performed for each scanner (1 day worth of data). Results: The validation revealed differences in mean power values <1.4% for all nonproductive modes and both scanners. In the scan system mode, the mean power values ranged from 29.8 to 37.2 kW and the total energy consumed for 1 month ranged from 11 106 to 14 466 kWh depending on the scanner. Over the course of 1 month, the portion of time the scanners were in nonproductive modes ranged from 76% to 80% across scanners and the nonproductive energy consumption ranged from 8010 to 6722 kWh depending on the scanner. The M1 (outpatient) scanner consumed 99.9 and 183.9 kWh/day in idle mode for weekdays and weekends, respectively, because the scanner spent 23% more time proportionally in idle mode on the weekends. Conclusions: A semi-automatic method for quantifying energy consumption characteristics of MRI scanners was introduced and validated. This method is relatively simple to implement as it requires only power data from the scanners and avoids the technical challenges associated with extracting and processing scanner log files. Finally, the methodology enables quantitative evaluation of the power, time, and energy characteristics of MRI scanners in scan and nonproductive system modes, providing baseline data and the capability of identifying potential opportunities for enhancing the energy efficiency of MRI scanners.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Nanofiltration Membranes for Li + /Mg 2+ Separation: Materials and Mechanisms

Nanofiltration (NF) membranes have garnered significant interest for Li + /Mg 2+ separation, a crucial step in lithium extraction from brines. The state-of-the-art commercial LiNE-XD membrane exhibits a Li + /Mg 2+ separation factor (SF Li/Mg ) of 42 at pH 3.3, due to the positive charges on the membrane surface and its strong size-sieving ability. Membranes with higher separation factors at a broad pH range are being pursued to improve separation efficiency. This work aims to provide a timely and comprehensive assessment of advanced NF membranes with superior Li + /Mg 2+ separation properties, as well as their structure and property relationships for designing next-generation membranes. We describe transport mechanisms for ions in NF membranes and discuss governing parameters and models employed to quantify the Li + /Mg 2+ separation. High-performance membrane materials are exhaustively introduced, including commercial and modified polyamides, two-dimensional materials, metal–organic frameworks, crown ethers, and their blends. Finally, we critically compare these membranes in an upper bound plot and highlight the opportunities and challenges of NF membranes for practical Li + /Mg 2+ separations.

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

Improving the five-point bootstrap

We present a new algorithm for the numerical evaluation of five-point conformal blocks in d-dimensions, greatly improving the efficiency of their computation. To do this we use an appropriate ansatz for the blocks as a series expansion in radial coordinates, derive a set of recursion relations for the unknown coefficients in the ansatz, and evaluate the series using a Padé approximant to accelerate its convergence. We then study the 〈σσϵσσ〉 correlator in the 3d critical Ising model by truncating the operator product expansion (OPE) and only including operators with conformal dimension below a cutoff ∆ ⩽ ∆cutoff. We approximate the contributions of the operators above the cutoff by the corresponding contributions in a suitable disconnected five-point correlator. Using this approach, we compute a number of OPE coefficients with greater accuracy than previous methods.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Analytic reconstruction with massive particles: one-loop amplitudes for $0\to \overline{q} qt\overline{t}H$

We present an analytic reconstruction of one-loop amplitudes for the process $0\to \overline{q} qt\overline{t}H$. Our calculation is a novel use of analytic reconstruction, retaining explicit covariance in the massive spin states through the massive spinor-helicity formalism. The analytic reconstruction relies on embedding the massive five-point kinematics in a fully massless eight-point phase space while still building a minimal ansatz directly in the five-point phase space. In order to obtain compact analytic expressions it is necessary to identify suitable partial fraction decompositions and extract common numerator factors, which we achieve through careful inspection of limits in which pairs of denominators vanish. We find that the resulting amplitudes are more numerically efficient than ones computed using automatic methods but that the gains are not as significant as in the massless case, at least at present. The method opens the door to applications at two-loop order, where numerical efficiency and improvements in the reconstruction methodology are more crucial, especially with regards to the number of free parameters in the ansatz.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

Flame stability analysis of flame spray pyrolysis by artificial intelligence

Flame spray pyrolysis (FSP) is a process used to synthesize nanoparticles through the combustion of an atomized precursor solution; this process has applications in catalysts, battery materials, and pigments. Current limitations revolve around understanding how to consistently achieve a stable flame and the reliable production of nanoparticles. Machine learning and artificial intelligence algorithms that detect unstable flame conditions in real time may be a means of streamlining the synthesis process and improving FSP efficiency. In this study, the FSP flame stability is first quantified by analyzing the brightness of the flame's anchor point. This analysis is then used to label data for both unsupervised and supervised machine learning approaches. The unsupervised learning approach allows for autonomous labeling and classification of new data by representing data in a reduced dimensional space and identifying combinations of features that most effectively cluster it. The supervised learning approach, on the other hand, requires human labeling of training and test data but is able to classify multiple objects of interest (such as the burner and pilot flames) within the video feed. The accuracy of each of these techniques is compared against the evaluations of human experts. Both the unsupervised and supervised approaches can track and classify FSP flame conditions in real time to alert users of unstable flame conditions. This research has the potential to autonomously track and manage flame spray pyrolysis as well as other flame technologies by monitoring and classifying the flame stability.

42 ENGINEERING↗
DOE OSTI2023

Experimental approach for development of a powder spreading metric in additive manufacturing

The powder spreading is a vital step of powder-based additive manufacturing (AM) processes. The quality of spread powder can considerably influence the properties of fabricated parts. Poorly packed powder beds with high surface roughness result in printed part layers with large porosity and low dimensional accuracy, leading to poor mechanical properties. Therefore, the powder spreadability and its dependence on process parameters and powder characteristics should be quantified to improve the efficiency of powder-based AM methods. This study proposes a novel dimensionless powder spreadability metric that can be commonly used in different powder-based AM processes. The quality of spread powder in terms of powder bed density and surface roughness was evaluated by adjusting the process parameters including recoating velocity and layer thickness, and powder characteristics including particle size distribution. In addition, the dynamic repose angle was proposed and examined as another powder spreadability metric. Furthermore, the results showed that these two proposed metrics were strongly correlated and lower recoating velocity and larger layer thickness led to higher spreadability and lower dynamic repose angle.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Towards High-Speed friction stir welding of 25 mm Thick AA2139-T8: tool innovation and process development

Joining thick plates (≥ 12 mm) of aluminum (Al) alloys is challenging due to high tool forces, uneven material flow, and non-uniform heat distribution through the material’s thickness. Recent advancements in tool design and welding parameters for friction stir welding (FSW) in thick plates butt joining have encountered a developmental plateau, highlighting the need for innovative approaches to overcome existing limitations. Here, this study focuses on the systematic development of single-pass and double-pass FSW processes for high-strength aluminum alloy AA2139-T8, to improve joint efficiency and enable high-speed welding capabilities. Experimental evidence is presented for a novel tool design with opposing pin threads, enabling high-speed (178 mm/min) single-pass friction stir butt welding of 25 mm thick AA2139-T8. A series of FSW trials was conducted both in air and with a trailing water spray, using steel backing plates (BPs) to investigate the impact of quenching and cooling rates on process response and joint performance. A joint efficiency of 83% was attained using the novel tool features and effectively controlling process forces and thermal boundary conditions.

AA2139-T8↗
DOE OSTI2026

FIRM: federated image reconstruction using multimodal tomographic data

Here, we propose a federated algorithm for reconstructing images using multimodal tomographic data sourced from dispersed locations, addressing the challenges of traditional unimodal approaches that are prone to noise and reduced image quality, as well as the limitations of centralized multimodal approaches that require extensive data transfer, leading to significant communication overhead, storage demands, and potential data privacy concerns. Our approach formulates a joint inverse optimization problem incorporating multimodality constraints and solves it in a federated framework through local gradient computations complemented by lightweight central operations, thereby ensuring data decentralization. Leveraging the connection between our federated algorithm and the quadratic penalty method, we introduce an adaptive step-size rule with guaranteed sublinear convergence. Numerical results demonstrate superior computational efficiency and improved image reconstruction quality compared to existing approaches.

federated algorithm↗
DOE OSTI2019

A Thermodynamic Model Toward the Comprehension of Ferrous Burden Softening and Melting Using FactSage Macro-Processing

The softening and melting properties of iron-bearing materials play a decisive role in the formation of the cohesive zone, which greatly affects blast furnace gas flow distribution and heat-transfer efficiency. To improve the understanding regarding the evolution of condensed phases during reduction, softening, and melting, a thermodynamic model has been developed using FactSage™ thermodynamic software and macro-processing. The model was constructed using a series of equilibrium stages and splitters to determine flow directions of streams and to consider kinetic inhibitions. For all iron-bearing materials studied, the methodology proposed for modeling was capable of obtaining reduction degrees in very good agreement to its experimental data. The evolution of solid phases was qualitatively comparable to the available literature, with Fayalite, Kirschsteinite, Melilite, and FeO as the main solid phases in equilibrium before slag formation. The comparison between the profiles of the calculated slag mass fraction and the experimental pressure drop showed a close relation between these properties. Moreover, the level of heterogeneity of each raw material may play a significant role in the interpretation of its results.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Energy cost savings and expected payback for Re-tuning the controls of US Army buildings

The Headquarters Department of the Army (HQDA) sponsored a study to determine the national impact of deploying the Re-tuning™ methodology in 5 buildings types that account for over 40% of the Army’s conditioned building stock. Re-tuning is a systematic process that improves operational efficiency and reduces energy consumption at no- or low-cost through the building automation system (BAS) by correcting operational problems that plague buildings. The study relied on successful demonstration of the re-tuning methodology at 4 pilot US Army installations that informed a holistic effort that included simulating 12 individual re-tuning energy efficiency measures (EEMs) and 6 packages of EEMs in 5 selected Army building prototype models that represent 311 million ft2 (28.9 million m2) of the Army’s conditioned floor space. Both the baseline buildings and the packages were customized to capture the expected outcomes of re-tuning a diverse set of buildings. The study highlighted the benefit of individual re-tuning EEMs and economics of implementing packages of EEMs in applicable Army buildings across 16 climates and 2 building vintages. The average whole-building energy savings ranged from 10.8% to 40.5% by building type, with the company operations facility (COF) building having the highest value proposition from re-tuning. In addition, the study reveals that all large office (LO) buildings in the Army are economical to re-tune. The total modeled cost savings potential for re-tuning the five building types across the US Army is $204/1,000 sf ($220/100 m2), or $64M annually. This cost savings represents 5.6% of all the Army’s energy expenditures.

Fernandez, Nicholas EP↗