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All sources NASA NTRS DOE OSTI

DOE OSTI2026

Microchannel-based Membrane-less Extraction of Li from Unconventional Lithium Sources & the Separation of REE

This final report provides an overview of the Project's entire duration, covering July 1, 2021 to December 31, 2023. It primarily focuses on the achievements, technological developments, and unique challenges the team faced while working on separating and extracting Lithium from produced waters. The project's primary aim was to create an integrated, high-throughput, membrane-less, and modular microfluidic platform that could extract Lithium from unconventional sources. We have successfully met all goals and milestones envisioned in the SOPO document. The most critical primary milestones, including the Go-No-Go milestone (refer to the Gantt chart in the Appendices), were successfully accomplished. We demonstrated phase separation (>90%) and extraction (>85%) performance in the MPSE using synthetic, and representative produced water composition feed at 50 ml/min total flow through MPSE 36. We have also performed a parametric study of the MPSE operations, beyond the scope of SOPO, exploring operating conditions of current and broader interest. The extended investigation of operational parameters is concurrent with our efforts to seek further development of the MPSE technology beyond the scope of the Project. Along these lines of development, we have made efforts to be responsive to DOE calls for technological developments of other types of resources (beyond PW) for the recovery of Critical Materials and higher TRL development (beyond TRL 4). During the work on this Project, we developed and implemented three innovative technical approaches that emerged from our efforts to successfully meet the Project milestones. The innovative & original technical approaches developed and implemented in this Project are now the contributions to process engineering that could be clearly credited to the Project. First, Convergent Design Approach is a comprehensive feedforward & feedback loop of four design phases: i) design for functionality, ii) design for manufacturing, iii) design for sustainability, and iv) design for market. Next was Process Intensification. A major aim of this Project was to create an innovative phase separation & extraction microscale-based technology for Li separation – thus the words microchannel-based in the Project title. A microscale-based technology is intrinsically in the center of the Process Intensification domain as defined by its unique principles. Therefore, Process Intensification was implicitly envisioned in the Project’s SOPO. Lastly, Time Scale Analysis is a novel tool for discovering the needs and directions of Process Intensification implementations in any process technology. This Project is fully credited for developing and implementing the three novel technical approaches mentioned above. These are general contributions to process engineering that emerged from this Project. Beyond the original SOPO scope, the OSU-U.Pitt research group utilized a Convergent Design methodology, integrating first-principles mathematical modeling with experimental validation on the Minimum Development Vehicle. By creating these Digital Twins, the team rapidly assessed manufacturing iterations to support TEA analysis. This framework further enabled the development of advanced Surface Modification Techniques, where hydrophobic and oleophobic coating strategies were optimized via Digital Twin tools and validated through rigorous 100-hour longevity testing. TEA Analysis: The closing efforts of this Project were focused on the TEA analysis. TEA analysis had two primary functions: i) enabling critical assessments of design variations withing 10 the Concurrent Design Approach, thus enabling evolution of the MPSE design to reach faster- better-cheaper alternatives; and ii) to create a bridge between the accomplishments of this Project and future projects of higher TRL, beyond TRL 6 level. It is important to note that the TEA model created in the Project stirred the technological solutions for the recovery of critical materials toward a vision of a very profitable modular plant that has unique zero-waste water discharge signature. More importantly, thanks to our experimental performance data and conservative assumptions, the TEA model predicts minimal technological and investment risks. Low cost of a modular unit of a nominal capacity of [1000 tons of Li 2 CO 3 /year] positions the MPSE based technology within the reach of community investors, thus offering a paradigm shift in the development of critical technologies. The project successfully navigated two primary challenges: solvent selection and manufacturing adaptation. Restricted by the SOPO to existing literature for lithium recovery, the team identified a critical need for a "material excellence program" to develop next-generation solvents, eventually concluding with a preliminary investigation into promising Ionic Liquids (ILs). Simultaneously, COVID-19 supply chain disruptions forced a pivot from traditional manufacturing to advanced additive methods at ATAMI-OSU. By transitioning from stainless steel to 3D-printed polymer substrates, the team achieved a transformative three-order-of- magnitude reduction in manufacturing costs and compressed prototyping timelines from several months to just two days. The MPSE technology offers significant energy, environmental, and economic advantages by overcoming the traditional bottlenecks of phase-separation hardware and contactor size. Unlike conventional mixer-settlers or membrane-based systems, MPSE operates without moving parts or fouling-prone membranes, achieving robust performance even with challenging, viscous, or particulate-heavy feeds. Key performance metrics include an energy intensity reduction of 5–50x (3–40 kJ/m 3 ) compared to incumbent technologies and a dramatic reduction of processing time to under 60 seconds, which drastically reduces the physical plant footprint. These technical efficiencies translate into superior economic outcomes; for a 100 t/year Li 2 CO 3 facility, implementing MPSE is projected to nearly halve contactor CAPEX (from $\$$6.08M to $\$$3.01M) and significantly increase the project's Net Present Value (NPV), derisking new investment and enabling distributed critical-mineral processing configurations. The commercialization of MPSE technology is being spearheaded by Vigsur Dynamics Inc., which has adopted a structured, parallel approach to technical and business development since its formation in January 2026. Following extensive customer discovery and engagement with the Oregon State University accelerator, Vigsur Dynamics is working to establish a business model that transitions from pilot demonstrations to modular hardware sales, ultimately aiming for a "build-own-operate" service strategy. Current technical milestones—including 100 hours of continuous operation, superior energy efficiency, and successful 6-unit modular scale-up— provide a foundation for this transition. Backed by ongoing IP licensing and a growing network of industrial and venture advisors, the company is actively de-risking the platform to replace conventional mixer-settler systems in the critical minerals market.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Toward large-scale simulation of residual stress and distortion in wire and arc additive manufacturing

In this study, we aim to advance the structural analysis of wire and arc additive manufacturing (WAAM) by considering the thermomechanical features inherent in direct energy deposition. Simulation approaches including the iterative substructure method (ISM), dynamic mesh refining method (DMRM), and graphics processing unit (GPU) based explicit finite element method (FEM) were developed for accelerating additive manufacturing stress analysis that is very time consuming by conventional numerical methods. ISM and DMRM take advantage of the strong nonlinearity phenomenon near the moving heat source by reducing the global iterations and refining the local mesh, respectively. In addition to the use of GPUs, the explicit FEM is accelerated by a time scaling technique based on the inherent strain concept. The residual stress and distortion of two large builds were analyzed, showing very consistent numerical results and good agreement with experiments. Compared with the commercial software Abaqus, the novel approaches reduced the computational cost substantially without compromising accuracy. The GPU code showed the highest computational efficiency (30~70×), while DMRM and ISM had acceleration factors of 9× and 3×, respectively. Finally, such high-fidelity modeling approaches will be very useful for building up a digital twin of WAAM to reduce development time and cost.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Biopolymer Concrete

Cement production for concrete has been responsible for ~7–8% of global greenhouse gas (GHG) emissions, and nearly equally contribution for steel production processes (EPA, 2020). In order to achieve carbon neutrality by 2050, a novel solution has to be investigated. This project aims to develop fundamental mechanistic understanding and experimental characterization to create a 3D printable biopolymer concrete using plant-based polyurethane as an innovative and sustainable alternative for Portland cement concrete, with significantly low carbon footprint. Future construction will utilize the advances in digital additive manufacturing (3D printing) to produce optimal geometries with a minimum waste of materials. Understanding the polymerization process, factors impacting the composite rheology, and the structural behavior of this biopolymer concrete will enable us to engineer the next generation of concrete structures with low carbon footprint. This project aims to improve the nation’s ability to control Greenhouse Gas emission neutrality for the set goal of 2050 via introducing a structurally viable bio-based polymer concrete.

42 ENGINEERING↗

NASA NTRS1972

Development of a digital control system for a spacecraft propulsion test facility.

A digital computer control and abort system which is used at NASA-Lewis Research Center's Plum Brook Test Facilities is described. The system was designed by NASA personnel to control test operations such as rocket engine testing, structure testing, and wind tunnel tests. Because of the nature of spacecraft system testing, particularly rocket engine testing, the unique features of the system are, control function updating at a 20 millisecond rate, continuous abort monitoring and a software system designed for short duration tests rather than continuous on-line control. To accomplish these system requirements, special hardware was designed. The presentation will include a description of the computer system including special interface hardware as well as a general description of the software used.

Smalley, R. R.↗

NASA NTRS1994

Cell Libraries

A NASA contract led to the development of faster and more energy efficient semiconductor materials for digital integrated circuits. Gallium arsenide (GaAs) conducts electrons 4-6 times faster than silicon and uses less power at frequencies above 100-150 megahertz. However, the material is expensive, brittle, fragile and has lacked computer automated engineering tools to solve this problem. Systems & Processes Engineering Corporation (SPEC) developed a series of GaAs cell libraries for cell layout, design rule checking, logic synthesis, placement and routing, simulation and chip assembly. The system is marketed by Compare Design Automation.

Source record↗

NASA NTRS2002

Data Acquisition and Control Systems Laboratory

The Data Acquisition and Control Systems (DACS) Laboratory is a facility at Stennis Space Center that provides an off test-stand capability to develop data-acquisition and control systems for rocket-engine test stands. It is also used to train new employees in state-of-the-art systems, and provides a controlled environment for troubleshooting existing systems, as well as the ability to evaluate the application of new technologies and process improvements. With the SSC propulsion testing schedules, without the DACS Laboratory, it would have been necessary to perform most of the development work on actual test systems, thereby subjecting both the rocket-engine testing and development programs to substantial interference in the form of delays, restrictions on modifications of equipment, and potentially compromising software configuration control. The DACS Laboratory contains a versatile assortment of computer hardware and software, digital and analog electronic control and data-acquisition equipment, and standard electronic bench test equipment and tools. Recently completed Control System development and software verification projects include support to the joint NASA/Air Force Integrated Powerhead Demonstration (IPD) LOX & LH2 PreBurner and Turbopump ground testing programs. In other recent activities, the DACS Laboratory equipment and expertise have supported the off-stand operation of high-pressure control valves to correct valve leak problems prior to installation on the test stand. Future plans include expanding the Laboratory's capabilities to provide cryogenic control valve characterization prior to installation, thereby reducing test stand activation time.

Holland, Randy↗

DOE OSTI2025

Probing the Kitaev honeycomb model on a neutral-atom quantum computer

Quantum simulations of many-body systems are among the most promising applications of quantum computers. In particular, models based on strongly correlated fermions are central to our understanding of quantum chemistry and materials problems, and can lead to exotic, topological phases of matter. However, owing to the non-local nature of fermions, such models are challenging to simulate with qubit devices. Here we realize a digital quantum simulation architecture for two-dimensional fermionic systems based on reconfigurable atom arrays. We utilize a fermion-to-qubit mapping based on Kitaev’s model on a honeycomb lattice, in which fermionic statistics are encoded using long-range entangled states. We prepare these states efficiently using measurement and feedforward, realize subsequent fermionic evolution through Floquet engineering with tunable entangling gates interspersed with atom rearrangement, and improve results with built-in error detection. Leveraging this fermion description of the Kitaev spin model, we efficiently prepare topological states across its complex phase diagram and verify the non-Abelian spin-liquid phase by evaluating an odd Chern number. We further explore this two-dimensional fermion system by realizing tunable dynamics and directly probing fermion exchange statistics. Finally, we simulate strong interactions and study the dynamics of the Fermi–Hubbard model on a square lattice. These results pave the way for digital quantum simulations of complex fermionic systems for materials science, chemistry and high-energy physics.

atomic and molecular physics↗

NASA NTRSDate not supplied

Lean Model-Based Systems Engineering on the NASA High-Density Vertiplex Subproject

The High Density Vertiplex (HDV) subproject of NASA’s Advanced Air Mobility (AAM) project adopted Model-Based Systems Engineering (MBSE) in July of 2020, prior to subproject formulation. A small and lean team of HDV Systems Engineers (SE) are utilizing MagicDraw to execute NASA SE processes via MBSE. The SEs learned how to use MagicDraw from scratch and HDV is the first project for which the SEs have utilized MagicDraw. This presentation will demonstrate project technical execution via MBSE, utilizing the digital elements built into the SysML (Systems Modeling Language). SysML provides a model-centric means of carrying out the NASA SE common technical processes by providing tools for complete system modeling, including requirements and interface management and design capture. The authors also leverage and extend SysML to perform other SE tasks, such as Verification and Validation (V&V) tracking. MBSE has two main purposes for HDV: 1) documenting the subproject’s logical architecture for distribution outside of the subproject, 2) capturing the subproject’s physical architecture in a single-source-of-truth for use by the subproject’s members. This presentation details the challenges, lessons learned, and solutions that were encountered in implementing MBSE in the first iteration on a multi-iteration, full-lifecycle design, build, fly project.

systems engineering↗

DOE OSTI2025

Adapting Traditional Hazards Analysis Methods to Address Cyber Risks

Traditional hazards analysis (HA) methods, originally developed to address physical and operational risks, often fall short when it comes to identifying and mitigating cyber threats. These cyber threats pose unique and evolving risks to critical infrastructure and industrial control systems (ICS). This report explores the integration of Cyber-Informed Engineering (CIE) principles into existing HA methods to enhance their ability to address cyber-induced risks. CIE provides organizations with a practical, cost-effective approach to closing the gap between traditional HA methods and the need for cyber risk mitigation. By leveraging existing safety processes and controls, CIE allows users to examine and mitigate cyber vulnerabilities without overhauling existing HA methods. This report identifies areas where HA and CIE naturally align and where their approaches diverge. It emphasizes how CIE principles can be used to adapt HA methods, broadening their scope to include cyber risks and enabling the mitigation of cyber- induced impacts alongside traditional hazards and failure scenarios. This report examines how CIE can be applied across various HA methods—such as Hazard and Operability Studies (HAZOP), Probabilistic Risk Assessment (PRA), Failure Modes and Effects Analysis (FMEA), Systems-Theoretic Process Analysis (STPA), Hazard and Consequence Analysis for Digital Systems (HAZCADS), and Layers of Protection Analysis (LOPA). It provides strategies for integrating CIE to strengthen the identification, assessment, and mitigation of cyber-induced risks. The findings offer a structured entry point for organizations to embed CIE concepts into hazards and safety analyses, as well as broader engineering processes, ultimately supporting the design and operation of a more resilient infrastructure.

42 ENGINEERING↗

DOE OSTI2025

Adapting Traditional Hazards Analysis Methods to Address Cyber Risks

42 - ENGINEERING↗

NASA NTRS1990

Automating analog design: Taming the shrew

The pace of progress in the design of integrated circuits continues to amaze observers inside and outside of the industry. Three decades ago, a 50 transistor chip was a technological wonder. Fifteen year later, a 5000 transistor device would 'wow' the crowds. Today, 50,000 transistor chips will earn a 'not too bad' assessment, but it takes 500,000 to really leave an impression. In 1975 a typical ASIC device had 1000 transistors, took one year to first samples (and two years to production) and sold for about 5 cents per transistor. Today's 50,000 transistor gate array takes about 4 months from spec to silicon, works the first time, and sells for about 0.02 cents per transistor. Fifteen years ago, the single most laborious and error prone step in IC design was the physical layout. Today, most IC's never see the hand of a layout designer: and automatic place and route tool converts the engineer's computer captured schematic to a complete physical design using a gate array or a library of standard cells also created by software rather than by designers. CAD has also been a generous benefactor to the digital design process. The architect of today's digital systems creates the design using an RTL or other high level simulator. Then the designer pushes a button to invoke the logic synthesizer-optimizer tool. A fault analyzer checks the result for testability and suggests where scan based cells will improve test coverage. One obstinate holdout amidst this parade of progress is the automation of analog design and its reduction to semi-custom techniques. This paper investigates the application of CAD techniques to analog design.

Barlow, A.↗

NASA NTRS1994

Generalized implementation of software safety policies

As part of a research program in the engineering of software for safety-critical systems, we are performing two case studies. The first case study, which is well underway, is a safety-critical medical application. The second, which is just starting, is a digital control system for a nuclear research reactor. Our goal is to use these case studies to permit us to obtain a better understanding of the issues facing developers of safety-critical systems, and to provide a vehicle for the assessment of research ideas. The case studies are not based on the analysis of existing software development by others. Instead, we are attempting to create software for new and novel systems in a process that ultimately will involve all phases of the software lifecycle. In this abstract, we summarize our results to date in a small part of this project, namely the determination and classification of policies related to software safety that must be enforced to ensure safe operation. We hypothesize that this classification will permit a general approach to the implementation of a policy enforcement mechanism.

Knight, John C.↗

NASA NTRS2003

Dual-Pump Coherent Anti-Stokes Raman Scattering Temperature and CO2 Concentration Measurements

Measurements of temperature and CO2 concentration using dual-pump coherent anti-Stokes Raman scattering, (CARS) are described. The measurements were performed in laboratory flames,in a room-temperature gas cell, and on an engine test stand at the U.S. Air Force Research Laboratory, Wright-Patterson Air Force Base. A modeless dye laser, a single-mode Nd:YAG laser, and an unintensified back-illuminated charge-coupled device digital camera were used for these measurements. The CARS measurements were performed on a single-laser-shot basis. The standard deviations of the temperatures and CO2 mole fractions determined from single-shot dual-pump CARS spectra in steady laminar propane/air flames were approximately 2 and 10% of the mean values of approximately 2000 K and 0.10, respectively. The precision and accuracy of single-shot temperature measurements obtained from the nitrogen part of the dual-pump CARS system were investigated in detail in near-adiabatic hydrogen/air/CO2 flames. The precision of the CARS temperature measurements was found to be comparable to the best results reported in the literature for conventional two-laser, single-pump CARS. The application of dual-pump CARS for single-shot measurements in a swirl-stabilized combustor fueled with JP-8 was also demonstrated.

Lucht, Robert P.↗

DOE OSTI2020

Vehicle Platooning: An Energy Consumption Perspective

Urban traffic congestion is a chronic problem faced by many cities in the US and worldwide. It results in inefficient infrastructure use as well as increased vehicle fuel consumption and emission levels. Excessive fuel consumptions add extra costs to commuters as well as transportation businesses. Consuming less fuel and thus reducing costs by a single percentage digit can have a significant impact on the balance sheet as well as the protection of the environment. Researchers have developed, and continue to develop, tools and systems to optimize the operations of fleets as well as engines in order to burn less fuel and therefore generate less CO2 emissions. Platooning is one such tool that attempts to maintain relatively small distances (i.e. pre-determined time gap) between consecutive vehicles. It has the potential to increase the capacity of the road as well as reduce the consumed fuel. In this paper, we use a fuel consumption model for internal combustion light-duty vehicles, electric vehicles, hybrid electric vehicles, buses and trucks in order to determine and quantify the effects of platooning on a fleet fuel consumption. The results suggest that a reduction of up to 3%, 3.5%, 4.5 %, 10%, and 15% in fuel consumption can be achieved for internal combustion engine vehicles, hybrid electric vehicles, electric vehicles, buses and trucks.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2014

The Apollo Lunar Sample Image Collection: Digital Archiving and Online Access

The primary goal of the Apollo Program was to land human beings on the Moon and bring them safely back to Earth. This goal was achieved during six missions - Apollo 11, 12, 14, 15, 16, and 17 - that took place between 1969 and 1972. Among the many noteworthy engineering and scientific accomplishments of these missions, perhaps the most important in terms of scientific impact was the return of 382 kg (842 lb.) of lunar rocks, core samples, pebbles, sand, and dust from the lunar surface to Earth. Returned samples were curated at JSC (then known as the Manned Spacecraft Center) and, as part of the original processing, high-quality photographs were taken of each sample. The top, bottom, and sides of each rock sample were photographed, along with 16 stereo image pairs taken at 45-degree intervals. Photographs were also taken whenever a sample was subdivided and when thin sections were made. This collection of lunar sample images consists of roughly 36,000 photographs; all six Apollo missions are represented.

Todd, Nancy S.↗

DOE OSTI2022

Safety-Related Instrumentation and Control Pilot Upgrade: Initial Scoping Phase Implementation and Lessons Learned

In May 2016, the U.S. Nuclear Regulatory Commission (NRC) staff provided a digital instrumentation and control (I&C) regulatory infrastructure integrated action plan to the NRC for approval. One of the objectives of that plan was to establish a clear regulatory structure with reduced regulatory uncertainty to enable the expanded safe use of digital I&C in commercial nuclear reactors while continuing to ensure safety and security. To achieve this end, the NRC, with collaboration from industry, developed a streamlined License Amendment Request Alternate Review (AR) process for safety-related (SR) digital I&C upgrades. In spite of this effort, the industry has remained reluctant to perform such I&C upgrades because of perceived regulatory and financial risks associated with being the first or an early adopter of the AR process for SR I&C upgrades. The U.S. Department of Energy Light Water Reactor Sustainability Program at the Idaho National Laboratory performed Initial Scoping Phase research to help break this impasse by supporting a SR I&C Pilot Upgrade, working with MPR Associates, ScottMadden Inc., and Exelon Generation. Exelon’s Limerick Generating Station (LGS) was selected as the target for this research. This paper summarizes the Initial Scoping Phase engineering and operations, licensing, and project management activities necessary to bound the scope, schedule, and estimated cost of the project sufficiently to enable utility management authorization of Conceptual Design Phase activities. These efforts and associated products are intended to provide a template to support larger industry efforts to perform similar upgrades as a foundation stone for a digital transformation that will improve plant safety, reliability, and operational performance while lowering plant total cost of ownership. As a result of the combined effort of Exelon Generation and research participants, Conceptual Design Phase activities for the subject upgrade at LGS were approved by Exelon. Further, the U.S. Department of Energy also awarded a $50 million cost share award to Exelon in order to pave the way for SR I&C modernization and associated control room upgrades across the U.S. nuclear fleet. Additional research reports are planned for the Conceptual Design Phase, Detailed Design Phase, and the Implementation Phase of the LGS project to document the process followed and promulgate lessons learned to industry.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

High-Fidelity Modeling of a Type-5 Wind Turbine Gearbox

Type-5 wind turbines are characterized by their use of a hydraulic torque converter and permanent synchronous generator. This combination promotes steady and grid-ready energy without the use of a power converter. Thus, researchers were prompted to study the potential impact on grid reliability, stability, and resilience using a Real Time Digital Simulator (RTDS) model of the type-5 turbine, including a high-fidelity model of its gear box.

13 - HYDRO ENERGY↗

DOE OSTI2021

From the Starship Enterprise to Los Alamos National Laboratory: Artificial Intelligence and Machine Learning in the NSRC

Artificial Intelligence (AI) conjures up different emotions in different people. Some view it with fear, imagining a malevolent AI similar to Skynet in the Terminator movies. Others see something benevolent, such as the character Data in Star Trek: The Next Generation. Still others see it as a means to advance the frontiers of science, engineering, and technology to new levels not possible through traditional means. At the National Security Research Center (NSRC or the Center), we see AI as a tool to help us go through the monumental tasks we have in digitizing, cataloging, and searching our collections.

97 MATHEMATICS AND COMPUTING↗