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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 sources NASA NTRS DOE OSTI

DOE OSTI2017

Cluster 1: commercializing additive manufacturing—hurdles in materials characterization and testing

A major challenge in the commercialization of additive manufactured (AM) materials and processes is the ability to achieve acceptance of processes and products. There has been some progress towards acceptance has been made by adapting legacy qualification paradigms to match with the very limited process control and monitoring offered by AM machines. The opportunity for in-situ measurement can provide process monitoring and control perhaps changing the way we qualify parts however it is limited by lack of adequate process measurement methods. New measurement techniques, sensors and correlations to relevant phenomena are needed that enable process control and monitoring for consistently producing high quality articles. Beyond process data we need to characterize uncertainties of performance in all aspects of material, process and final part. These are prerequisites to achieving articles that are indeed worthy of materials characterization efforts that establish a microstructural reference of desirable performance through process-structure-property relations. Only then can industry apply physics based understanding of the material, part and process to probabilistically predict performance of an AM part. Our paper provides a brief overview, discussion of hurdles and key areas where R&D investment is needed.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Conflicts in the coastal zone: human impacts on commercially important fish species utilizing coastal habitat

Abstract Coastal ecosystems are ecologically, culturally, and economically important, and hence are under pressure from diverse human activities. We reviewed the literature for existing evidence of effects of human-induced habitat changes on exploited fish utilizing coastal habitats. We focused on fish species of the Northeast Atlantic for which fisheries advice is provided by International Council for the Exploration of the Sea (ICES) and which utilize coastal habitats for at least one life-history stage (LHS). We found that 92% of these species are impacted by human activity in at least one LHS while utilizing coastal habitat and 38% in multiple stages. Anthropogenic pressures most commonly shown to impact these fish species were toxicants and pollutants (75% of species). Eutrophication and anoxia, invasive species, and physical coastal development affected about half of the species (58, 54, and 42% of species, respectively), while indirect fishing impacts affected a minority (17% of species). Moreover, 71% of the ICES advice species that utilize coastal habitats face impacts from more than one pressure, implying cumulative effects. Given that three-fourths of the commercial landings come from fish species utilizing coastal habitats, there is an obvious need for a better understanding of the impacts that human activities cause in these habitats for the development of ecosystem-based fisheries management.

Brown, Elliot J.↗

DOE OSTI2024

Generalizability of heat-related health risk associations observed in a large healthcare claims database of patients with commercial health insurance

Extreme ambient heat is unambiguously associated with higher risk of illness and death. The Optum Labs Data Warehouse (OLDW), a database of medical claims from US-based patients with commercial or Medicare Advantage health insurance, has been used to quantify heat-related health impacts. Whether results for the insured sub-population are generalizable to the broader population has to our knowledge not been documented. We sought to address this question, for the US population in California from 2012 to 2019. We examined changes in daily rates of emergency department (ED) encounters and in-patient hospitalization encounters for all-causes, heat-related outcomes, renal disease, mental/behavioral disorders, cardiovascular disease, and respiratory disease. OLDW was the source for health data for insured individuals in California, and health data for the broader population were gathered from the California Department of Health Care Access and Information (HCAI). We defined extreme heat exposure as any day in a group of 2 or more days with maximum temperatures exceeding the county-specific 97.5 th percentile and used a space-time-stratified case–crossover design to assess and compare the impacts of heat on health. Average incidence rates of medical encounters differed by dataset. However, rate ratios for ED encounters were similar across datasets for all causes (ratio of incidence rate ratios (rIRR) = 0.989; 95% confidence interval (CI) = 0.973, 1.011), heat-related causes (rIRR = 1.080; 95% CI = 0.999, 1.168), renal disease (rIRR = 0.963; 95% CI = 0.718, 1.292), and mental health disorders (rIRR = 1.098; 95% CI = 1.004, 1.201). Rate ratios for inpatient encounters were also similar. This work presents evidence that OLDW can continue to be a resource for estimating the health impacts of extreme heat.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

A 1kV, 480V Power Electronics Hub for DER Integration in Commercial Buildings

Power electronic (PE) systems are increasingly being integrated into distribution and sub-distribution networks in support of distributed energy resource integration (DERs), electric vehicle (EV) charging (particularly in the case of fast charging infrastructure), and improvement in power quality for high performance computing and/or servers farms. This provides an opportunity to research and develop integrated PE systems that can function as single systems thereby bringing additional functionality and benefits to the overall system. The goal of this paper is to demonstrate foundational technologies and capabilities for a multiport power electronics energy hub that can intelligently coordinate and control integrated sources and loads. The focus for this digest is on a commercial building use case which is demonstrated in hardware.

Starke, Michael↗

DOE OSTI2024

Disruption of Commercial Solar Inverter System by TLS Proxy Man-in-the-Middle Attack

Transport Layer Security (TLS) is a cryptographic protocol that encrypts communication data, providing end-to-end communication encryption and authentication. Currently, TLS is widely adopted for securing communication between servers and end devices, including solar inverter systems. Therefore, users/operators can securely access the solar inverters through a web user interface (WebUI) application programmable interface (API) on a PC or server over TLS-enabled Wi-Fi or Ethernet. However, the security of the TLS-based network becomes compromised if it is breached by a TLS proxy man-in-the-middle (MITM) exploit. This report explores potential vulnerabilities in a commercial solar inverter system that leverages a TLS proxy MITM and discusses the impacts through assume-breached penetration testing. Furthermore, the paper explores recommended mitigation methods against the TLS proxy MITM exploit in solar inverters.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

Mission planning for photogrammetry-based autonomous 3D Mapping of Dams using a commercial UAV

The application of autonomous unmanned aerial vehicles (UAVs) for conducting inspections of dams represents an innovative approach aimed at enhancing safety, efficiency, and cost-effectiveness. In this context, this paper presents algorithms for UAV mission design in autonomous dam inspections that include the creation of a 3D map based on photogrammetry. The algorithms were systematically developed to incorporate a comprehensive set of parameters that account for the geometric characteristics of the dam and adhere to photogrammetry specifications. To validate the proposed methodology, we utilized a commercial programmable quadrotor, specifically the Parrot Anafi USA Gov drone, which is equipped with high-quality cameras and can be programmed with the help of a software development kit (SDK) provided by the manufacturer. Our results demonstrate the efficacy of our method, highlighting how the generated maps can be used for hazard detection in the downstream slope of dams.

42 ENGINEERING↗

DOE OSTI2026

Artificial Soiling Replication of Field Losses on Commercial Photovoltaic Modules

Here, this study demonstrates the capabilities of an indoor artificial soiling approach developed to closely replicate the natural, cyclic soil accumulation processes in the field-dust suspension, deposition, and sedimentation/cementation-for a subtropical climate. In this work, a near-field environment is replicated in an artificial soiling cubic chamber through controlled regulation of humidity, temperature, dust type, and dust concentration, based on site-specific historical climate data. Two different models (MA and MB) of full-size commercial photovoltaic modules from a single manufacturer, installed side by side in the mid-Atlantic United States, were retrieved and subjected to artificial soiling experiments and various characterization measurements, including short-circuit current, colorimetry, reflectance, X-ray fluorescence, laser diffraction, and optical microscopy. Both in the field and in our improved field-representative artificial soiling tests, the MA model experienced roughly twice the soiling loss as the MB model. To closely replicate the field soiling losses for a site-specific climate, it is critical to include: 1) The use of field-collected dust with identical dust chemistry and particle distribution instead of standardized ISO 12103 Arizona Road dusts, 2) the use of only a small amount of field-collected dust inside the chamber during the deposition process (e.g., 0.15 g), and 3) the preconditioning of the surface coating for the partial/full dose of UV stress as experienced in the field during sunlight exposure and the abrasion as experienced in the field during regular module cleaning activities, if/as needed. The field-representative artificial soiling method developed here could potentially be adopted for rank ordering of various antisoiling coatings developed by researchers and industry stakeholders.

14 SOLAR ENERGY↗

DOE OSTI2020

A Critical Exploration of the Efficiency Impacts of Demand Response From HVAC in Commercial Buildings

Increasing quantities of renewable energy generation has yielded a need for greater energy storage capacity in power systems. Thermal storage in variable air volume (VAV) heating, ventilation, and air conditioning (HVAC) in commercial buildings has been identified as an inexpensive source of grid storage, but the true costs are not known. Recent literature explores the inefficiency associated with providing grid services from these HVAC-based demand response (DR) resources by employing a battery analogy to calculate round-trip efficiency (RTE). Results vary significantly across studies and in some cases reported efficiencies are strikingly low. This article has three objectives to address these prior results. First, we synthesize and expand on insights into existing literature by systematically exploring the potential causes for the discrepancies in results. We reinforce previous work indicating baseline modeling may drive differences across studies and deduce that control accuracy plays a role in the major differences between experiments and simulation. Second, we discuss why the RTE metric is problematic for DR applications, discuss another proposed metric, additional energy consumption (AEC), and propose an extension, which we call uninstructed energy consumption (UEC), to evaluate DR performance. Finally, we explore the merits of different metrics using experimental data and highlight UEC's reduced sensitivity to the characteristics of the DR signal than previously proposed metrics.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Calibration of Distributed Temperature Sensors Using Commercially Available SMF-28 Optical Fiber From 22 °C to 1000 °C

Optical frequency domain reflectometry (OFDR) is a family of optical techniques which can be used to produce distributed temperature measurements from the spectral shift of an interference pattern based on the Rayleigh backscatter signature of an optical fiber. Adaptive signal processing techniques have recently been used with OFDR to record meaningful spectral shift data from commercially available SMF-28 optical fibers heated beyond 950 °C. Furthermore, a correlation between the measured spectral shift and temperature has not yet been developed at these high temperatures. To extend the measurable temperature range of OFDR in SMF-28, this work describes the development of such a correlation from room temperature (22 °C) to 1000 °C. The relationship between spectral shift and temperature change over this range was found to be best characterized by the fourth-order polynomial ΔT=(-4.241 * 10 -11 )S 4 + (-2.017 * 10 -7 )S 3 + (-3.677 * 10 -4 )S 2 + (-0.8057)S, where ΔT represents the temperature difference compared to the reference temperature, and S represents the spectral shift measured by the fibers. The calibration developed in this work assumes that the fiber has been fully annealed by heating the fiber to 1000 °C for a few hours. This paper is the first to demonstrate the calibration and use of SMF-28 distributed optical fiber sensors up to 1000 °C, enabled using adaptive OFDR-based signal processing.

47 OTHER INSTRUMENTATION↗

DOE OSTI2021

Optimization of Carbon-Nanotube-Reinforced Composite Gridlines Towards Commercialization

Solar cells in PV modules crack during field operation from environmental stressors, including extreme weather events, such as hailstorms and hurricanes. These cracks can lead to gradual or immediate acute power degradation. To directly address cell-crack-induced degradation, we have formulated a carbon nanotube additive for commercial screen printed silver pastes. We have shown in previous work that these metal matrix composites have little to no effect on the cell’s efficiency while enhancing the metallization’s fracture toughness and electrical gap-bridging capability. In this work, we focus on optimizing the composite metallization to achieve the best possible performance. We discover that reducing carbon nanotube agglomerations in the paste not only improves the printability for narrow gridlines, but also increases the modulus of toughness of the metallization by over 500%.

carbon nanotubes↗

DOE OSTI2021

Field-Array Benchmark of Commercial Bifacial PV Technologies with Publicly Available Data

We present results for a 75-kW field array deployed with rows of 5 different commercially available bifacial technologies. Four PERC (multi and mono) and 1 Silicon Heterojunction manufacturers are represented. Reference strings of equivalent monofacial PV modules are also installed in the 10-row field. High accuracy string-level DC monitoring and module-level measurements have been recorded for six months. Analysis indicates performance within expectation, with a cumulative model mean error within +/- 2% for both bifacial and monofacial models and cumulative bifacial energy gain between 6-9%. A custom-module to measure shading loss from the torque-tube was installed. One month data shows up to 6% irradiance non-uniformity. A fixed-tilt test-site with 3 years of bifacial data is also presented, with a bifacial gain of 3%.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2019

Measurements of the Strain Dependence of Critical Current of Commercial REBCO Tapes at 15 T Between 4.2 and 40 K for High Field Magnets

Interest for high magnetic fields (>16 T) for applications in high energy physics (HEP) and fusion machines, requires the development of high current cables capable to withstand the large forces, mechanical and electromagnetic, experienced during manufacturing and operations. The critical current (I c ) of REBCO tapes depends on strain, magnetic fields, and operational temperatures. Understanding how these parameters affect the I c of the conductor will be critical to develop robust high-current REBCO cables. However, there are limited reports on the strain dependence of I c , in particular at high fields and elevated temperatures relevant for future high-field compact fusion reactor magnets. We present here I c of commercial REBCO tapes measured as a function of compressive and tensile strain (between -0.6% and +0.65%) at high magnetic fields (12 and 15 T) and different temperatures (within 4.2-40 K). Results at 4.2 and 20 K showed less than 5% reduction in the normalized I c at high strain, while a stronger strain dependence was observed at 40 K. Samples tested at 12 T and 4.2 K showed similar strain dependence as 15 T and 4.2 K. In all tested conditions, the tape experienced reversible I c reduction in both tension and compression. Finite element analysis was used to predict the residual thermal strain accumulated in the REBCO layer prior of testing to account for the effect of the cooldown. A method was also developed to account for the current sharing observed between the sample and the sample holder during the ramp of the current. Our results provide useful input for the development of high-field fusion and HEP magnets using REBCO conductors.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2019

Commercially Fabricated Low Loss Superconducting Resonators Integrated With Detectors for Frequency Domain Multiplexing Readout of Future Cosmic Microwave Background Experiments

Planned Stage-IV cosmic microwave background (CMB) experiments call for telescopes with the order of 500 000 transition edge sensor (TES) bolometers. Such large arrays would benefit from detector multiplexing, as well as miniaturization and integration of readout components. Additionally, fabrication of micro-fabricated devices at a commercial foundry could potentially boost production rate and reduce overall cost. To this end, HYPRES, Inc., LBNL, and U.C. Berkeley are developing low loss, superconducting LC resonators integrated with antenna coupled TES bolometers for frequency multiplexing readout. The resonators are fabricated on the same wafer and are in the same process flow as the TES detectors, reducing size, weight, and wiring complexity of a detector module compared to the conventional design, where each component is fabricated separately. We have fabricated and tested resonators from 0.6 to 70 MHz, both as standalone devices and integrated with TES bolometers, all fabricated on 150- mm wafers. Finally, we discuss the design and fabrication of these devices and present measurements of the standalone resonators.

47 OTHER INSTRUMENTATION↗

DOE OSTI2018

Aggregate Protection Response of Motor Loads in Commercial Buildings

Protection plays a critical role in determining the dynamic response of the induction motor loads and the overall performance of composite load models when subjected to voltage sags or disturbances. Up to date, due to lack of understanding of the aggregate performance of the protection of motors, protection modeling of the motors becomes one of the least accurate parts in dynamic (composite) load models. This paper fills this gap by providing detailed analysis of the motor loads and their associated protection in commercial buildings and deriving the aggregate protection response based on integrated transmission and distribution dynamic co-simulation. The results showed that the aggregate protection response of motor loads varies significantly among different classes, which indicates the protection modeling that has been developed based on the assumption of similar or even identical responses and used in some composite load models need to be updated.

Huang, Qiuhua↗

DOE OSTI2020

Identifying DQ-Domain Admittance Models of a 2.3-MVA Commercial Grid-Following Inverter Via Frequency-Domain and Time-Domain Data

Here, we present two methods to identify the admittance of a 2.3-MVA commercial grid-following inverter through frequency-domain data and time-domain data. In addition to the well-known harmonic injection method to obtain the admittance at frequency points followed by vector fitting, we adopt a step response-based method where the step response data of the converter are collected and their s-domain expressions are obtained. In turn, the s-domain admittance model of the converter is found. The two methods can be used for cross validation. Step responses and frequency-domain responses obtained from the two methods are compared. Results show that the time- domain data-based method leads to an admittance comparable with that from the frequency-domain measurement in the range less than 60 Hz. In addition, two insights are obtained from the frequency-domain admittance measurements. First, when the dq- frame is aligned to the point of common coupling (PCC) voltage, the per unit DQ-domain admittance directly reflects operating conditions. Second, existence of negative-sequence control can be detected via sequence-domain admittances.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2016

Response Variability in Commercial MOSFET SEE Qualification

Single-event effects (SEE) evaluation of five different part types of next generation, commercial trench MOSFETs indicates large part-to-part variation in determining a safe operating area (SOA) for drain-source voltage (V DS ) following a test campaign that exposed >50 samples per part type to heavy ions. These results suggest a determination of a SOA using small sample sizes may fail to capture the full extent of the part-to-part variability. An example method is discussed for establishing a Safe Operating Area using a one-sided statistical tolerance limit based on the number of test samples. Finally, burn-in is shown to be a critical factor in reducing part-to-part variation in part response. Implications for radiation qualification requirements are also explored.

43 PARTICLE ACCELERATORS↗

DOE OSTI2018

Single-Event Effects in the Peripheral Circuitry of a Commercial Ferroelectric Random Access Memory

This paper identifies the failure modes of a commercial 130-nm ferroelectric random access memory. The devices were irradiated with heavy-ion and pulsed focused X-ray beams. Various failure modes are observed, which generate characteristic error patterns, affecting isolated bits, words, groups of pages, and sometimes entire regions of the memory array. Furthermore, the underlying mechanisms are discussed.

42 ENGINEERING↗

DOE OSTI2023

The Effects of Gamma Ray Integrated Dose on a Commercial 65-nm SRAM Device

Here this work shows that the static random access memory (SRAM) error rate for a commercial 65-nm device in a dose rate environment can be highly dependent upon the integrated dose (dose rate × pulse duration). While the typical metric for such testing is dose rate upset (DRU) level in rad(Si)/s, a series of dose rate experiments at Little Mountain Test Facility (LMTF) shows dependence on the integrated dose. The error rate is also found to be dependent on the core voltage, and the preradiation value of the bits. We believe that these effects are explained by a well charge depletion caused by gamma ray photocurrent.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗