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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Red-Ox Robust SOFC Stacks for Affordable, Reliable Distributed Generation Power Systems

While SOFC systems are expected to operate reliably and with limited degradation in steady state or transient performance, SOFC stacks may ultimately fail due to the loss of structural integrity of one or several of the cells as a result of the weakening of the materials and interfaces due to physico-chemical changes that occur during continuous operation as a result of plastic and creep deformations, modification of the temperature profile, and/or degradation of the electrochemical performance of the cells. Degradation mechanisms originating from the cell components include coarsening of the microstructure over time; decomposition of materials; chemical reaction of electrode materials with electrolyte at the interface; delamination from each other; and for the anode, coking and sulfur poisoning. Of all the reliability issues that may occur for SOFCs, the main limitation for Ni-based cermet anodes (e.g., NiO-YSZ) is the poor stability during reduction-oxidation (red-ox) cycling. This project was aimed at the development of ceramic anode SOFCs based on SFCM (SrFe0.2Co0.4Mo0.4O3), which is a conductive perovskite that is red-ox stable. Additionally, the project involved the development of a red-ox robust stack. Scale up of SFCM-based cells to a large format (10 cm by 10 cm) cell size was achieved as well as a maximum power density of 0.9 W/cm 2 at 600 °C (>0.6 W/cm 2 at 0.6 V). Up to a 10-cell stack was successfully assembled and demonstrated, and cells showed similar performance in reformed, pipeline natural gas as in hydrogen. Finally, a 3-cell stack was red-ox cycled without degradation for 40 cycles at ~600 °C.

03 NATURAL GAS↗
DOE OSTI2024

Fitness-for-Service Analysis of Reactor Components under Flexible Load-Following Operating Conditions

Conventional power-generation plants, including nuclear plants, have been traditionally designed to provide a steady baseload energy capacity, optimizing output efficiency while minimizing variable costs. However, the growing adoption of large-scale renewable energy-generation systems, which rely on intermittent sources such as solar and wind, has introduced more variability into the energy supply in interconnected electricity grids. As a result, the next generation of power plants needs to operate in what is known as the load-following mode, requiring flexible adjustments in electricity production to align with the energy demand on the grid. This transition from the steady baseload operation to load-following operating conditions can significantly increase the number of times various plant components are exposed to transient stresses. This increased thermo-mechanical cycling can lead to accelerated material degradation, thereby elevating the risk of premature failure of a component. It becomes imperative to conduct a comprehensive analysis of fatigue, creep-fatigue, and stress corrosion cracking life, to assess the resilience of the various engineering components under these flexible load-following operating conditions. This study aims to develop a comprehensive numerical model of a light-water reactor pressure vessel (RPV) to investigate its degradation under various operating scenarios. This coupled thermo-mechanical finite element analysis evaluated the stress response of the RPV caused by considering fluctuations in thermal and mechanical loads caused by the varying pressure and temperature occurring during the load-following operation. Critical locations on the RPV are subsequently identified based on the stress response. The stress intensity factors for the postulated flaws at those locations are then calculated, followed by an evaluation of the reactor's life in accordance with the ASME Boiler and Pressure Vessel Code Section XI. This comprehensive life assessment covers a number of transients expected during the flexible load-following operation, providing invaluable insights into the RPV's structural integrity. Moreover, the development methodology can be adapted to other reactor components, as well as components of conventional power stations that are affected by varying operating conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Nanoengineered Shape-Memory Hemostat

Uncontrolled hemorrhage is the predominant cause of preventable combat deaths. Various biomaterials serve as hemostatic agents due to their procoagulant or absorptive activity. However, these biomaterials often lack expansion capabilities, which severely limits use in noncompressible wounds. This study combines a hemostatic nanocomposite with a shape-memory polymer foam to design a composite material with both hemostatic and physical expansion properties. This composite is fabricated in two formulations: a foam externally coated in a highly concentrated nanocomposite (“coated composite”) and a foam containing a diluted nanocomposite infused throughout its pores (“infused composite”). Both formulations retain the shape-memory foam's expansion property. Further, the coated composite shows improved fluid uptake (>2-fold) versus infused composites or foam. The nanocomposite component dissociates from the foam under degradative conditions, with the foam remaining stable for 30 days. Hemostatic studies illustrate that the coated composite reduces the clotting time by ≈20%. Alternatively, the infused composite improves clotting over a larger distance (up to ≈2× distance from the composite). These results signify a modular hemostatic ability: the coated composite reduces clotting and improves fluid uptake, while the infused composite achieves diffuse clotting and maintains mechanical properties. Thus, these materials pose a strong potential for use in noncompressible wounds.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2023

Low-cost thermal/environmental barrier coatings: A first-principles study

Development of low-cost advanced thermal/environmental barrier coating (T/EBC) materials with acceptable thermal and mechanical properties is essential for safeguarding ceramic composites substrate against thermal and chemical degradation, thereby enhancing the efficiency of components in the high-temperature section of gas turbine engines. To this end, here we employed density functional theory-based approaches to predict the thermodynamic, mechanical, and thermal properties of rare earth disilicates based on abundant rare earth elements, namely La 2 Si 2 O 7 and Ce 2 Si 2 O 7 , as potential alternatives to the current-state-of-the-art ytterbium disilicate EBCs that uses expensive and scarce element Yb. The present study predicts that G-phase Ce 2 Si 2 O 7 has an ultralow thermal conductivity (0.26 W/m/K at 1500 K) and the apparent bulk coefficient of thermal expansion (ABCTE) (≈6.9x10 -6 K -1 ) slightly higher than SiC, demonstrating great potential as low-cost high-performance T/EBC. However, La 2 Si 2 O 7 and Ce 2 Si 2 O 7 undergo an A- to G-phase polymorphic transition at around 1470 K, resulting in significant changes to crystal structure and lattice parameters, and accordingly CTE and lattice thermal conductivity.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Quantification of Reactive Oxygen Species Produced from Electrocatalytic Materials

Oxygen electrochemistry goes beyond O 2 , as the formation of reactive oxygen species (ROS) such as H 2 O 2 and O 3 during water oxidation is key in the destruction of persistent pollutants in water remediation technologies as well as in the degradation of fuel cell and electrolyzer components. In this study, we developed an in situ method utilizing the rotating ring-disk electrode technique to quantify the formation of O 2 , O 3 , and H 2 O 2 species across a broad pH range (1–8.3). Oxygen selectivity trends over Pt, IrO 2 , and PbO 2 surfaces reveal that even O 2 evolution catalysts may produce small yet measurable amounts of ROS, further modulated by pH and electrode potential. In conclusion, these findings emphasize the need to probe the selectivity of oxygen electrochemistry for a more complete picture of advanced materials for electrochemical technologies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Reconstruction of 3D Concrete Microstructures Combining High-Resolution Characterization and Convolutional Neural Network for Image Segmentation

After water, concrete is the second most used material in the world. Concrete’s forming adaptability and low-cost constituents make it a predominant material used in the construction of civil infrastructures in nuclear power plants such as concrete biological shields, containment buildings, turbine buildings, fuel handling and storage buildings, underground piping for cooling, cooling towers, and so on. Depending on environmental and operating conditions, these passive structures are subject to time-dependent phenomena that can either enhance (e.g., continued hydration) or degrade concrete’s structural performance. Unlike components such as the reactor pressure vessel and the primary circuit, concrete composition varies regionally because it is manufactured using local aggregates and cement. Hence, concrete performance metrics over time cannot be derived confidently using empirical relations. Alternatively, the specific characteristics of the local concrete constituents and their assemblage in concrete must be considered.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Solid State Transformer Architecture and Control Compensation for Common Mode Currents

A high-altitude electromagnetic pulse (HEMP) or similar geomagnetic disturbance (GMD) has the potential to impact the operation of large-scale electric power grids. By introducing low-frequency common-mode (CM) currents, these events can degrade the performance of critical system components, such as large power transformers by introducing CM currents which can lead to magnetic saturation of the transformer core. In this work, a solid-state transformer (SST) is developed to replace susceptible equipment and improve grid resiliency by safely absorbing these CM disturbances. This device will be referred to as a common-mode solid-state transformer (CM-SST). An SST architecture based on a four-legged AC/DC converter is developed. This architecture enables active control of CM signals without disturbing the AC voltages or the real and reactive power delivery capabilities. A system-level model of this architecture is created, and time-domain simulations are performed to evaluate the SST’s performance in response to simulated CM disturbances. A control strategy for mitigating CM current is also investigated. Hamiltonian surface shaping and power flow control (HSSPFC) is used to design a nonlinear controller for the SST’s output inverter. The objectives of the controller are to suppress CM-induced AC current offsets and regulate AC currents to desired setpoints. Nonlinear system analysis is applied to design and validate the controller. Two cases are tested: (a) the proposed four-leg inverter and (b) a standard three-leg inverter. The results show that the proposed controller rapidly mitigates CM disturbances while maintaining high-quality AC current waveforms in the four-leg configuration. Finally, the hardware performance of an SST prototype is evaluated. In particular, the ability of the SST to safely redirect and absorb CM currents is demonstrated, showing how it can protect neighboring conventional transformers in the system. The study confirms that appropriate control laws allow the SST to protect both itself and adjacent transformers during a HEMP or GMD event.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Diagnostics, Prognostics, and Optimization for Lithium-Ion Battery Systems

Health management of lithium-ion battery systems presents a host of challenges due to their complex physics, large numbers of components, and a wide variety of degradation behaviors across different battery types. Dr. Paul Gasper will present on research from the Electrochemical Energy Storage Group on Lithium-ion battery diagnostics, prognostics, and optimization. Diagnostics research, including state-estimation via machine-learning from electrochemical impedance spectroscopy and DC pulses as well as continuous state-estimation via Kalman filters, will highlight the ongoing challenges for accurately measuring the state of batteries without performing time-consuming characterization tests. NLR's industry-recognized battery prognostics work, which predicts real-world battery degradation by identifying degradation rate models from accelerated aging data using statistical modeling and machine-learning, will be used to demonstrate the critical impact of battery controls, thermal management, and operating strategy on durability and lifetime. Finally, the use of prognostic models for financial or lifetime optimization will be discussed.

25 ENERGY STORAGE↗
DOE OSTI2020

Systems and devices for pumping and controlling high temperature fluids

The disclosed technology includes pumps, pipes, valves, seals, and systems for pumping and controlling high temperature fluids, such as liquid tin, at temperatures of between 1000-3000° C. The systems and device may be partially or entirely constructed using brittle materials, such as ceramics, that are capable of withstanding extreme heat without significantly degrading, and may be secured using components made of refractory metals, such as tungsten. The systems and devices may utilize static and dynamic seals made from brittle materials, such as graphite, to enable the high temperature operation of such pumps, pipes, valves, and systems without leakage.

Henry, Asegun↗
DOE OSTI2025

A Risk-Informed Approach to Trustworthiness Assessment in Digital Twins-Based Autonomous Control

In autonomous control systems, digital twins (DTs) are used to perform diagnostic and prognostic functions. The trustworthiness of these DTs is dependent on quality and coverage of the training data, model accuracy and integrity of sensor data. This work introduces a methodology to determine the trustworthiness of a DT system given faulty sensor data using a risk informed approach. Bayesian Belief Networks (BBNs) are used to propagate uncertainties and determine the probability of trustable recommendations. The decision to trust the control action provided by the DT is based on the DT output, expert opinion, and severity of problems. The performance of DTs is reliant on the data they are trained on. When they encounter out of distribution data, the trustworthiness of the recommendations decreases. To address this issue, we include an expert component that provides input on sensor degradation. For this, we utilize a generative artificial intelligence (AI) model, such as Generative Pretrained Transformer (GPT). The GPT functions as an expert with broad knowledge. The GPT is fine-tuned to understand and discriminate sensor degradation scenarios using manufactured data. This methodology is demonstrated through a case study on a Nearly Autonomous Management and Control System (NAMAC) during a steady state scenario. Various sensor degradation types with different severity levels are considered. Degraded sensor data is processed by the DT system and the fine-tuned GPT. Finally, using the BBN, we combine the GPT information and the DT output with its sources of uncertainty. This provides an output regarding the trustworthiness of the DT recommendation.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Model-Based Investigation of Multi-Fault Interactions and Performance Degradation in Residential Heat Pump Systems

Faults in heat pump systems can significantly degrade performance, reduce efficiency, and accelerate component wear, leading to higher operating costs and maintenance demands. While numerous studies have investigated the impact of individual faults, the interactions between multiple concurrent faults remain insufficiently understood, despite their common occurrence in real-world operation. This study conducts a comprehensive simulation analysis of multiple simultaneous faults in a vapor compression heat pump using a validated heat pump design model (HPDM) tool. Detailed component-level modeling methods are implemented to examine performance sensitivity under combinations of refrigerant flow and heat exchanger faults. The results reveal complex fault interactions that can mask or amplify system deviations, challenging conventional diagnostic approaches. Findings from this work provide meaningful insights for the development of more robust fault detection and diagnosis algorithms, supporting improved reliability and energy efficiency in next-generation heat pump technologies.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗
DOE OSTI2023

Degradation of Insulating Glass Units: Thermal Performance, Measurements and Energy Impacts

Insulating glass unit (IGU) degradation has been studied extensively. However, there is limited understanding of how present durability evaluation standards relate to product lifetime. Furthermore, there is debate on how to quantify performance of installed windows over time to better understand degradation processes. More knowledge on these topics is required to link durability evaluation to product lifetime projections based on energy performance. Energy models provide helpful estimations of total annual building energy consumption. However, most models are based on “as installed” performance of envelope components and fail to account for performance degradation. This can lead to an underestimation of building lifetime energy consumption. A better understanding of the relationship between durability and energy performance can inform integration of degradation dynamics into energy modeling software. This will improve lifetime building energy consumption estimations as well as inform appropriate retrofit strategies and timing. This paper reviews current durability literature, various standards for window performance ratings and weathering methods, existing in situ IGU energy performance measurement techniques, and whole-building energy effects. The challenges and disparities among various studies are analyzed and discussed. The authors hope that further work in this area will lead to the development of improved in situ test methods to assess IGU degradation in the field and link this knowledge to improved energy performance modeling approaches.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Scintillator ageing of the T2K near detectors from 2010 to 2021

The T2K experiment widely uses plastic scintillator as a target for neutrino interactions and an active medium for the measurement of charged particles produced in neutrino interactions at its near detector complex. Over 10 years of operation the measured light yield recorded by the scintillator based subsystems has been observed to degrade by 0.9–2.2% per year. Extrapolation of the degradation rate through to 2040 indicates the recorded light yield should remain above the lower threshold used by the current reconstruction algorithms for all subsystems. This will allow the near detectors to continue contributing to important physics measurements during the T2K-II and Hyper-Kamiokande eras. Additionally, work to disentangle the degradation of the plastic scintillator and wavelength shifting fibres shows that the reduction in light yield can be attributed to the ageing of the plastic scintillator. The long component of the attenuation length of the wavelength shifting fibres was observed to degrade by 1.3–5.4% per year, while the short component of the attenuation length did not show any conclusive degradation.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Model bias in simulating major chemical components of PM 2.5 in China

High concentrations of PM 2.5 (particulate matter with an aerodynamic diameter less than 2.5 µm) in China have caused severe visibility degradation. Accurate simulations of PM 2.5 and its chemical components are essential for evaluating the effectiveness of pollution control strategies and the health and climate impacts of air pollution. In this study, we compared the GEOS-Chem model simulations with comprehensive datasets for organic aerosol (OA), sulfate, nitrate, and ammonium in China. Model results are evaluated spatially and temporally against observations. The new OA scheme with a simplified secondary organic aerosol (SOA) parameterization significantly improves the OA simulations in polluted urban areas, highlighting the important contributions of anthropogenic SOA from semivolatile and intermediate-volatility organic compounds. The model underestimates sulfate and overestimates nitrate for most of the sites throughout the year. More significant underestimation of sulfate occurs in winter, while the overestimation of nitrate is extremely large in summer. The model is unable to capture some of the main features in the diurnal pattern of the PM 2.5 chemical components, suggesting inaccuracies in the presented processes. Potential model adjustments that may lead to a better representation of the boundary layer height, the precursor emissions, hydroxyl radical concentrations, the heterogeneous formation of sulfate and nitrate, and the wet deposition of nitric acid and nitrate have been tested in the sensitivity analysis. The results show that uncertainties in chemistry perhaps dominate the model biases. The proper implementation of heterogeneous sulfate formation and the good estimates of the concentrations of sulfur dioxide, hydroxyl radical, and aerosol liquid water are essential for the improvement of the sulfate simulation. The update of the heterogeneous uptake coefficient of nitrogen dioxide significantly reduces the modeled concentrations of nitrate. However, the large overestimation of nitrate concentrations remains in summer for all tested cases. The possible bias in the chemical production and the wet deposition of nitrate cannot fully explain the model overestimation of nitrate, suggesting issues related to the atmospheric removal of nitric acid and nitrate. A better understanding of the atmospheric nitrogen budget, in particular, the role of the photolysis of particulate nitrate, is needed for future model developments. Moreover, the results suggest that the remaining underestimation of OA in the model is associated with the underrepresented production of SOA.

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

Degradation of impact toughness in cast stainless steels during long-term thermal aging

Cast austenitic stainless steels (CASSs) have been extensively used for the large components of nuclear reactor primary coolant systems. Since the cast steels inevitably contain degradable metastable phases and replacement of the large coolant system components is impractical, the thermal embrittlement of CASS components has been a serious concern in the extended-term operation of nuclear power plants. This study aimed to systematically measure and analyze the effect of long-term thermal aging on the Charpy impact toughness to provide a comprehensive understanding of thermal degradation behavior and a practical aging model to predict the degree of thermal degradation in the cast stainless steels. Additionally, the materials tested in the research include eight CASS alloys (two CF3s, one CF3M, three CF8s, and two CF8Ms) and two reference wrought materials (304L and 316L), in which the nominal δ-ferrite content ranges from ~2% to 33%. These stainless steels have been thermally aged at two light water reactor (LWR) temperatures (290 and 330 °C) and at two accelerated-aging temperatures (360 and 400 °C) for up to 30,000 h; these include both under-aged and over-aged conditions relative to the extended service lifetime (80 years). Charpy impact testing was performed for aged and non-aged specimens, and the impact (absorbed) energy parameters were correlated with a new aging parameter (A). Both the reduction of impact fracture toughness and the shift of ductile-brittle transition temperature were strongly dependent on the δ-ferrite content and degree of thermal aging. A linear relationship was found between the increasing rate of the index transition temperature T 41J and aging parameter A; base on which an empirical model was proposed for prediction of the transition temperature as a simple function of the aging parameter (A) and δ-ferrite content (F). Finally, the critical aging parameter for embrittlement (AC) was evaluated and compared with the existing δ-ferrite content criteria.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A Miniaturized, High-Bandwidth Optical Fiber Fabry–Perot Cavity Vibration Sensor Demonstrated up to 800 °C

A typical structural health monitoring technique involves measuring the vibrational characteristics of components or systems to detect signs of degradation or damage. Many industrial applications require engineered systems to safely operate under extreme, high-temperature environments that pose challenges not only to materials but also to sensors that would be used for structural health monitoring. Here, in this study, miniaturized optical Fabry-Perot cavities (FPCs) were developed and tested as a means of measuring the resonant frequencies of metal components that are most relevant to extreme-environment applications. Two of the three candidate FPC designs tested up to 800 ° C provided accurate measurements (validated by theoretical models and laser Doppler vibrometry) of the fundamental vibrational mode of the specimen to which each was bonded, although both sensors failed during thermal cycling. An analysis of the reflected optical spectrum from the FPC and X-ray computed tomography revealed two opportunities to improve the sensor reliability. First, the Cu optical fiber coating that was used could either be replaced with a more oxidation-resistant material or protected with commercially available films. Second, the adhesives used to bond the fibers to metal capillaries and establish the FPC could be replaced with a more robust solution, although the Resbond 907TS adhesive appeared to outperform Resbond 907.

Birri, Anthony [Oak Ridge National Laboratory (ORN↗
DOE OSTI2025

Simulations of Heat Transfer Using Tight-Fitting Twisted Tape Inserts for First Wall Cooling in Molten Salt Breeder Blankets

One of the major components in fusion energy systems is the fusion blanket, which has a vacuum vessel to contain the plasma. As part of the fusion blanket/vacuum vessel, the first wall and plasma-facing components require sufficient cooling to prevent material degradation during operation from the superheated plasma. Most fusion blanket concepts involve first wall and divertor coolant channels with heat transfer enhancements (HTEs) that are intended to withstand the incident high heat fluxes of 1 to 5 MW/m 2 . Twisted tape inserts are a proposed HTE that have been investigated previously for first wall cooling and monoblock divertor cooling channels and in other nonfusion heat transfer components. By inserting twisted tapes into straight pipes, the amount of turbulence in the system can be increased at lower Reynolds numbers by swirling the flow. This results in better heat transfer characteristics with marginal increases in frictional pressure losses. In particular, simulations of high-Prandtl-number fluids such as the proposed molten salt FLiBe in twisted tapes, which is prototypic to liquid immersion blankets, have not been previously explored. Here, in this study, we simulate various Prandtl numbers in pipes with twisted tape inserts using large eddy simulations to determine the effects of increasing Prandtl numbers on heat transfer performance. The quantities of particular interest are the Nusselt number and the friction factor, which were recovered using data reduction techniques to determine impacts on heat transfer and pressure losses. This work serves as a starting point for determining the feasibility of twisted tape inserts for liquid immersion blanket concepts.

LES↗
DOE OSTI2023

Multi-Constituent Airborne Contaminants Capture with Low Cost Oxide Getters and Mitigation of Cathode Poisoning in Solid Oxide Fuel Cell

The technical effort and scientific findings, discussed in this report, documents operational barriers and associated long term performance stability challenges posed by the presence of trace airborne multi-constituent contaminants present in high-temperature electrochemical systems, including Solid Oxide Fuel Cells (SOFCs), Solid Oxide Electrolysis Cells (SOECs), Ion Transport Membranes, and Gas Separation systems. Above systems, offering promises for cleanliness and energy efficiency, face challenges with electrode poisoning stemming from the presence of trace contaminants including gaseous Cr/B/Si vapors in the presence of intrinsic contaminants SO 2 /CO 2 /H 2 O gases. The study indicates that the long-term electrical performance degradation in SOFC systems can be traced to electrochemical, structural, and mechanical changes across cell, stack, and balance of plant components resulting from interactions with trace contaminants leading to increase in both ohmic and non-ohmic polarizations. The degradation primarily results from solid-state and gas-phase materials migration, electrode poisoning, and interactions at the cell and stack levels. Cathode degradation emerges as a significant factor impacting overall SOFC performance, especially related to the presence of intrinsic and extrinsic airborne impurities such as SOx, CrOx(OH)y, SOx, Si(OH)x, and HBOx. Although at trace levels, prolong systems operation at higher airflow (3-10X stoichiometric) allow the accumulation of contaminants within the cell components leading to electrical performance degradation through poisoning and electrode deactivation.

20 FOSSIL-FUELED POWER PLANTS↗