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DOE OSTI2026

Quantitative Analysis and Prediction of Thermal Runaway Metrics of High-Nickel Oxide Cathodes by Machine Learning Models

The pursuit of higher energy density in lithium-ion batteries has made high-nickel (Ni) layered oxides leading cathode candidates for next-generation electric vehicles. However, their poor thermal stability, particularly at Ni contents ≥ 90%, increases the risk of cathode-initiated thermal runaway. Furthermore, we present a data-driven framework combining linear and nonlinear machine learning models to predict key thermal runaway descriptors from a high-throughput differential scanning calorimetry database. With cathode composition and state of charge (SOC) as input features, the ensemble model accurately predicts peak temperature, heat release, and peak heat flow. SHAP analysis identifies Ni content and SOC as the dominant factors controlling thermal runaway temperature, while SOC primarily governs heat release and peak heat flow. Al, Mg, and Mn improve thermal stability by strengthening metal–oxygen bonding and delaying structural transformation, whereas B mainly reduces heat release through surface passivation. Validation with a new cathode composition confirms accurate prediction of SOC-dependent thermal runaway behavior and critical SOC.

25 ENERGY STORAGE↗

DOE OSTI2026

Holistic energy analysis method for thermal management architectures of data centers

Modern high-performance computing (HPC) data centers (DCs), particularly those supporting energy-intensive artificial intelligence (AI) workloads, face escalating thermal management challenges that degrade performance through thermal throttling and drive up cooling power consumption and operational costs. To address this challenge, many have developed a wide variety of thermal management solutions (single-phase, two-phase, direct, indirect, hybrid, and more) which attempt to cool HPC DCs effectively while attempting to minimize overall system power consumption. However, the analysis of these solutions and methods to effectively compare one with another is lacking. Overall power usage effectiveness (PUE) and total-power usage effectiveness (TUE) provide a metric to quantify power consumption but fail to identify components in the system which require further optimization. To address this, we propose a holistic analytical framework – the waterfall diagram (WFD) – which leverages a waterfall chart methodology, offering a comprehensive visualization of both the thermal management system loop and heat flow pathways from individual server components to the outdoor ambient. Use of the WFD enables graphical estimations of power efficiency and cooling performance across each component of a DC cooling system and complements Sankey-style energy flow visualizations by additionally resolving stage-wise temperature changes and incremental TUE contributions. The framework is used in conjunction with simulation-based approaches, to conduct a detailed pressure drop and flow distribution analysis aimed at identifying the optimal coolant distribution architecture for a single-phase direct-to-chip water-cooled DC, which serves as the baseline for subsequent WFD analysis. Among the evaluated architectures, the 3 U modular coolant distribution architecture is found to demonstrate the best performance, considering minimal pressure drop and uniform flow distribution. In addition, TUE is calculated for each cooling loop component based on its associated pressure drop and corresponding pumping power, which are integrated into the WFD. This correlation between TUE and local temperature offers immediate insight into the power efficiency and thermal performance contributions of individual components, facilitating further development and optimization. Examples of WFD applications are presented under varying thermal loads and ambient conditions, demonstrating reasonable cooling strategies. Notably, the 3 U modular architecture maintains a consistent chip case temperature of 85°C, achieving a TUE of 1.016 at ambient temperature of 47°C, and a TUE of 1.026 at ambient temperature of 52°C. The WFD methodology provides an efficient, holistic, and streamlined framework for DC thermal management architecture assessment and enables design optimization which is important for addressing the thermal-fluidic energy challenges of current and next-generation DCs.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS2010

Failure Analysis of Fractured Poppet from Space Shuttle Orbiter Flow Control Valve

This slide presentation reviews the failure analysis of a fractured poppet from a flow control valve (FCV) used on the space shuttle. This presentation has focused on the laboratory analysis of the failed hardware. The use of Scanning electron fractography during the investigation led to the conclusion that the poppet failed due to fatigue cracking that, most likely, occurred under changing loading conditions. The initial investigation led to a more thorough test of poppets that had been retired, this testing led to the conclusion that the thumbnail cracks in the flight hardware had existed for the life of the shuttle program. This led to a program to develop an eddy current technique that was capable of detecting small very tight cracks.

Russell, Richard↗

NASA NTRS2006

Interaction Between Eddies and Mean Flow in Jupiter's Atmosphere: Analysis of Cassini Imaging Data

Beebe et al. [Beebe, R.F., et al., 1980. Geophys. Res. Lett. 17, 1-4] and Ingersoll et al. [Ingersoll, A.P., et al., 1981. J. Geophys. Res. 86, 8733-8743] used images from Voyagers 1 and 2 to analyze the interaction between zonal winds and eddies in Jupiter's atmosphere. They reported a high positive correlation between Jupiter's eddy momentum flux, pu'v', and the variation of zonal velocity with latitude, du/dy. This correlation implied a surprisingly high rate of conversion of energy from eddies to zonal flow: approx. 1.5-3.0 W/sq m, a value more than 10% of Jupiter s thermal flux emission. However, Sromovsky et al. [Sromovsky, L.A., et al., 1982. J. Atmos. Sci. 39,1413-1432] argued that possible biases in the analysis could have caused an artificially high correlation. In addition, significant differences in the derived eddy flux between datasets put into question the robustness of any one result. We return to this long-standing puzzle using images of Jupiter from the Cassini flyby of December 2000. Our method is similar to previous analyses, but utilizes an automatic feature tracker instead of the human eye. The number of velocity vectors used in this analysis is over 200,000, compared to the 14,000 vectors used by Ingersoll et al. We also find a positive correlation between u'v' and du/dy and derive a global average power per unit mass, u'v' du/dy, ranging from (7.1-12.3) x 10(exp -5)W/kg. Utilizing Ingersoll et al.'s estimate of the mass per unit area involved in the transport, this would imply a rate of energy conversion of approx.0.7-1.2 W/sq m. We discuss the implications of this result and employ several tests to demonstrate its robustness.

Salyk, Colette↗

NASA NTRS2019

The Effect of Turbulence Modeling on the Mixing Characteristics of Several Fuel Injectors at Hypervelocity Flow Conditions

CFD analysis is presented on the effects of turbulence modeling choices on the mixing characteristics and performance of three fuel injectors at hypervelocity flow conditions. The analyses were carried out with the VULCAN-CFD solver using Reynolds-Averaged Simulations (RAS). The hypervelocity flow conditions match the high Mach number flow of the experiments conducted as a part of the Enhanced Injection and Mixing Project (EIMP) at the NASA Langley Research Center. The three injectors are the baseline configurations used in the experiments and represent three categories of injectors typically considered individually or in combination for fueling high-speed propulsive devices. The current work discusses the impact of the turbulence model and the turbulent Schmidt number on the mixing flow field behavior and the mixing performance as described by the one-dimensional values of the Mach number, total pressure recovery, and the mixing efficiency. Because planar laser induced fluorescence (PLIF) images are available from the EIMP experiments, the sensitivity of the synthetic LIF signal to turbulence modeling choices is also examined to determine whether PLIF can be extended beyond its intended qualitative visualization purpose and used to guide CFD turbulence model and parameter selections. It is found that the mixing performance, as quantified using mixing efficiency, exhibits a strong sensitivity to both turbulence model choice and turbulent Schmidt number value. However, the synthetic LIF signal only demonstrates a modest level of sensitivity, which suggests that PLIF is of limited use for guiding CFD turbulence model and parameter selections.

Drozda, Tomasz G.↗

NASA NTRS1988

Analysis of the convergence history of flow through nozzles with shocks

Acceleration techniques such as Wynn's (1986) epsilon algorithm and analysis techiques such as eigensystem analysis are used here to study numerically the convergence properties of an iterative scheme applied to the quasi-one-dimensional Euler and Navier-Stokes equations for flow through nozzles with shocks. The convergence and stability properties are studied by analyzing the dependence of convergence of the code on the discretization technique, boundary conditions, time-step, number of grid points, and the physics of the problem.

Cheer, A. Y.↗

DOE OSTI2025

An experimental study of the existence regions and non-linear interactions of drift wave and Kelvin–Helmholtz instabilities in a linear magnetized plasma

Experimental observations of the intrinsic excitation and non-linear interactions of drift wave (DW) and Kelvin–Helmholtz (KH) instabilities in a linear magnetized plasma column are presented. The experiments are carried out in the inverse mirror plasma experimental device (IMPED)—a cylindrical, magnetized, linear plasma machine designed to study low-frequency waves and instabilities in plasma. A novel feature of IMPED is the ability to control plasma profiles, such as the density n(r)⁠, electron temperature T e (r)⁠, and plasma potential V p (r) by varying the ratio Rm of the magnetic field in the main chamber to that in the source chamber. At high values of Rm, higher-density gradient scale length promotes the drift wave (DW) instability while lower Rm value results in a higher radial electric field, inducing a sheared poloidal flow that enhances the dominance of the Kelvin–Helmholtz (KH) mode. The background and fluctuating plasma parameters are characterized using various configurations of multiple in situ electric probes at different spatial locations to quantify the local gradients that excite the low-frequency primary instabilities. Statistical, spectral, and bispectral analysis of the density and potential signals help identify these modes in terms of wave number, frequency, phase, and amplitude and also delineate the nature of their non-linear interactions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1998

On the Environmental Realizability of Algebraically Growing Disturbances and Their Relation to Klebanoff Modes

A theoretical explanation of some experimentally observed phenomena associated with the so-called Klebanoff modes is obtained by analyzing the flow over a finite thickness flat plate resulting from a small-amplitude distortion imposed on the upstream mean flow. The analysis shows (among other things) how the stretching of the vortex lines around the plate leads to streamwise vorticity at the plate surface, which then produces a streamwise velocity perturbation within the boundary layer that can be related to the experimentally observed Klebanoff mode. The complete evolution of this flow must be found by solving the boundary-region equations of Kemp (1951) and Davis and Rubin (1980), but a limiting analytical solution can also be obtained. Since the initial growth of the boundary-layer disturbance is nearly algebraic, our results demonstrate how the algebraically growing disturbances promoted by Landahl and others can be generated by a realistic external-disturbance environment. The relationship between these results and various bypass transition mechanisms is discussed.

Goldstein, Marvin E.↗

NASA NTRS1998

On the Environmental Realizability of Algebraically Growing Disturbances and Their Relation to Klebanoff Modes

Goldstein, M. E.↗

NASA NTRS1997

Pulmonary blood flow distribution in sheep: effects of anesthesia, mechanical ventilation, and change in posture

BACKGROUND: Recent studies providing high-resolution images of pulmonary perfusion have questioned the classical zone model of pulmonary perfusion. Hence the present work was undertaken to provide detailed maps of regional pulmonary perfusion to examine the influence of anesthesia, mechanical ventilation, and posture. METHODS: Pulmonary perfusion was analyzed with intravenous fluorescent microspheres (15 microm) in six sheep studied in four conditions: prone and awake, prone with pentobarbital-anesthesia and breathing spontaneously, prone with anesthesia and mechanical ventilation, and supine with anesthesia and mechanical ventilation. Lungs were air dried at total lung capacity and sectioned into approximately 1,100 pieces (about 2 cm3) per animal. The pieces were weighed and assigned spatial coordinates. Fluorescence was read on a spectrophotometer, and signals were corrected for piece weight and normalized to mean flow. Pulmonary blood flow heterogeneity was assessed using the coefficient of variation of flow data. RESULTS: Pentobarbital anesthesia and mechanical ventilation did not influence perfusion heterogeneity, but heterogeneity increased when the animals were in the supine posture (P < 0.01). Gravitational flow gradients were absent in the prone position but present in the supine (P < 0.001 compared with zero). Pulmonary perfusion was distributed with a hilar-to-peripheral gradient in animals breathing spontaneously (P < 0.05). CONCLUSIONS: The influence of pentobarbital anesthesia and mechanical ventilation on pulmonary perfusion heterogeneity is small compared with the effect of changes in posture. Analysis of flow gradients indicate that gravity plays a small role in determining pulmonary blood flow distribution.

NASA Discipline Cardiopulmonary↗

NASA NTRS1991

Streamlines, vorticity lines, and vortices

The properties of vortical flows are studied using both theoretical analysis and computational flow fields. The consequences of two definitions of the vortex core, a minimum in the streamline curvature and a maximum in the normalized helicity, are examined. Analysis indicates that several criteria must be met if the cores defined by these two methods are to coincide. In certain regions of the flow, computational flow fields indicate that these two definitions are coincident, that the velocity and vorticity fields are aligned at the core, and that extrema in the velocity magnitude, vorticity magnitude, pressure, and density occur at the core.

Yates, Leslie A.↗

DOE OSTI2026

Bio-inspired alula-based winglet design for enhanced heat transfer in high temperature fin-and-tube heat exchangers

Fin-and-tube heat exchangers (FTHEs) are widely used for high-temperature flue-gas heat recovery, but their performance is often limited by wake regions and non-uniform fin-surface temperatures. This study proposes and numerically evaluates four bio-inspired longitudinal vortex generator (VG) configurations in a high-temperature FTHE with flue-gas inlet temperature ∼1230 K: double-delta, curved double-delta, alula, and a new curved-alula geometry. The reference fin is not hydraulically plain; it already incorporates leading-edge separation columns and convex protrusions, so the alula-type winglets are assessed as downstream add-ons acting on a strongly disturbed flow. In a second step, perforations (one, two and three circular holes) are introduced into the curved-alula VGs to further tailor the flow field. Three-dimensional simulations with the Shear Stress Transpor (SST) $k - ω$ model, temperature-dependent flue-gas properties and conjugate conduction are carried out for gas-side Reynolds numbers $Re_g ≈ 8.0$ x $10^2 - 3.6$ x $10^3$ (mass flow rates 0.5 – 2.5 g/s), and the designs are compared in terms of surface heat flux, Nusselt number, friction factor and hydrothermal performance factor (HTPF). For this already-promoted fin, the additional downstream winglets provide moderate, incremental hydrothermal gains. At the highest Reynolds number, the best non-perforated design (curved-alula) increases surface heat flux from 1630.9 to 1794.7 kW/m² (∼ 10 % gain) and the Nusselt number from 227.6 to 242.6 (∼ 7 % gain), while the friction factor rises from 0.26 to about 0.30, yielding HTPF values close to unity (∼ 0.9 – 1.0). Introducing circular perforations into the curved-alula winglets acts mainly as a wake-bleeding refinement: the three-hole configuration provides a heat flux of 1824.7 kW/m² and a pressure drop of 127.9 Pa, with HTPF in the range ∼ 1.03 – 1.14 and a small (∼ 1 – 3 %) improvement over the solid curved-alula design. Flow-field analysis shows that the perforated curved-alula VGs shrink tube-wake regions, thin the thermal boundary layer and homogenize the fin-surface temperature (outlet-gas temperature ∼ 510 – 520 K and fin-surface temperature ∼ 420 – 421 K for the three-hole case). An optimal flue-gas mass flow rate of ∼ 1 g/s ($Re_g ≈ 1.5$ x $10^3$) is identified, beyond which additional heat-transfer gains are offset by rapidly increasing pressure losses. Overall, the results highlight that initial fin geometry and VG placement are as important as VG shape: alula-based winglets are expected to yield larger relative gains on simpler flat-fin layouts or when positioned closer to the fin leading edge and tube

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Particle Image Velocimetry and Total Temperature Characterization of Arc-Heated Mach 4.5 Free Jet

Particle image velocimetry (PIV) measurements were conducted in the Arc-Heated Combustion Tunnel (ACT-II) on a high-enthalpy Mach 4.5 nozzle flow. The primary motivation for the current work is to establish the feasibility of PIV as a high-quality flow diagnostic technique in hypersonic arc-heated flows and produce a high-resolution hypersonic nozzle flow characterization, including nozzle free jet shear layer velocity profiles. Due to the uncertain nature of the gas composition in the flowfield of interest, PIV measurements of a supersonic wedge flow were used to couple the flow velocities to the oblique shock relations. This enabled a PIV-derived total temperature calculation that does not require a priori assumptions of the exact gas composition. A PIV expansion module was developed for this study, and proper seed sizing and material were selected for the present flow. An analysis of the seed particle response from the PIV measurements provided an initial validation of the seed performance while revealing potential issues with consistent seed sizing. These measurements and derived conditions represent a means of acquiring high-resolution velocimetry and temperature datasets that consider uncertainties in the experimental generation of hypersonic high-enthalpy flows.

Engineering↗

DOE OSTI2024

Topological Data Analysis for Particulate Gels

Soft gels, formed via the self-assembly of particulate materials, exhibit intricate multiscale structures that provide them with flexibility and resilience when subjected to external stresses. Here, this work combines particle simulations and topological data analysis (TDA) to characterize the complex multiscale structure of soft gels. Our TDA analysis focuses on the use of the Euler characteristic, which is an interpretable and computationally scalable topological descriptor that is combined with filtration operations to obtain information on the geometric (local) and topological (global) structure of soft gels. We reduce the topological information obtained with TDA using principal component analysis (PCA) and show that this provides an informative low-dimensional representation of the gel structure. We use the proposed computational framework to investigate the influence of gel preparation (e.g., quench rate, volume fraction) on soft gel structure and to explore dynamic deformations that emerge under oscillatory shear in various response regimes (linear, nonlinear, and flow). Our analysis provides evidence of the existence of hierarchical structures in soft gels, which are not easily identifiable otherwise. Moreover, our analysis reveals direct correlations between topological changes of the gel structure under deformation and mechanical phenomena distinctive of gel materials, such as stiffening and yielding. In summary, we show that TDA facilitates the mathematical representation, quantification, and analysis of soft gel structures, extending traditional network analysis methods to capture both local and global organization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2005

Techniques and Tools of NASA's Space Shuttle Columbia Accident Investigation

The Space Shuttle Columbia accident investigation was a fusion of many disciplines into a single effort. From the recovery and reconstruction of the debris, Figure 1, to the analysis, both destructive and nondestructive, of chemical and metallurgical samples, Figure 2, a multitude of analytical techniques and tools were employed. Destructive and non-destructive testing were utilized in tandem to determine if a breach in the left wing of the Orbiter had occurred, and if so, the path of the resultant high temperature plasma flow. Nondestructive analysis included topometric scanning, laser mapping, and real-time radiography. These techniques were useful in constructing a three dimensional virtual representation of the reconstruction project, specifically the left wing leading edge reinforced carbon/carbon heat protectant panels. Similarly, they were beneficial in determining where sampling should be performed on the debris. Analytic testing included such techniques as Energy Dispersive Electron Microprobe Analysis (EMPA), Electron Spectroscopy Chemical Analysis (ESCA), and X-Ray dot mapping; these techniques related the characteristics of intermetallics deposited on the leading edge of the left wing adjacent to the location of a suspected plasma breach during reentry. The methods and results of the various analyses, along with their implications into the accident, are discussed, along with the findings and recommendations of the Columbia Accident Investigation Board. Likewise, NASA's Return To Flight efforts are highlighted.

McDanels, Steve J.↗

NASA NTRS2001

Time-Dependent Simulations of Turbopump Flows

The objective of the current effort is to provide a computational framework for design and analysis of the entire fuel supply system of a liquid rocket engine, including high-fidelity unsteady turbopump flow analysis. This capability is needed to support the design of pump sub-systems for advanced space transportation vehicles that are likely to involve liquid propulsion systems. To date, computational tools for design/analysis of turbopump flows are based on relatively lower fidelity methods. An unsteady, three-dimensional viscous flow analysis tool involving stationary and rotational components for the entire turbopump assembly has not been available for real-world engineering applications. The present effort will provide developers with information such as transient flow phenomena at start up, impact of non-uniform inflows, system vibration and impact on the structure. In the proposed paper, the progress toward the capability of complete simulation of the turbo-pump for a liquid rocket engine is reported. The Space Shuttle Main Engine (SSME) turbo-pump is used as a test case for evaluation of the hybrid MPI/Open-MP and MLP versions of the INS3D code. The relative motion of the grid systems for the rotor-stator interaction was obtained using overset grid techniques. Time-accuracy of the scheme has been evaluated with simple test cases. Unsteady computations for the SSME turbo-pump, which contains 114 zones with 34.5 million grid points, are carried out on Origin 2000 systems at NASA Ames Research Center. Results from these time-accurate simulations with moving boundary capability will be presented along with the performance of parallel versions of the code.

Kris, Cetin C.↗

NASA NTRS1988

Analysis of homogeneous turbulent reacting flows

Full turbulence simulations at low Reynolds numbers were made for the single-step, irreversible, bimolecular reaction between non-premixed reactants in isochoric, decaying homogeneous turbulence. Various initial conditions for the scalar field were used in the simulations to control the initial scalar dissipation length scale, and simulations were also made for temperature-dependent reaction rates and for non-stoichiometric and unequal diffusivity conditions. Joint probability density functions (pdf's), conditional pdf's, and various statistical quantities appearing in the moment equations were computed. Preliminary analysis of the results indicates that compressive strain-rate correlates better than other dynamical quantities with local reaction rate, and the locations of peak reaction rates seem to be insensitive to the scalar field initial conditions.

Leonard, A. D.↗

NASA NTRS1998

"Reagentless" flow injection determination of ammonia and urea using membrane separation and solid phase basification

Flow injection analysis instrumentation and methodology for the determination of ammonia and ammonium ions in an aqueous solution are described. Using in-line solid phase basification beds containing crystalline media. the speciation of ammoniacal nitrogen is shifted toward the un-ionized form. which diffuses in the gas phase across a hydrophobic microporous hollow fiber membrane into a pure-water-containing analytical stream. The two streams flow in a countercurrent configuration on opposite sides of the membrane. The neutral pH of the analytical stream promotes the formation of ammonium cations, which are detected using specific conductance. The methodology provides a lower limit of detection of 10 microgram/L and a dynamic concentration range spanning three orders of magnitude using a 315-microliters sample injection volume. Using immobilized urease to enzymatically promote the hydrolysis of urea to produce ammonia and carbon dioxide, the technique has been extended to the determination of urea.

NASA Center JSC↗