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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Enhanced Depolarized Electro-Membrane System (EDEMS) for Direct Capture of Carbon Dioxide from Ambient Air (Final Report)

The goal of this final project report is to summarize the work conducted on project DE-FE0031962. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky Center for Applied Energy Research (UK CAER) (Recipient) developed an intensified process to capture CO2 from ambient conditions (400 ppm CO2). The process combines low-temperature solvent-aided membrane capture with electrochemically-mediated solvent regeneration to simultaneously capture ambient CO2 while regenerating the solvent. The technology employs only two primary units (regenerator and absorber/contactor) while generating high purity hydrogen as a co-product that can be sold, used for energy storage, or cost-saving depolarization of the direct air capture (DAC) system during the grid peak demand, allowing for flexible operation. When depolarization is employed, the operating voltage is reduced by more than 1 V. Since the technology is powered directly by DC electricity, it can seamlessly tie in with power sources like solar cells without the need for AC/DC converters, therefore allowing for a remote operation to further mitigate greenhouse gas generation toward deploying a negative carbon emissions technology that is completely decoupled from the carbon emissions from the power source for the DAC unit. The project results verified that UK CAER’s integrated approach addressed the complexities of incumbent DAC systems by demonstrating at ambient conditions, including (1) low gas-side pressure-drop facile CO2 capture via a membrane contactor with in-situ generated hydroxide as capture solvent, (2) multi-functional electrochemical regenerator for hydroxide regeneration, CO2 concentration and hydrogen production, and (3) depolarization using cathode-produced hydrogen to reduce energy requirement. The EH&S Assessment of the process did not identify any obvious concern for the bench-scale operation and no apparent barriers to implementing UK CAER’s carbon capture and solvent regeneration system at a larger scale.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1999

The TRMM Precipitation Radar: Opportunities and Challenges

Although studies on the feasibility of spaceborne weather radar date back to the 1960's, it was only with the launch of the Tropical Rainfall Measuring Mission (TRMM) Satellite in November 1997 that the first weather radar was placed into low earth orbit. The long delay between the initial concept and implementation was caused not only by the demanding requirements of active sensors such as mass, power, and reliability, but because of scientific and technological challenges. For example, the demand for adequate spatial resolution arises from the need to resolve the horizontal structure of convective storm cells and to avoid surface contamination of the rain return at off-nadir angles. To achieve a horizontal resolution on the order of 4 km from low earth orbit with a modest antenna size of 2 m requires the use of a much higher frequency (Ku-band) than those typically used for ground-based weather radars (S- and C-band). Higher frequencies are subject to higher attenuation. As Hitschfeld and Bordan (1954) showed in their classic paper, attenuation correction with a single-wavelength radar is inherently unstable at high attenuations unless the drop size distribution and the radar constant are known precisely. Since these conditions are seldom met, much work over the last decade has been devoted to formulating and testing alternative methods of attenuation correction. The operational method used in the TRMM radar processing is discussed in section 3 of the paper.

Meneghini, R.↗
DOE OSTI2026

Metal additively manufactured wavy fin cold-plate architecture for improved thermal-hydraulic performance

Rapid growth in artificial intelligence and data center workloads demands high-performance liquid cooling to manage increasing chip power. This study presents two metal-additive-manufactured cold plates with sinusoidal fins, constant-amplitude wavy fins and linearly variable-amplitude wavy fins and compares them against metal-additive-manufactured straight fins using experiments conducted at 1 kW heat dissipation as well as high-fidelity 3D conjugate computational fluid dynamic simulations. The cold plates were printed in AlSi10Mg material and underwent design using a Python-automated workflow prior to manufacture and testing. The experiments show that wavy fins reduce the normalized thermal resistance by 35 to 45 % at water flow rates from 1 to 4 LPM. At a fixed 20 kPa pressure drop, the variable-waviness design lowered peak surface temperature by 9 °C and thermal resistance by 51 %, while edge-channel maldistribution in the constant wavy fin design limited gains. A thermal resistance breakdown revealed that 55–63 % of the total thermal resistance in wavy designs comes from base heat conduction, 27–33 % from fin heat conduction, and 9–13 % from fin heat convection, indicating the need to address conduction bottlenecks. Parametric sweeps identify a 3 mm fin pitch as optimal, and that horizontal inlet/outlet manifolds further reduce pressure drop by 30–60 % and thermal resistance by 9–16 % relative to vertical inlet-outlet manifolds. The results yield comprehensive guidelines for fin geometry, manifold alignment, material selection and additive-manufacturing constraints to realize high-performance liquid-cooled cold plates for power-dense electronics.

3d printing↗
DOE OSTI2026

An Overview of Potential Future Aviation Energy Carriers

Global jet fuel demand is projected to grow to 165 billion gallons by 2050 and there is growing interest in the aviation industry to understand the capabilities of alternative energy carriers. This report considers several potential energy carriers, reviewing their production potential, operational considerations, and economic implications to inform potential next steps in aeronautics research. The following energy carriers (i.e., fuels) were evaluated in this study for future use in aviation: sustainable aviation fuel (SAF) - both biomass-based and power-to-liquids (PtL) - based SAF - cryogenic hydrogen (LH 2 ) - also known as liquid hydrogen - liquefied natural gas (LNG), liquefied ethane (LE), and Jet X. The barriers and opportunities for the evaluated energy carriers vary. SAF is a commercially available drop-in fuel compatible with existing aircraft and infrastructure. SAF is limited by both higher prices and slow commercialization of multiple pathways using different feedstocks necessary to significantly grow supply. Cryogenic fuels, in contrast, have very different thermal, physical, and chemical properties than SAF and Jet A, requiring the construction of new airport storage and dispensing infrastructure and the design of new aircraft energy systems capable of mitigating heat transfer and boil-off. Cryogenic fuels offer an opportunity to diversify aviation fuel carriers from domestic energy relevant for both energy security and resilience. This means cryogenic fuels are more of a longer-term solution for aircraft but are worth exploring for potential future cost savings and emissions benefits. Jet X refers to non-drop-in liquid hydrocarbon fuels in the early stages of investigation seeking favorable properties. There are substantial barriers to non-drop-in liquid aviation fuels that are not compatible with existing aircraft and fuel infrastructure.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Silicon Carbide Inverter for Off-Road Heavy-Duty Applications: The Importance of Thermal and Thermomechanical Design in Power Electronics Packaging

Electrification of drivetrain systems is now seen as a major opportunity by the transportation industry across the globe to reduce the greenhouse gas emissions and revolutionize the travel patterns of millions of people. The cumulative number of plug-in hybrid and battery electric vehicles (EVs) sold in the United States has now surpassed 2 million in 2021, according to the International Energy Agency. The introduction of EVs in different classes of passenger vehicles and the continued drop in prices spurred by government incentives have attracted the attention of consumers despite certain barriers, such as higher initial cost and range anxiety. In the United States, the EV market share is now growing at an exponential pace, with the domestic automakers allocating a lion's share of new and future car sales to EVs. Additionally, different market studies project decreasing cost and rising sales of medium- and heavy-duty electric trucks. Although electrification initiatives are strongly pursued in the on-road passenger vehicle market, off-highway sectors, such as construction, mining, and agriculture, are also gradually implementing electric drivetrain technologies in their machineries. As EVs grow in popularity on a global scale, innovative drivetrain technologies must meet the increasing energy demand by significantly increasing system efficiency.

ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1994

Structural evaluation of concepts for a solar energy concentrator for Space Station advanced development program

Solar dynamic power systems have a higher thermodynamic efficiency than conventional photovoltaic systems; therefore they are attractive for long-term space missions with high electrical power demands. In an investigation conducted in support of a preliminary concept for Space Station Freedom, an approach for a solar dynamic power system was developed and a number of the components for the solar concentrator were fabricated for experimental evaluation. The concentrator consists of hexagonal panels comprised of triangular reflective facets which are supported by a truss. Structural analyses of the solar concentrator and the support truss were conducted using finite-element models. A number of potential component failure scenarios were postulated and the resulting structural performance was assessed. The solar concentrator and support truss were found to be adequate to meet a 1.0-Hz structural dynamics design requirement in pristine condition. However, for some of the simulated component failure conditions, the fundamental frequency dropped below the 1.0-Hz design requirement. As a result, two alternative concepts were developed and assessed. One concept incorporated a tetrahedral ring truss support for the hexagonal panels: the second incorporated a full tetrahedral truss support for the panels. The results indicate that significant improvements in stiffness can be obtained by attaching the panels to a tetrahedral truss, and that this concentrator and support truss will meet the 1.0-Hz design requirement with any of the simulated failure conditions.

Kenner, Winfred S.↗
DOE OSTI2024

Fiber Sorbents – A Versatile Platform for Sorption-Based Gas Separations

Increasing demand for high-purity fine chemicals and a drive for process intensification of large-scale separations have driven significant work on the development of highly engineered porous materials with promise for sorption-based separations. While sorptive separations in porous materials offer energy-efficient alternatives to longstanding thermal-based methods, the particulate nature of many of these sorbents has sometimes limited their large-scale deployment in high-throughput applications such as gas separations, for which the necessary high feed flow rates and gas velocities accrue prohibitive operational costs. These processability limitations have been historically addressed through powder shaping methods aimed at the fabrication of structured sorbent contactors based on pellets, beads or monoliths, commonly obtained as extrudates. These structures overcome limitations such as elevated pressure drops commonly recorded across powder adsorption beds but often accrue thermal limitations arising from elevated particle density and aggregation, which ultimately cap their maximum separation performance. Furthermore, the harsh mechanical strain to which powder particles are subjected during contactor fabrication, in the form of extrusion/compression forces, can result in partial pore occlusion and framework degradation, further limiting their performance. Here, we present the development of porous fiber sorbents as an alternative sorbent contactor design capable of addressing sorbent processability limitations while enabling an array of performance-maximizing heat integration capabilities. This new sorbent form factor leverages pre-existing know-how from hollow fiber spinning to produce fiber-shaped sorbent contactors through the phase inversion of known polymers in a process known as dry-jet/wet quenching. The process of phase inversion allows microporous sorbent particles to be latched onto a macroporous polymer matrix under mild processing conditions, thus making it compatible with soft porous materials prone to amorphization under traditional pelletization conditions. Sorbent fibers can be created with different geometries through control of the spinning apparatus and process, offering the possibility to produce monolithic and hollow fibers alike, the latter of which can be integrated with thermalization fluid flows. In this Account, we summarize our progress in the field of fiber sorbents from both design and application standpoints. We further guide the reader through the evolution of this field from the early inceptive work on zeolite hollow fibers to recent developments on MOF fibers. We highlight the versatile nature of fiber sorbents, both from the composition, fabrication and structure points of view, and further demonstrate how fiber sorbents offer alternative paths in tackling new and challenging chemical separation challenges like direct air capture (DAC), with a final perspective on the future of the field.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Cities Topology - Curbs and Parking

Curbside activity has not traditionally been represented in transportation network modeling in high fidelity. Growing demand for curbside mean that prevailing practices are becoming increasingly untenable. Through outreach to expert practitioners, we established the state-of-practice and needs for quantitative modeling. We proposed a new modeling framework to allow curbspace managers to make optimal decisions about space allocation between legacy and emerging uses. Proposed future work will take the proposed approach and refine it to be suitable for standardized use by practitioners – to facilitate mobility and energy optimization through smart curbside management.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Crystal Chemistry and Thermodynamics of HREE (Er, Yb) Mixing in a Xenotime Solid Solution

Rare earth elements (REEs), the 15 naturally occurring lanthanides plus yttrium and scandium, are ubiquitously used in modern life as they are critical components of many advanced devices and technologies. However, the demand for REEs is not equal, with the heavy rare earth elements (HREEs) having a higher demand. Xenotime (HREEPO 4 ) is an important HREE ore mineral and globally is an economical source of HREE. Most of the crystallographic and thermodynamic properties of xenotime endmembers have been elucidated by calorimetric, solubility, and high-pressure studies. Yet, in natural systems, endmembers are rarely encountered, and instead, REE solid solutions are more commonly observed. Here, we characterize the crystal chemistry, thermodynamics of HREE mixing, and high-temperature material behaviors and thermochemistry of a synthetic erbium (Er)-ytterbium (Yb) binary xenotime solid solution (Er (x) Yb (1-x) PO 4 ) using a suite of experimental techniques, including X-ray fluorescence spectroscopy, synchrotron X-ray powder diffraction implemented with Rietveld analysis, Fourier transform infrared spectroscopy coupled with attenuated total reflectance, Raman spectroscopy, thermogravimetric analysis coupled with differential scanning calorimetry, and high-temperature oxide melt drop solution calorimetry. Our results shed light on the formation of natural xenotimes and lay the foundation for their industrial applications as thermal coating materials.

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

Digital Real-Time Simulation and Power Quality Analysis of a Hydrogen-Generating Nuclear-Renewable Integrated Energy System

This paper investigates the challenges and solutions associated with integrating a hydrogen-generating nuclear-renewable integrated energy system (NR-IES) under a transactive energy framework. The proposed system directs excess nuclear power to hydrogen production during periods of low grid demand while utilizing renewables to maintain grid stability. Using digital real-time simulation (DRTS) in the Typhoon HIL 404 model, the dynamic interactions between nuclear power plants, electrolyzers, and power grids are analyzed to mitigate issues such as harmonic distortion, power quality degradation, and low power factor caused by large non-linear loads. A three-phase power conversion system is modeled using the Typhoon HIL 404 model and includes a generator, a variable load, an electrolyzer, and power filters. Active harmonic filters (AHFs) and hybrid active power filters (HAPFs) are implemented to address harmonic mitigation and reactive power compensation. The results reveal that the HAPF topology effectively balances cost efficiency and performance and significantly reduces active filter current requirements compared to AHF-only systems. During maximum electrolyzer operation at 4 MW, the grid frequency dropped below 59.3 Hz without filtering; however, the implementation of power filters successfully restored the frequency to 59.9 Hz, demonstrating its effectiveness in maintaining grid stability. Future work will focus on integrating a deep reinforcement learning (DRL) framework with real-time simulation and optimizing real-time power dispatch, thus enabling a scalable, efficient NR-IES for sustainable energy markets.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Decentralised demand response market model based on reinforcement learning

A new decentralised demand response (DR) model relying on bi‐directional communications is developed in this study. In this model, each user is considered as an agent that submits its bids according to the consumption urgency and a set of parameters defined by a reinforcement learning algorithm called Q‐learning. The bids are sent to a local DR market, which is responsible for communicating all bids to the wholesale market and the system operator (SO), reporting to the customers after determining the local DR market clearing price. From local markets’ viewpoint, the goal is to maximise social welfare. Four DR levels are considered to evaluate the effect of different DR portions in the cost of the electricity purchase. The outcomes are compared with the ones achieved from a centralised approach (aggregation‐based model) as well as an uncontrolled method. Numerical studies prove that the proposed decentralised model remarkably drops the electricity cost compare to the uncontrolled method, being nearly as optimal as a centralised approach.

Shafie‐Khah, Miadreza↗
NASA NTRS1999

Systematic Differences between Satellite-Based Presipitation Climatologies over the Tropical Oceans

Since the beginning of the World Climate Research Program's Global Precipitation Climatology Project (GPCP) satellite remote sensing of precipitation has made dramatic improvements, particularly for tropical regions. Data from microwave and infrared sensors now form the most critical input to precipitation data sets and can be calibrated with surface gauges to so that the strengths of each data source can be maximized in some statistically optimal sense. It is clear however that there still remain significant uncertainties with satellite precipitation retrievals which limit their usefulness for many purposes. Systematic differences i'A tropical precipitation estimates have been brought to light in comparison activities such as the GPCP Algorithm Intercomparison Project and more recent Wetnet Precipitation Intercomparison Project 3. These uncertainties are assuming more importance because of the demands for validation associated with global climate modeling and data assimilation methodologies. The objective of the present study is to determine the physical basis for systematic differences in spatial structure of tropical precipitation as portrayed by several different satellite-based data sets. The study is limited to oceanic regions only and deals primarily with aspects of spatial variability. We are specifically interested in why MSU channel 1 and GPI precipitation differences are so striking over the Eastern Pacific ITCZ and why they both differ from other microwave emission-based precipitation estimates from SSM/I and a scattering-based deep convective ice index from MSU channel 2. Our results to date have shown that MSU channel I precipitation estimates are biased high over the Eastern Pacific ITCZ because of two factors: (1) the hypersensitivity of this frequency to cloud water in contrast to falling rain drops, and (2) unaccounted for scattering effects by precipitation-size ice which depresses the signal of the liquid water emission. Likewise, cold cloud top climatologies such as the GPI show an excess (a deficit) in estimated rainfall over the E. Pacific ITCZ (Warm Pool region). We show that these algorithms need to account for regionally varying heights (or temperatures) at which tropical convection detrains to form cirrus shields. A second objective we pursue is to identify variations in the macroscale cloud physical and thermodynamic properties of precipitation regimes" and relate these differences to tropical dynamical mechanisms of tropical heat and moisture balance. Finally, we interpret the algorithm differences and their associations with tropical dynamics in terms of WCRP GPCP goals for constructing precipitation climatologies.

Robertson, Frankin R.↗
DOE OSTI2024

Electrochemically Regenerated Solvent for Direct Air Capture with Co-generation of Hydrogen at Bench-scale

The goal of this final project report is to summarize the work conducted on project DE-FE0032125. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky Institute for Decarbonization and Energy Advancement (UK IDEA) (Recipient) developed an intensified process to capture CO 2 from ambient conditions (415 ppm CO 2 ). The process combines low-temperature solvent-aided membrane capture with electrochemically-mediated solvent regeneration to simultaneously capture ambient CO 2 while regenerating the solvent. The technology employs only two primary units, a regenerator and an absorber/contactor, while generating high purity hydrogen as a co-product that can be sold, used for energy storage, or cost-saving depolarization of the direct air capture (DAC) system during the grid peak demand, allowing for flexible operation. Since the technology is powered directly by DC electricity, it can seamlessly tie in with power sources like solar cells without the need for AC/DC converters, therefore allowing for a remote operation to further mitigate greenhouse gas generation toward deploying a negative carbon emissions technology that is completely decoupled from the carbon emissions from the power source for the DAC unit. The completion of the project results in significant progress toward the Department of Energy’s (DOE’s) goal of advancing lab and bench-scale DAC systems to a sufficient maturity level that can justify their continued scale-up through the verification testing of the electrochemically regenerated solvent system for DAC with co-generation of hydrogen at bench-scale. The technology addressed the complexities of incumbent DAC systems by demonstrating at ambient conditions (1) low gas-side pressure-drop facile CO 2 capture via an intensified membrane absorber with in-situ regenerated hydroxide as capture solvent, (2) multi-functional electrochemical regenerator for hydroxide regeneration, CO 2 concentration and hydrogen production at less than 3 V, and (3) stable DAC performance including >90% capture with air influent at the CFM scale. The data from this project enables the completion of Techno-Economic Analysis (TEA) and Life Cycle Assessment (LCA). TEA and LCA demonstrate the potential of the proposed electrochemical solvent-based process to be a viable DAC option. The analysis did not identify any obvious concern for the bench-scale operation and no apparent barriers to implementing UK IDEA carbon capture and solvent regeneration system at a larger scale.

08 HYDROGEN↗
NASA NTRS1986

Parametric and cycle tests of a 40-A-hr bipolar nickel-hydrogen battery

A series of tests was performed to characterize battery performance relating to certain operating parameters which included charge current, discharge current, temperature and pressure. The parameters were varied to confirm battery design concepts and to determine optimal operating conditions. Spacecraft power requirements are constantly increasing. Special spacecraft such as the Space Station and platforms will require energy storage systems of 130 and 25 kWh, respectively. The complexity of these high power systems will demand high reliability, and reduced mass and volume. A system that uses batteries for storage will require a cell count in excess of 400 units. These cell units must then be assembled into several batteries with over 100 cells in a series connected string. In an attempt to simplify the construction of conventional cells and batteries, the NASA Lewis Research Center battery systems group initiated work on a nickel-hydrogen battery in a bipolar configuration in early 1981. Features of the battery with this bipolar construction show promise in improving both volumetric and gravimetric energy densities as well as thermal management. Bipolar construction allows cooling in closer proximity to the cell components, thus heat removal can be accomplished at a higher rejection temperature than conventional cell designs. Also, higher current densities are achievable because of low cell impedance. Lower cell impedance is achieved via current flow perpendicular to the electrode face, thus reducing voltage drops in the electrode grid and electrode terminals tabs.

Cataldo, R. L.↗
DOE OSTI2022

Enabling practical nanoparticle electrodeposition from aqueous nanodroplets

The rapid rise of technology in the modern world has led to an increased demand for energy. Consequently, it is essential to increase the efficiency of current energy-producing systems due to the poor activity of their catalysts. Nanoparticles play a significant role in energy storage and conversion; however, electrodeposition of nanoparticles is difficult to achieve due to surface heterogeneities, nanoparticle diffusion layer overlap, and the inability to electrodeposit multi-metallic nanoparticles with stoichiometric control. These problems can be solved through nanodroplet-mediated electrodeposition, a technique where water nanodroplets are filled with metal salt precursors that form stable nanoparticles when they collide with a negatively-biased electrode. Further, this method has demonstrated control over nanoparticle size and morphology, displaying a wide variety of applications for the generation of materials with excellent catalytic properties. Historically, the cost of nanodroplet-mediated electrodeposition experimentation is prohibitive because practitioners use 0.1 M to 0.5 M tetrabutylammonium perchlorate (TBAP) dissolved in the oil phase (∼10 mL). Such high concentrations of electrolytes have been used to lower ohmic drop and provide ions to maintain charge balance during electrodeposition. Here, we show that supporting electrolyte is not necessary for the oil phase. In fact, one can use a suitable salt (such as lithium perchlorate) in the aqueous phase to achieve nanoparticle electrodeposition. This simple change, grounded in an understanding of ion transfer, drives down the cost per experiment by nearly three orders of magnitude, representing a necessary step forward in enabling practical nanoparticle electrodeposition from water nanodroplets. This approach is a promising procedure for future cost-effective energy conversion systems relying on electrocatalytic nanoparticles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

SPERLU Selective Process for Efficient Removal of Lignin and Upgrading (Final Technical Report)

To meet the growing demand for bio-based chemicals and improve the profitability and efficiency of the emerging biorefinery industry, lignin is an abundant and attractive feedstock. Spero Renewables has developed a proprietary and patent-pending technology, the Selective Process for Efficient Removal of Lignin and Upgrading (SPERLU). The technology is a catalytic deconstruction and upgrading of lignin in lignocellulosic biomass or commercially available technical lignin to produce multi-functional phenol (MFP) products. The SPERLU process has been demonstrated and vetted on a lab scale to convert commercially available technical lignin to MFPs in yields of 60-90% (based on lignin). The MFP products can be separated and further upgraded through catalytic or biological means. Spero performed a detailed kinetic study of the SPERLU process and used the resulting kinetic data to design and construct a mini-pilot-scale reactor for routine production of hundreds of grams of MFP products. Spero’s lignin-based MFPs have been demonstrated for use as a drop-in replacement for bisphenol A (BPA) in the synthesis of thermoset polymers. Spero’s lignin-based thermoset polymers exhibit excellent mechanical properties and can be used in many applications. Additionally, a collaboration with the National Renewable Energy Lab (NREL) was used to evaluate the feasibility of upgrading SPERLU products through biological means into valuable chemicals. A comprehensive technoeconomic analysis (TEA) and Life-cycle analysis (LCA) have been completed and support the case for commercialization of the SPERLU technology. Through this project Spero has significantly de-risked the SPERLU technology and is actively planning larger scale pilot projects.

09 BIOMASS FUELS↗
DOE OSTI2025

Helium recovery system at IB3A

The growing demand for sustainable cryogenic operations at Fermilab has underscored the need to improve helium management, particularly at the Industrial Building 3A (IB3A) test facility. IB3A characterizes and tests superconductors, cables, and coils for projects such as the HL-LHC AUP and Mu2e, yet currently relies on 500 L Dewars whose boil-off is vented to atmosphere, wasting a critical, non-renewable resource and increasing the cost of testing. A project is therefore under way to link IB3A to an existing purification and liquefaction station in a neighboring building through a dedicated pipeline. Captured helium will be transferred, purified, reliquefied, and returned for reuse, cutting losses and operating costs. This paper details the first two project phases: "Design and Engineering" and "Procurement and Installation." The design phase finalizes pipeline specifications, establishes flow-control requirements, and resolves integration challenges with existing cryogenic infrastructure. The procurement and installation phase covers material sourcing, pipeline construction, and deployment of control and monitoring systems to assure reliable, efficient operation. Key technical hurdles-route optimization, pressure drop mitigation, and interface compatibility-are discussed alongside implemented solutions. Implementing the pipeline and upgrading IB3A will dramatically reduce helium consumption and therefore testing cost, strengthening Fermilab's capacity to support frontier science far into the future.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗
NASA NTRSDate not supplied

Thermal-Fluid Analysis of a Liquid-Cooled Battery Module for Electrified Aircraft

The development of safe, energy-dense batteries is critical to advancing hybrid electric and fully electrified aircraft propulsion. Achieving this capability requires a thermal management system that can maintain battery performance and safety under demanding operational conditions. The objective of this project is to support the maturation of next-generation lithium-ion batteries for electrified aircraft by conducting performance testing on integrated battery modules, specifically a 2-cell series configuration module housed within an aluminum enclosure. Designed to operate at a nominal 7.2 V with discharge rates up to 2.5C, the module will eventually be used to power an electric motor and DC-DC converter, generating substantial thermal loads that must be effectively managed to increase the usable energy and power density of electrified aircraft. To address these thermal challenges, this study presents the development and thermal-fluid analysis of a liquid-cooled thermal management system. While the full aircraft architecture utilizes an eight-string configuration, the present work evaluates a representative single-string water coolant loop to characterize baseline performance. The active cooling loop circulates water through a reservoir, pump, the battery module, and a variable area flow meter. Key performance metrics including component-level temperatures, mass flow rates, and pressure drops are quantified across the loop. Across discharge rates ranging from 0.5C to 2.5C, the active thermal loop consistently and effectively removed heat from the module, validating the design approach and confirming readiness for further development. The validated thermal performance indicates a path toward scalable battery modules that could enable energy and power dense systems for hybrid electric aircraft.

Electrified Aircraft↗