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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 OSTI2020

Conceptual Design and Rationale for a New Agrivoltaics Concept: Pastured-Raised Rabbits and Solar Farming

Land-use conflicts created by the growth of solar photovoltaics (PV) can be mitigated by applying the concept of agrivoltaics, that is, the co-development of land for both PV and agricultural purposes, to commercial-scale solar installations. In this study, we present a conceptual design for a novel agrivoltaic system based on pasture-fed rabbit farming and provide the technical, environmental and economic analyses to demonstrate the viability of the concept. Included in our analysis are the economic advantages to the PV operator of grazing rabbits at a density sufficient to control vegetative growth, thus reducing the economic and environmental costs of mowing; the dual-revenue stream from the sale of both rabbits and electricity, contrasted with estimates of the capital-investment costs for rabbits co-located with, and also independent of, PV; and the economic value to the rabbit farmer of higher colony-growth rates (made possible by the shading and predator protection provided by the PV arrays and of reduced fencing costs, which are the largest capital cost, by being able to leverage the PV systems for rabbit fencing. We also provide an environmental analysis that suggests that rabbit-PV farming is a pathway to a measurable reduction in agriculturally-generated greenhouse-gas emissions. Here, our calculations indicate that the co-location of solar and rabbit farms is a viable form of agrivoltaics, increasing overall site revenue by 2.5%-24.0% above projected electricity revenue depending on location and rental/ownership of rabbits, while providing a high-value agricultural product that, on a per weight basis, has significantly less environmental impact than cattle.

14 SOLAR ENERGY↗
DOE OSTI2021

The SAMI Galaxy Survey: stellar population and structural trends across the Fundamental Plane

ABSTRACT We study the Fundamental Plane (FP) for a volume- and luminosity-limited sample of 560 early-type galaxies from the SAMI survey. Using r-band sizes and luminosities from new multi-Gaussian expansion photometric measurements, and treating luminosity as the dependent variable, the FP has coefficients a = 1.294 ± 0.039, b = 0.912 ± 0.025, and zero-point c = 7.067 ± 0.078. We leverage the high signal-to-noise ratio of SAMI integral field spectroscopy, to determine how structural and stellar population observables affect the scatter about the FP. The FP residuals correlate most strongly (8σ significance) with luminosity-weighted simple stellar population (SSP) age. In contrast, the structural observables surface mass density, rotation-to-dispersion ratio, Sérsic index, and projected shape all show little or no significant correlation. We connect the FP residuals to the empirical relation between age (or stellar mass-to-light ratio Υ⋆ ) and surface mass density, the best predictor of SSP age amongst parameters based on FP observables. We show that the FP residuals (anti)correlate with the residuals of the relation between surface density and Υ⋆ . This correlation implies that part of the FP scatter is due to the broad age and Υ⋆ distribution at any given surface mass density. Using virial mass and Υ⋆, we construct a simulated FP and compare it to the observed FP. We find that, while the empirical relations between observed stellar population relations and FP observables are responsible for most (75 per cent) of the FP scatter, on their own they do not explain the observed tilt of the FP away from the virial plane.

D’Eugenio, Francesco↗
DOE OSTI2022

Boron Nitride Solid-State Neutron Detectors

The goal of this project is to build upon the work performed under the Texas Tech IDEAS project (DE-AR0000964 monitored by Dr. Isik Kizilyalli) to bring the developed B-10 enriched hexagonal boron nitride (h- 10 BN or 10 BN or BN) semiconductor neutron detector technology to the next level of maturity. In comparison to He-3 ( 3 He) gas detectors, BN neutron detectors possess all the intrinsic advantages of semiconductor devices: light weight, compact size, fast response speed, high spatial resolution, high temperature and low voltage operation capability, ease of mass production via existing semiconductor infrastructures, low cost of operation and maintenance, flexible form factors, and durability. The project will develop a prototype h- 10 BN neutron detector as a potential replacement for the 3 He gas neutron detectors (LND 25185 or equivalent) used in various neutron survey meters currently produced and commercialized by Ludlum Measurements, Inc. (LMI). To increase the overall detection efficiency, it is essential to maximize the collection efficiency of charge carriers (electrons and holes) generated by the nuclear reaction, which demands a further push to achieve 10 BN epilayers with improved material quality. The material growth processes will be guided by characterization of structural, optical, and electrical properties of h-BN. Selective devices will be calibrated at LMI. During ARPA-E supporting period, the key material parameters of h-BN produced by metal organic chemical vapor deposition (MOCVD), including the layer thickness, mobility-lifetime product, surface recombination field and detector size for maintaining a high charge collection efficiency all have been improved by several orders of magnitude. These improvements have enabled the realization of high-performance h 10BN semiconductor thermal neutron detectors. Presently, h- 10 BN thermal neutron detectors developed under ARPA-E’s support hold the record high detection efficiency among all solid-state detectors at 59%. With further development in manufacturing, there is no question that h-BN detectors will replace the traditional He-3 gas detectors in certain application areas by offering obvious advantages of semiconductor technologies over gas detectors and opportunities for users to dedicate the scarce and expensive supply of He-3 gas to other application areas where substitutes of He-3 gas are not possible.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2020

Differential credibility assessment for statistical downscaling

Climate science is increasingly using (i) ensembles of climate projections from multiple models derived using different assumptions and/or scenarios and (ii) process-oriented diagnostics of model fidelity. Efforts to assign differential credibility to projections and/or models are also rapidly advancing. A framework to quantify and depict the credibility of statistically downscaled model output is presented and demonstrated. Here, the approach employs transfer functions in the form of robust and resilient generalized linear models applied to downscale daily minimum and maximum temperature anomalies at 10 locations using predictors drawn from ERA-Interim reanalysis and two global climate models (GCM; GFDL-ESM2M and MPI-ESM-LR). The downscaled time series are used to derive several impact relevant CLIMDEX temperature indices that are assigned credibility based on (1) the reproduction of relevant large-scale predictors by the GCMs (i.e. fraction of regression beta-weights derived from predictors that are well-reproduced) and (2) the degree of variance in the observations reproduced in the downscaled series following application of a new variance inflation technique. Credibility of the downscaled predictands varies across locations, between the two GCM and is generally higher for minimum temperature than maximum temperature. The differential credibility assessment framework demonstrated here is easy to use and flexible. It can be applied as is to inform decision makers regarding projection confidence, and/or extended to include other components of the transfer functions, and/or used to weight members of a statistically downscaled ensemble.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Low Temperature Cyclic Deformation Behavior of Ultrafine-grained Pure Magnesium (Final Technical Report)

The primary goal of the project is to explore the fundamental deformation and fatigue failure mechanisms for magnesium with a hexagonal close packed (HCP) crystal structure. It is important to perform the project for several reasons. Firstly, magnesium is the lightest structural metal and its application in various structural components can reduce the final component weight.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The DESI-Lensing Mock Challenge: large-scale cosmological analysis of 3x2-pt statistics

The current generation of large galaxy surveys will test the cosmological model by combining multiple types of observational probes. Realising the statistical promise of these new datasets requires rigorous attention to all aspects of analysis including cosmological measurements, modelling, covariance and parameter likelihood. In this paper we present the results of an end-to-end simulation study designed to test the analysis pipeline for the combination of the Dark Energy Spectroscopic Instrument (DESI) Year 1 galaxy redshift dataset and separate weak gravitational lensing information from the Kilo-Degree Survey, Dark Energy Survey and Hyper-Suprime-Cam Survey. Our analysis employs the 3x2-pt correlation functions including cosmic shear and galaxy-galaxy lensing, together with the projected correlation function of the spectroscopic DESI lenses. We build realistic simulations of these datasets including galaxy halo occupation distributions, photometric redshift errors, weights, multiplicative shear calibration biases and magnification. We calculate the analytical covariance of these correlation functions including the Gaussian, noise and super-sample contributions, and show that our covariance determination agrees with estimates based on the ensemble of simulations. We use a Bayesian inference platform to demonstrate that we can recover the fiducial cosmological parameters of the simulation within the statistical error margin of the experiment, investigating the sensitivity to scale cuts. This study is the first in a sequence of papers in which we present and validate the large-scale 3x2-pt cosmological analysis of DESI-Y1.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Gearbox bearing crack growth prognostics and uncertainty quantification with physics-informed machine learning

This paper introduces the extreme theory of functional connections (X-TFC), a physics-informed machine learning algorithm, and tailors it to estimate the remaining useful life (RUL) of wind turbine gearbox bearings experiencing fatigue crack growth. Unlike purely data-driven methods, X-TFC embeds a physics model, based on Head's theory in this work, into its training objective. The core of X-TFC is a random-projection single-layer neural network trained via an extreme learning machine, which requires only limited damage progression data and solves for output weights with a least-squares optimization algorithm. A composite loss function balances the network's fit to observed degradation data against the residuals of the governing crack growth differential equation, ensuring the learned damage trajectory remains physically plausible. When applied to a vibration-based health-index (HI) dataset measured during the growth of a crack on the inner ring of a high-speed bearing in a wind turbine gearbox (Bechhoefer and Dubé, 2020), X-TFC achieves near-zero prediction bias. Even when trained on only the first 10 %–20 % of the damage progression data, with sufficient physics weighting its predictions remain monotonic and smooth, delivering high prognosability and trendability. To quantify the epistemic uncertainty, we employ a Monte Carlo ensemble of independently initialized X-TFC models trained on noise-perturbed data, which yields confidence intervals around each RUL estimate and captures both model-parameter and epistemic uncertainty. In addition to a vibration-based HI, we demonstrate that the proposed framework can be directly applied to a supervisory control and data acquisition (SCADA) data-based HI (Eftekhari Milani et al., 2026) measured during similar wind turbine gearbox bearing crack faults, preserving its accuracy and interpretability. This extension shows the versatility of our approach, which is applicable to bearings of multiple gearbox manufacturers, models, and ratings using only SCADA data. By integrating domain knowledge with machine learning, X-TFC offers a rapid, reliable tool for crack prognostics. Its adaptability to other bearing failure modes, such as pitch bearing ring cracks, positions X-TFC as a powerful enabler of data-driven, physics-informed asset management in the wind energy sector and beyond.

17 WIND ENERGY↗
DOE OSTI2024

Geothermal Play Fairway Analysis of Low-Temperature Resources for Sedimentary Basin Geothermal Play Types: An Example in the Denver Basin

This project is part of a nationwide effort to highlight the advantages of incorporating low-temperature geothermal resource evaluation into the implementation of combined heat and power (CHP), and geothermal direct use (GDU) technologies (e.g., space heating and/or cooling). The initiative aims to hasten the nation's decarbonization process by exploring the potential for using low-temperature geothermal resources (< 150 Degrees Celsius) in selected sedimentary basins that have several population centers. The Play Fairway Analysis (PFA) techniques were modified from earlier studies of sedimentary basin geothermal play types (SBGPTs) that assessed the viability of low-temperature resources. The decision-making process for leveraging low-temperature geothermal resources for GDU and CHP applications is complex and considers a variety of factors, including geological, economic, and risk criteria. This study covers workflows, relevant datasets, python code, and both common and composite maps used to create low-temperature geothermal resource favorability maps for the Denver Basin, which extends across Colorado, Nebraska, and Wyoming. The replication of these methodologies in other SBGPTs can evaluate potential for low-temperature resources. The proposed geothermal PFA approach for low-temperature geothermal resources includes: (1) identifying available relevant data and grouping data sets into PFA criteria (e.g., geological, economic, and risk criteria); (2) analyzing data gaps enable future focalized exploration; (3) performing uncertainty quantification; (4) weighting relevant data; (5) developing favorability and common risk maps for low-temperature geothermal resources to identify potential locations for more focused data collection. This project will facilitate future deployment of CHP and GDU by providing data, tools, and a workflow applicable to low-temperature geothermal resources in sedimentary basins.

15 GEOTHERMAL ENERGY↗
DOE OSTI2023

Projections of Hourly Meteorology by Balancing Authority Based on the IM3/HyperFACETS Thermodynamic Global Warming (TGW) Simulations

This dataset contains 40 years (1980-2019) of historical hourly meteorology and 80 years (2020-2099) of projected hourly meteorology for 54 Balancing Authorities (BAs) in the conterminous United States. Details about the scenarios and variables included in this dataset are in the readme.pdf file. This dataset is derived from the IM3/HyperFACETS Thermodynamic Global Warming (TGW) simulations (https://doi.org/10.57931/1885756). More details on the TGW approach can be found at: https://tgw-data.msdlive.org/. If you use this dataset please also cite the raw TGW dataset (Jones, A. D., Rastogi, D., Vahmani, P., Stansfield, A., Reed, K., Thurber, T., Ullrich, P., & Rice, J. S. (2022). IM3/HyperFACETS Thermodynamic Global Warming (TGW) Simulation Datasets (v1.0.0) [Data set]. MSD-LIVE Data Repository. https://doi.org/10.57931/1885756). To go from the TGW data to these BA-level aggregated data we first averaged the raw gridded data by county in the United States. That intermediate data step is also stored in MSD-LIVE (https://doi.org/10.57931/1960548). We then population-weight the county-level hourly data in order to create population-weighted meteorology time series for each BA. Historical populations are from the United States Census Bureau and the evolving future populations are based on Shared Socioeconomic Pathways (SSPs) 3 and 5. The four climate scenarios crossed with the two SSPs yield eight different future projections for each BA: rcp45cooler_ssp3, rcp45cooler_ssp5, rcp45hotter_ssp3, rcp45hotter_ssp5, rcp85cooler_ssp3, rcp85cooler_ssp5, rcp85hotterssp3, rcp85hotterssp5. For the historical period and each of the eight future scenarios the dataset has hourly estimates of the population-weighted average of five meteorological variables: Temperature, specific humidity, shortwave radiation, longwave radiation, and wind speed. All times are in Coordinated Universal Time (UTC). The code to go from the raw TGW data to county-level and then BA-level projections is available at: https://github.com/IMMM-SFA/im3components/tree/main/im3components/wrf_to_tell.

Balancing Authority↗
DOE OSTI2021

Utah FORGE Well 16A(78)-32 X-ray Diffraction Data

This submission contains x-ray diffraction data taken from 3,600 to 10,987 feet deep in well 16A(78)-32 in the Roosevelt Hot Springs Geothermal Area as part of the Utah FORGE project. 78 rock samples were taken. Samples are taken in a range of ten feet at 100 foot increments. Mineral abundances are given in weight percent of the sample, with results rounded to the nearest whole number. Fields marked with tr (trace) indicate that mineral is present, but that its abundance calculated from the Rietveld refinement was less than one weight percent; that it was observed in the clay-sized fraction, but not the bulk; and/or that it was observed in low abundance during petrographic analyses. The samples were taken between 10/29/2020 and 12/24/2020 during the drilling of well 16A(78)-32.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Conformable, Composite Tank for Liquid Hydrogen Storage in Heavy-duty Ground Transportation

Raytheon Technologies Research Center (RTRC), with its partners, Argonne National Labs and University of Dayton Research Institute proposed to design and manufacture a conformable composite tank prototype to store liquid Hydrogen (LH2) for heavy-duty truck applications. A dual-wall tank concept was proposed where an outer shell covers and protects an inner pressure vessel that stores liquid hydrogen. The inner pressure vessel is liner-less and designed with a conformable concept, derived from prior RTRC ARPA-E program where multiple vessels are coalesced into one, maximizing space utilization and reducing surface area for heat leak. The gap between the dual wall is evacuated of air pressure, and filled with multi-layer insulation to minimize radiative heat transfer. Fiber reinforced composites were proposed for light-weighting and conformable shape manufacture. To minimize LH2 leakage, carbon nanotubes-infused composites were proposed, in addition to use of thin plies. The project was divided into two 18-month budget periods (BP), BP1 and BP2, separated by a Go/No-Go gate review. The high-level goal for BP1 was to demonstrate the feasibility of the overall approach, the tank design, material selection, and manufacturing methodology, build and test a prototype tank; and the goal for BP2 was to design and manufacture a conformal tank per DOE requirements (minimum 20 kg of LH2) and perform a successful test of the tank. The program was terminated about two-thirds of the way through BP1. The outcome of this program would have permitted long-haul trucks and construction vehicles to use liquid Hydrogen, reducing the emission of green-house gases. This technology is applicable to other transportation sectors as well.

08 HYDROGEN↗
DOE OSTI2023

High-Performance Coal-Based Commercial Facade Panels and Architectural Components (Phase I Final Report)

Semplastics has developed, tested, and documented the viability for commercialization of a new class of composite architectural panel materials that use coal as the primary constituent. This project produced sample panels using these novel materials that comprise 55% coal by mass (71% carbon by mass) and are comparable in dimensions to commercially available materials, while displaying superior mechanical strength, significant weight savings, and better insulating ability at a competitive cost. Phase I moved this coal-based composite materials technology from a Technology Readiness Level (TRL) of 3 to TRL 5. Semplastics’ new coal-based composite materials display an array of high-performance characteristics, including light weight, mechanical durability, temperature stability, and water resistance. These new materials require less energy to produce than comparable commercial products and could be manufactured on existing conventional plastic resin processing equipment in commercial quantities. The coal particles are completely encapsulated in ceramic from a polymer-derived ceramic (PDC) precursor, then bonded together by another inorganic resin. The material can be molded and cured to produce fireproof components such as ceiling panels, facades, and extruded underlayment, blocking, and backer boards, as well as other architectural design components such as moldings. The project included the production of sample panels for proof of concept, testing of the panels to show their improved characteristics, and development of a scale-up strategy to demonstrate the viability of the coal-based panels as a commercial alternative to existing building materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

FTR for: Reducing plug-load electricity footprint of residential buildings through low-cost, non-intrusive sub-metering and personalized feedback technology

The project started in October 2016 and ended in December 2022. The project's principal goals and achievements were: (i) Measure real and reactive electric power consumption in ~400 apartments in multifamily settings of varying size and vintage and publish the data; data was published according to New York State's recommended 15x15 rule continuously from Jan 2019 through December 2022 (10 second time resolution); with the combination of large number of apartments, real and reactive power, as well as high time resolution (10-seconds), the dataset is first of its kind worldwide; because the dataset New York City apartment consumption pre, during, and post pandemic, it further offers unique insights into changes in residential electricity consumption during lockdowns and after modified work from home schedules. (ii) Measure effectiveness of different feedback types to prompt residents to lower their electricity consumption; achieved 11% (kWh-weighted) reduction versus baseline consumption; confirmed previous studies that social comparisons elicit above average responses; showed, for the first time, that the so called boomerang effect in power consumption feedback projects can be explained by a previously hypothesized norm-conforming "magnet effect" (rather than a non-conforming defiance effect), thus substantially advancing the research in the field. (iii) Disaggregate apartment-level consumption to appliance level; because the hardware for electricity consumption unexpectedly allowed only for 10-second time resolution (rather than the 1-second resolution we had planned on), the disaggregation algorithms we developed on sample data could not be applied to the actual field data we collected. The project has yielded high visibility, with a total of 17 publications, from peer reviewed journals, published data sets (free access), blog posts, NY Times, National Public Radio, and CNN.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Evaluating the Interplay between Trajectory Segmentation and Mode Inference Error

Travel behavior changes are essential to transportation decarbonization. Travel diaries, consisting of sequences of trips between places, are typically used to instrument human travel behavior. However, these diaries are only as accurate as the underlying methods used to construct them. Travel diary algorithms have been a popular research topic since the advent of Global Positioning System tracking surveys. These algorithms have typically been validated using prompted recall of presegmented trips, thus disregarding the continuity of mode inference. Phone operating systems have adopted battery-conserving techniques, but the resulting data collection errors have not been studied extensively. We introduce a framework to evaluate the accuracy of trip length computations and mode inference by analyzing continuous mode-segmented trajectories for groups of trips. We then use the framework to identify the input data quality and the impact of postprocessing. Our primary inputs to this evaluation are MobilityNet, a public dataset containing information from three artificial timelines covering 15 different travel modes, and sample open-source travel diary creation algorithms from the OpenPATH project. Our framework concretely shows that the variance of the distance error drops from (0.217, 0.0848) to (o.011, 0.0407) (Android, iOS) after postprocessing. Similarly, the weighted F-scores for mode inference increase from (0.25, 0.29) to (0.60, 0.74) (iOS, Android) between random forest and geographic information system-based models. We hope that this standardized method will be adapted to evaluate other, potentially proprietary, travel diary algorithms. Finally, the results can be used to understand and improve the state of the art in the travel diary creation field.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Thermocatalytic Ethylene Production using Targeted RF Induction Heating

Ethylene, a key building block in the petrochemical industry is a top five chemical in annual production and the second highest energy consuming chemical per weight. Industrial-scale production of ethylene remains an energy consuming process and is conventionally practiced by steam cracking of ethane or naphtha feedstocks. Our project using Targeted RF Induction Heating aims to optimize the heating of the catalyst to improve energy efficiency (>50%). Induction heating also improves ethylene low-temperature yield, selectivity, and stability that will increase catalyst lifetime by >20% and result in a >15% decrease in operational costs.

Colon-Mercado, Hector R.↗
DOE OSTI2024

Multi-Source Machine Learning and Thermoplastics Enhanced Aerostructure Manufacturing (mTEAM)

RTX Technology Research Center (RTRC), together with Collins Aerospace (Collins) and Oak Ridge National Laboratory (ORNL) has developed an Artificial Intelligence (AI) / Machine Learning (ML) guided solution to advance the manufacturing and assembly of high performance and lightweight thermoplastic composite (TPC) aerospace products. The solution aims to lower risk, cost and lead time for induction heating based welding and consolidation processes for TPC structure. The cost and lead time of part and material specific process development for induction welding (IW) and induction consolidation will be reduced by replacing traditional empirical methods with optimization methods that merge AI/ML and physics-based process simulations and process experiments with sensing and controls. TPC-IW process development is empirical in nature, and uncertainties in material & process behavior exist near & far from the induction coil. Physics-based simulations can be leveraged directly for process optimization but can be too computationally expensive to run in high fidelity and real time to do robust process optimization. The key impact of successful TPC induction consolidation and welding is cost & lead time reduction for part & material specific consolidation and welding recipes. This is an enabler for more rapid deployment of TPC structures via joining assembly, which can reduce energy & cost intensive usage of autoclaves & ovens. The solution aimed to advance the U.S. Department of Energy’s interests in using thermoplastics and automation in composite manufacturing for improvement of products for existing markets via increased production speeds, reduced costs, and lowered use of energy. Welded TPC structures can offer significant weight & energy savings for high-value commercial aerospace & industrial applications compared to metal & thermoset composite structures assembled by mechanical fastening and/or adhesive bonding. The project was organized into two Budget Periods. Budget Period 1 (BP1) was 15 months and its goal was to perform ML process optimization framework development & deployment on lab-coupon aerostructure components. A Go/No-Go Review was performed at the end of BP1 to verify fulfilment of key tasks & milestones to justify a Go Decision to move into the next Budget Period. Budget Period 2 (BP2) was 12 months and its goal was the deployment of the ML framework for ML process optimization of pilot industrial scale aerostructure components. The overall project aim was to develop & demonstrate ML-enhanced modeling framework that learns process-property mapping from multiple data sources at different fidelities. During BP1, the team accomplished key tasks & milestones to demonstrate the concept of multi-source ML for TPC aerostructure consolidation and assembly. First, the team completed documentation of induction based TPC heating requirements including baseline metrics to compare measured results against. Next the team completed demonstration of data generation from physics-based simulations for ML surrogate model generation and demonstrated the integration of physics-based simulation data into multi-source AI/ML algorithms. In parallel, the team established the lab-coupon scale induction welding system and completed a process to label and reduce generated data from physics-based simulation and experiments for ML surrogate models to enable multi-source ML model training & testing. To complete BP1, the team integrated physics-based simulation data and experimental data into multi-source ML algorithms. This was based on the team completing ML deployment of the induction welding on a lab system at RTRC and AI/ML deployment on existing induction welding line at Collins. ORNL visited both Collins and RTRC sites to witness the TPC induction welding process. Then, ORNL designed and constructed a new version of their vision-based sensing system better adapted to acquire process signals of the TPC induction welding process for process anomaly and defect detection. In BP2, the team accomplished key tasks & milestones to scale up multi-source ML for TPC aerostructure consolidation and assembly from the lab-coupon scale to the pilot-industrial scale. In BP2, the team demonstrated real time anomaly & defect detection via experiments performed by ORNL & RTRC. The team completed ML-optimization heating trials for TPC induction consolidation at Collins, and the team confirmed pilot industrial scale experimental data from Collins was compatible with the developed ML pipeline from RTRC. The team completed sub-element scale ML process optimization demonstration at RTRC, where the team leveraged RTRC’s robotic TPC welding setup to de-risk the ML process optimization by performing ML analysis of recorded temperatures to account for complex part features. Then, the team applied its ML-derived control strategies and ML process optimization framework at Collins to the pilot-industrial scale on a demo skin-stiffener part representative of a nacelle aerostructure fan cowl section. The key innovation is the AI/ML framework enabling effective process development of high performance, lightweight, energy efficient TPCs for composite aircraft structures.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Advancing Building Performance: Field Results of Thin-Glass Triple-Pane Window Demonstrations

To meet California and the nation's ambitious energy targets, energy use in the building sector must drop dramatically. Windows continue to be the lowest thermally performing envelope system in the nation's buildings, resulting in poor overall envelope performance and potential impacts to human health and comfort. Current best practice new window performance is typically met by double-pane low-solar-gain glazing. Thin-glass triple-pane windows are a highly promising next step forward in performance and have been deployed in two California multi-family sites to quantify field performance and building energy savings. The technology assessed offers the performance benefits of traditional triple-pane but with little increase in weight or cost, enabling incremental costs competitive with alternative energy reduction solutions for the building envelope. This paper covers a detailed investigation into the demonstration project and measured performance benefits of the windows after a full year of data collection.

Hart, Robert↗
DOE OSTI2020

Ultra-Light Hybrid Composite Door Design, Manufacturing and Demonstration

New Corporate Average Fuel Economy regulations require improved fuel efficiency of the future vehicle fleet. Weight reduction is key to achieving these targets. Replacing metallic body and chassis components with carbon fiber-reinforced composites offers the most weight reduction potential at up to 70%. Introduction of the BMW i3 and i8 in 2014 required mass production processes to meet 20,000+ units per year. Preforming with High Pressure Resin Transfer Molding has been implemented and meets rate, cost, and performance requirements. We will advance these technologies to develop an ultra-light driver’s side door for the vehicle with production rates of 40,000 units annually per plant in Detroit, Michigan. This project sought to employ a comprehensive systems approach for designing, manufacturing, and demonstrating an ultra-light hybrid composite automotive door. Composite structural components are integrated with other functional systems to reduce part count and full-system weight by a minimum of 42.5%. The approach will be demonstrated on a driver’s- side front door and will consider all fit, functional, safety, and cost requirements. These concepts will be evaluated using structural and crash simulations and linked to a manufacturing feasibility study, resulting in producible designs of an integrated door system. A cost model will evaluate part of the cost for the various designs and will ensure the cost target of less than $5 per pound of weight saved is met. Hybrid composites consisting of carbon, glass, and metal components will be included in our trade-off studies to satisfy these cost and performance goals.

02 PETROLEUM↗