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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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DOE OSTI2023

Heat Transfer of an Integrated Counterflow Ceramic Heat Exchanger

The ceramic-based heat exchanger is one of the leading contenders for high-efficiency concentrating solar power plants using a molten salt heat transfer fluid and a supercritical carbon dioxide Brayton power cycle operating at temperatures above 700 °C due to the excellent resistance of ceramics to corrosion, oxidation, erosion, creep, and fouling. In the present study, the thermal performance of a ceramic silicon carbide prototype heat exchanger, with semi-elliptical heat transfer channels, integrated header channels, and a counterflow configuration fabricated by using binder jetting additive manufacturing, was experimentally investigated. Experimental heat transfer tests of the prototype were conducted at high temperatures and under various test fluid flow rates and inlet temperatures. The experimental heat transfer rates compared favorably with simulation predictions.

Yu, Wenhua (ORCID:0000000219457014)↗

DOE OSTI2022

Modeling Integrated Electricity and Natural Gas Systems Using Co-Simulation

One approach for modeling natural gas and electricity networks as integrated systems is co-simulation, which involves separating a single model into subproblems that are solved iteratively, with coupling information passed between then. Although a fully integrated problem might be more direct, co-simulation offers advantages in that it can sometimes be more computationally tractable, and can also leverage existing simulation tools to represent the subproblems. Here we present a framework for co-simulation of natural gas and electricity networks using the HELICS tool. We provide validation of the co-simulation approach by comparing results with a fully integrated approach that uses the same simulation tool, finding that the two approaches provide identical results for a range of test cases. We then present results from natural gas and electricity network co-simulation case study of the Colorado Front Range, with an evaluation of the present-day system and also a future system with higher shares of renewable power. The presentation will close with a discussion on future avenues of work for co-simulation of gas and power networks.

co-simulation↗

DOE OSTI2025

Control System Upgrade for Battery State-of-Charge Indications

The Advanced Test Reactor (ATR) Complex at Idaho National Laboratory (INL) relies on Battery Backed Power (BBP) systems and Uninterruptible Power Supplies (UPS) to ensure continuous power supply to critical components. This project aims to enhance the reliability and functionality of the battery monitoring and control systems by updating the State-of-Charge (SOC) system, Programmable Logic Controller (PLC), and Human-Machine Interface (HMI) for the nuclear safety-related battery banks. The current system, while functional, has areas for improvement, particularly in recharging calculations and alarm functions. The project objectives include developing flow charts, programming the new PLC and HMI, conducting bench tests, and updating design documentation. Additionally, the project ensures compliance with safety standards, develops training materials, creates comprehensive documentation, and integrates seamlessly with existing ATR infrastructure. The new SOC system is designed to be scalable for future upgrades, improve efficiency, enhance data accuracy, implement redundancy features, and achieve project goals within budget constraints while considering environmental impact. The methodology involved familiarizing with BBP and UPS systems, collecting current readings, rescaling signals, learning ladder logic, and updating the HMI. The transition from SLC 5/03 PLC using RS Logix 500 to CompactLogix 5380 using Studio 5000 was a key step. Despite challenges in transferring outdated PLC ladder logic and HMI code, starting from scratch led to a more accurate and efficient monitoring system, contributing to improved safety and operational efficiency. The project is currently awaiting approval of the Engineering Calculation and Analysis Report (ECAR) before implementation.

42 - ENGINEERING↗

DOE OSTI2026

Mu2e Production Target Thermal Test Project

The Mu2e experiment requires a production target that is capable of operating under extreme thermal conditions caused by an 8 GeV proton beam. This project’s objective supports the development of the Mu2e Pro- duction Target by testing the Stickman model’s thermal behavior. Angel Flores Luviano has assisted Jonathan Williams in progressing this project by contributing to the development of a Radiative Cooling Test Fixture (RCTF) that will be used to evaluate the thermal behavior of the new production target model. Engineering calculations were performed to an- alyze thermal performance and pressure drop within the cold well and wa- ter cooling circuit. These calculations also determined the optimal sizing for key components of the water system. An engineering note was made to document these calculations. CAD models of the water circuit piping, thermocouple mounting bars, and radiator chimney were developed, and prototype test rig components were fabricated using 3D printing. Future work will focus on continued RCTF development which includes control system integration, heater hardware design, and interfaces that can be scaled up to increase thermal capacity.

Flores Luviano, Angel Augusto [Unlisted, US]↗

DOE OSTI2025

Comparative analysis of thermal management systems in electric vehicles at extreme weather conditions: Case study on Nissan Leaf 2019 Plus, Chevrolet Bolt 2020 and Tesla Model 3 2020

With the surge in electric vehicle (EV) adoption and the need for extended driving ranges, optimizing energy efficiency, particularly through thermal management, is critical, especially in extreme weather. Managing the substantial energy needed for cabin climate control and battery temperature regulation can increase energy demands by over 50 %, severely limiting range. This study conducts a comparative analysis of thermal management systems (TMS) in three popular EV vehicles, 2020 Chevrolet Bolt, 2019 Nissan Leaf Plus, and 2020 Tesla Model 3, evaluating their distinct TMS configurations and performance under varied weather conditions. Using both numerical simulations and experimental data collected on a controlled test bench at Argonne National Laboratory, we assess how TMS architecture and operational modes influence energy consumption and range. A comprehensive TMS model was developed, integrating cabin and battery thermal sub-models in the Autonomie software platform, to simulate temperature fluctuations and range impacts. Cabin climate was modeled using a mono-zonal approach, while battery cell temperature distribution was estimated through a 2D nodal structure. Each vehicle's distinct TMS setup was evaluated: the Chevrolet Bolt and Tesla Model 3 use a dual evaporator vapor compression cycle with a PTC heater for the cabin and a coolant loop for battery thermal management; the Nissan Leaf Plus employs a heat pump with a PTC heater for the cabin and air-cooling for the battery. Tests conducted at ambient temperatures of 35°C, 22°C, -7°C, and -18°C reveal significant differences in energy use and range reduction across both configurations and conditions. At 35°C, the Tesla Model 3, Chevrolet Bolt, and Nissan Leaf Plus have a range reduction of 8%, 9%, and 13%, respectively, due to air conditioning. In winter, heating technology is paramount; at -7°C, the Nissan Leaf's heat pump configuration achieves a lower range reduction (19.3%) compared to the Tesla and Chevrolet Bolt PTC heaters, which reduce range by 28.3% and 31%, respectively. Further, this study provides valuable insights for automotive engineers, EV technology researchers, and thermal management system designers aiming to enhance electric vehicle performance by understanding how different weather conditions and TMS architectures impact energy consumption and driving range.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

A State-Space Model of an Inverter-Based Microgrid for Multivariable Feedback Control Analysis and Design

In this work, a synchronous model for grid-connected and islanded microgrids is presented. The grid-connected model is based on the premise that the reference frame is synchronized with the AC bus. The quadrature component of the AC bus voltage can be cancelled, which allows to express output power as a linear equation for nominal values in the AC bus amplitude voltage. The model for the islanded microgrid is developed by integrating all the inverter dynamics using a state-space model for the load currents. This model is presented in a comprehensive way such that it could be scalable to any number of inverter-based generators using inductor–capacitor–inductor (LCL) output filters. The use of these models allows designers to assess microgrid stability and robustness using modern control methods such as eigenvalue analysis and singular value diagrams. Both models were tested and validated in an experimental setup to demonstrate their accuracy in describing microgrid dynamics. In addition, three scenarios are presented: non-controlled model, Linear-Quadratic Integrator (LQI) power control, and Power-Voltage (PQ/Vdq) droop–boost controller. Experimental results demonstrate the effectiveness of the control strategies and the accuracy of the models to describe microgrid dynamics.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2026

Web-based Preprocessing and Visualization of 3D FIB Tomography Data for Nuclear Fuel Characterization

Three-dimensional (3D) focused ion beam (FIB) tomography enables reconstruction of internal nuclear fuel features that can't be fully evaluated through surface imaging alone. This capability supports characterization of fuel constituents and defects under thermal and irradiation conditions relevant to microreactor development. However, large tomography datasets can create data-handling, loading, and visualization challenges, especially when image-stack preparation and file conversion must be completed with separate tools. The Computational Ultraspatial Tomography Toolkit for High-Resolution Object Analysis Tools (CUTTRHOAT) is an open-source web application being developed to display FIB tomography datasets available through the Nuclear Research Data System (NRDS). The current alpha version requires prepared HDF5 datasets and has limited integrated data-preparation capabilities. This project improves CUTTHROAT by adding dataset-folder selection, automatic input detection, dataset scanning, missing-slice identification, blank-slice insertion, and image-stack-to-HDF5 conversion. Two applications will be compared: the baseline CUTTHROAT alpha workflow and the updated application containing the integrated data-handling and preprocessing functions. Evaluation will consider dataset detection accuracy, conversion success, loading time, rendering responsiveness, application stability, and user interaction. Preliminary results demonstrate successful loading of existing HDF5 files and converted image stacks, while testing also identified performance reductions caused by excessive blank-slice generation. The updated workflow reduces reliance on external preparation tools and supports more direct movement from image stacks to color-code 3D visualization. Future work includes refining missing-slice handling, integrating additional preprocessing functions, like a denoising feature, parsing TIFF metadata for automatic voxel scaling, and adding manual X, Y, and Z voxel-spacing inputs for PNG and JPEG.

36 - MATERIALS SCIENCE↗

DOE OSTI2022

Developing reactors for electrifying bio-methanation: a perspective from bio-electrochemistry

The integration of microbial synthesis with renewable electricity is an emerging route for both CO 2 utilization and seasonal energy storage in the form of stored bio-electrofuels. The major benefits of electrifying bioreactors include: using highly selective bio-catalysts for CO 2 conversion under mild reaction conditions; decoupling the production of more facile electrochemical intermediates, such as hydrogen, at the electrode from the production of bio-catalyzed multi-electron and/or carbon products, such as methane or acetate; using microbes as robust and self-regenerating catalysts enabling higher efficiency and durability in CO 2 conversion systems compared to inorganic catalysis. In this Perspective, we propose research aimed at developing electro-bioreactor components that will increase the productivity of the reactor while maintaining high energy efficiency and biocompatible reaction conditions to fully realize the benefits of electrified bioreactors. Furthermore, these developments include: flow reactors with tailored 3D electrodes to optimally use the reactor volume, electrocatalysts designed for peak performance in neutral pH electrolytes, high conductivity microbial media, and new membrane separator materials with high ion conductivity and low gas permeability. Production of methane via a hybrid electrical-biological approach is taken as a case study to motivate these developments. Finally, an iterative design–manufacture–test cycle, enabled by additive manufacturing and 3D printing technologies, is proposed to rapidly prototype components prior to large-scale manufacturing.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Improved accuracy in degenerate variational integrators for guiding centre and magnetic field line flow

First-order-accurate degenerate variational integration (DVI) was introduced in Ellison et al. ( Phys. Plasmas , vol. 25, 2018, 052502) for systems with a degenerate Lagrangian, i.e. one in which the velocity-space Hessian is singular. In this paper we introduce second-order-accurate DVI schemes, both with and without non-uniform time stepping. We show that it is not in general possible to construct a second-order scheme with a preserved two-form by composing a first-order scheme with its adjoint, and discuss the conditions under which such a composition is possible. We build two classes of second-order-accurate DVI schemes. We test these second-order schemes numerically on two systems having non-canonical variables, namely the magnetic field line and guiding centre systems. Variational integration for Hamiltonian systems with non-uniform time steps, in terms of an extended phase space Hamiltonian, is generalized to non-canonical variables. It is shown that preservation of proper degeneracy leads to single-step (one-step) methods without parasitic modes, i.e. to non-uniform time step DVIs. This extension applies to second-order-accurate as well as first-order schemes, and can be applied to adapt the time stepping to an error estimate.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Event Screening Methods for the Eastern Interconnection Situational Awareness and Monitoring System (ESAMS)

The Eastern Interconnection Situational Awareness and Monitoring System (ESAMS) is a tool developed to explore the applications and advantages of sharing phasor measurement unit (PMU) data among operating entities. An initial conclusion from testing was that detected events required further screening before being reported to ensure that events would be of interest to system operators. The methods described in this report were integrated into ESAMS to meet this need. First, an event is screened for whether the change in voltage angle measurements indicates that the detected disturbance is sufficiently large. Next, an event is classified to determine if it was related to a loss of generation. Finally, a neural network is used to determine if the system’s response to the disturbance is normal or abnormal. These methods were tested with one month of field-measured PMU data. Results indicate that the additional information provided by these additional screening tools will improve selection of events for inclusion in the daily event reports automatically generated by ESAMS.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Long-Term Evaluation of Remedial Technology Performance in the Laboratory: Multi-year Experimental Test Plan

An understanding of the long-term effectiveness of remediation technologies is central to sustainable environmental cleanup. Long-term experiments are valuable for reducing uncertainty and predicting remediation outcomes at scales required for regulatory compliance. However, these types of tests can be costly and challenging to interpret. Therefore, contaminated sites often rely on short-term laboratory experiments that may not account for the potentially significant effects of gradual, time- dependent processes governing contaminant retention, release, and species transformation. For example, short-term lab experiments (from months to a year) conducted with sediments from the unsaturated and saturated zones at the Hanford Site play an important role in initial evaluations of remediation technologies but cannot capture the full extent of time-dependent reactions, leaving uncertainties in field-scale deployment. Here, long-term testing will be conducted on select technologies based on their performance in short-term testing. The overall objective is to directly address the challenges described above by generating and analyzing data on long-term (2–10 years) efficacy of selected remediation technologies, integrating this understanding into models, and providing critical input for remediation planning, monitoring, and 5-year review cycles for field-implemented remedies. Specific objectives include: 1. Evaluating long-term efficiency of promising remedies under site-specific conditions. 2. Generating robust parameters for modeling, reducing uncertainty in predictive simulations. 3. Advancing integrated monitoring by combining geochemical and geophysical observations. 4. Informing field-scale implementation by incrementally advancing technologies, identifying failure mechanisms early, and prioritizing robust, cost-effective remedies. Through systematic evaluation of technologies in laboratory-scale column experiments, integrated monitoring, and modeling support, this project is designed to bolster confidence in the long-term robustness of selected technologies. The ultimate outcome is the identification and deployment of more reliable, cost-effective remedies that safeguard human health and the environment while reducing the uncertainties that have historically hindered cleanup progress at Hanford Site. An experimental approach was developed and initiated for long-term testing potentially up to 10 years. The table below summarizes the experimental approach developed for testing select technologies and presented in this multi-year experimental test plan.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Automating methods for estimating metabolite volatility

The volatility of metabolites can influence their biological roles and inform optimal methods for their detection. Yet, volatility information is not readily available for the large number of described metabolites, limiting the exploration of volatility as a fundamental trait of metabolites. Here, we adapted methods to estimate vapor pressure from the functional group composition of individual molecules (SIMPOL.1) to predict the gas-phase partitioning of compounds in different environments. We implemented these methods in a new open pipeline called volcalc that uses chemoinformatic tools to automate these volatility estimates for all metabolites in an extensive and continuously updated pathway database: the Kyoto Encyclopedia of Genes and Genomes (KEGG) that connects metabolites, organisms, and reactions. We first benchmark the automated pipeline against a manually curated data set and show that the same category of volatility (e.g., nonvolatile, low, moderate, high) is predicted for 93% of compounds. We then demonstrate how volcalc might be used to generate and test hypotheses about the role of volatility in biological systems and organisms. Specifically, we estimate that 3.4 and 26.6% of compounds in KEGG have high volatility depending on the environment (soil vs. clean atmosphere, respectively) and that a core set of volatiles is shared among all domains of life (30%) with the largest proportion of kingdom-specific volatiles identified in bacteria. With volcalc , we lay a foundation for uncovering the role of the volatilome using an approach that is easily integrated with other bioinformatic pipelines and can be continually refined to consider additional dimensions to volatility. The volcalc package is an accessible tool to help design and test hypotheses on volatile metabolites and their unique roles in biological systems.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Near-Real-Time Forecast of Satellite-Based Soil Moisture Using Long Short-Term Memory with an Adaptive Data Integration Kernel

Nowcasts, or near-real-time (NRT) forecasts, of soil moisture based on the Soil Moisture Active and Passive (SMAP) mission could provide substantial value for a range of applications including hazards monitoring and agricultural planning. To provide such a NRT forecast with high fidelity, we enhanced a time series deep learning architecture, long short-term memory (LSTM), with a novel data integration (DI) kernel to assimilate the most recent SMAP observations as soon as they become available. The kernel is adaptive in that it can accommodate irregular observational schedules. Testing over the CONUS, this NRT forecast product showcases predictions with unprecedented accuracy when evaluated against subsequent SMAP retrievals. It showed smaller error than NRT forecasts reported in the literature, especially at longer forecast latency. The comparative advantage was due to LSTM’s structural improvements, as well as its ability to utilize more input variables and more training data. The DI-LSTM was compared to the original LSTM model that runs without data integration, referred to as the projection model here. We found that the DI procedure removed the autocorrelated effects of forcing errors and errors due to processes not represented in the inputs, for example, irrigation and floodplain/lake inundation, as well as mismatches due to unseen forcing conditions. The effects of this purely data-driven DI kernel are discussed for the first time in the geosciences. Furthermore, this work presents an upper-bound estimate for the random component of the SMAP retrieval error.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Quantum Monte Carlo benchmarking of large noncovalent complexes in the L7 benchmark set

We have used diffusion Monte Carlo (DMC) to perform calculations on the L7 benchmark set. DMC is a stochastic numerical integration scheme in real-space and part of a larger set of quantum Monte Carlo methods. The L7 set was designed to test the ability of electronic structure methods to include dispersive interactions. While the agreement between DMC and quantum-chemical state-of-the-art methods is excellent for some of the structures, there are significant differences in others. In contrast to wavefunction-based quantum chemical methods, DMC is a first-principle many-body method with the many-body wavefunction evolving in real space. It includes explicitly all electron–electron interactions and is relatively insensitive to the size of the basis set.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Field Emission Analysis in SRF Cavities for PIP-II Using GEANT4

Field emission (FE) remains a key limitation to achieving optimal performance and reliability in superconducting radiofrequency (SRF) cavities used in accelerator cryomodules. Addressing this challenge requires a detailed understanding of the generation and transport of FE-induced radiation; however, the absence of standardized measurement protocols complicates comparisons across different testing stages and facilities. This work presents initial steps toward a quantitative, systematic framework for analyzing FE-induced radiation using Geant4 simulations. We model four cavity types to be deployed in Fermilab’s Proton Improvement Plan-II (PIP-II) linac - HB650, LB650, SSR2, and SSR1 - to investigate radiation signatures and their dependence on emission conditions. By integrating simulation results with radiation diagnostics, our goal is to identify probable emission sites, enhance diagnostic accuracy, and optimize detector placement. Ultimately, this approach seeks to inform cavity preparation, assembly, and testing procedures, enabling the delivery of FE-free SRF cryomodules for PIP-II.

Wijethunga, Sajini [Fermilab] (ORCID:0000000287659↗

DOE OSTI2026

Field Emission Analysis in SRF Cavities for PIP-II Using GEANT4

Wijethunga, Sajini [Fermilab] (ORCID:0000000287659↗

DOE OSTI2024

Assessment of Electric Grid Transmission System Simulator for Human Factors Research

Over the past decades, various technologies have been developed for electric grid operations to support clean energy, meet rising electricity demands, and address infrastructure concerns. However, the human factors aspect is often overlooked during rapid integration. Questions persist about how these technologies impact human performance. Simulators play a critical role in supporting investigation of human factors design concepts and conducting comprehensive usability testing to evaluate human performance and assess human reliability. This paper aims to address human factors research simulator requirements and conduct a comparative study of six different simulators. A detailed evaluation reveals that the evaluated simulators lack the ability to customize user interfaces. Additionally, their user interface designs do not fulfill the basic human factors design principles, potentially leading to increased response variability and reduced statistical power when conducting controlled experimental research. In the future, it is essential to develop scripting tools to integrate customizable user interfaces and simulation models, ensuring meeting research requirements.

Li, Ruixuan↗

DOE OSTI2022

Interim Mechanical Properties Data from FY2022 ORNL Testing of A709 with Precipitation Treatment for ASME Code Case Data Package

A collaborative research and development effort in support of the Alloy 709 Code Case qualification in the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 5, High Temperature Reactors is being conducted at the US Department of Energy’s Oak Ridge National Laboratory, Idaho National Laboratory, and Argonne National Laboratory. A recent assessment on the Alloy 709 development and testing effort concluded that the mechanical properties of Alloy 709 with the precipitation treatment continued to outperform those of Type 316 stainless steel. The assessment also affirmed the recommendation for its Code qualification. This report provides the detailed integrated data generated to date on the two commercial heats of Alloy 709 in plate product form with precipitation treatment condition that were used as the basis for this assessment. Oak Ridge National Laboratory has continued to perform a subset of the Code Case testing for tensile properties, creep rupture, fatigue, and creep-fatigue. This report also updates the key Alloy 709 Code Case testing status and results in FY 2022 at Oak Ridge National Laboratory.

36 MATERIALS SCIENCE↗