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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Building the Eyes of Discovery

My presentation focuses on the development and enhancement of sensor modules that help particle detectors “see” particles invisible to the human eye, specifically the Compact Muon Shield detector, which is part of the High-Luminosity Large Hadron Collider. As a CCI intern at Fermilab’s Silicon Detector Facility, I worked on testing and visual inspection of different module parts before assembly and on testing the modules after assembly. My talk highlights how small sensors carry the capability to collect tiny particle signals within the detector and the reliability of control checks pre-assembly for scientists to produce reliable data for future discoveries.

Siddiqui, Hooriya [Fermilab] (ORCID:00090001510973↗
DOE OSTI2022

Accelerating Optimal Integration of Energy Efficiency Strategies with Industrialized Modular Construction: Preprint

The National Renewable Energy Laboratory's (NREL's) Industrialized Construction Innovation team first introduced the Industrialized Construction Assessment Framework to achieve affordable, net-zero energy (NZE) modular multifamily buildings in the 2020 ACEEE paper "Integrating Energy Efficiency Strategies with Industrialized Construction for our Clean Energy Future." Since then, NREL has continued to drive the ambitious plan to accelerate optimal integration of energy efficiency strategies during industrialized construction with little or no additional cost, labor, and production time. This follow-on paper introduces the Energy in Modular (EMOD) buildings method and presents NREL's research efforts over the last two years in collaboration with industry, including affordable housing partners. NREL has developed an idealized NZE modular multifamily building design that incorporates five energy efficiency strategies well suited for industrialized construction in factories: (1) envelope thermal control, (2) envelope infiltration control, (3) mechanical, electrical, and plumbing systems, (4) smart controls, and (5) solar plus storage. This paper highlights results from leveraging design for manufacturing and assembly principles, testing, and validation pilots with factory partners; demonstrating pod prototypes in test stand at NREL; and performing simulations. Overall, these research efforts address barriers to whole-building system integration, such as poor installation quality of thermal and air barriers; lack of unitized systems for space conditioning, energy recovery and ventilation, and water heating; problematic on-site installation, commissioning, and configuration of controls; and lack of cost-effective integration for grid-friendly design and emerging technologies. Conclusively, the paper delineates next steps for future work with NREL's partners toward developing a transformational pathway for our clean energy future.

affordable housing↗
DOE OSTI2021

Method for Rapid Modeling of Distortion in Laser Powder Bed Fusion Metal Additive Manufacturing Parts

The simulation and modeling of part-level distortion and residual stress in diverse metal additive manufacturing (AM) geometries has great potential to enable the rapid adoption of this technology in engineering design. Moreover, the use of additive manufacturing component libraries (CLs) offer a computationally efficient means of quantifying these part-level defects resultant from AM processing. We report on how the individual simulations of simple shapes, potential entries in a CL, can be superimposed to provide an indication of distortion and residual stresses in complex geometries. Laser powder bed fusion AM was used to construct test geometries of varied shapes and their combinations in the form of CLs in an effort to characterize location-dependent and feature-dependent distortion distributions. Blue light scanning was used to experimentally measure 3D distortions in order to investigate the interaction between the component shapes and local boundary conditions. Overall, part-level distortions were highly dependent on test component geometry, local boundary conditions, and shape combination. Commercial finite element software was used to verify experimental trends and to make predictions of distortion. The use of CLs resulted in over 20 times savings in computational cost while reproducing overall trends in distortion for test geometry assemblies. Therefore, it is anticipated that the use of CLs for L-PBF AM geometries has demonstrated potential to facilitate efficient simulations of full component AM assemblies, thereby reducing the need for costly trial-and-error-type experimental analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Synergistic effects of chlorine substitution in sulfide electrolyte solid state batteries

All-solid-state battery is considered as one of the most promising competitors to Li ion batteries. Two widely known performance metrics for solid electrolytes, among others, are ionic conductivity and stability. In this study, it is found that both can be improved by the synergistic effects of chlorine substitution in sulfide-based solid electrolytes. Particularly, instabilities arising from both bulk decompositions and interfacial reactions to electrodes can be better inhibited in the chlorine substituted sulfide solid electrolytes through the increased susceptibility to the mechanical constriction induced enhancement of voltage stability. As a result, the stability window of some chlorine-rich Li-argyrodites can be systematically higher than some other chlorine-deficient or chlorine-free electrolytes, especially under the implementation of the mechanical constriction battery assembly and test conditions. Thus, a solid-state battery system of 4 V to 5 V-class cathodes paired with lithium metal anode is demonstrated using these chlorine-rich Li-argyrodites without additional coatings. Furthermore, since Cl composition modulates the stability and instability of Li-argyrodite at low voltages, it allows us to design a multilayer configuration with a hierarchy of Li metal stabilities to demonstrate the stable cycling at relatively high current densities for solid-state batteries. It is found that a moderate Cl composition in the electrolyte is the best to inhibit Li dendrite penetration as the central electrolyte layer, emphasizing a slightly increased “instability” as the hidden performance metric of relevance here, in addition to the two well-known metrics of stability and ionic conductivity. The understanding of the chlorine substitution effect in sulfide electrolytes provides an important design principle for all-solid-state batteries.

25 ENERGY STORAGE↗
DOE OSTI2022

The Effect of Cell Geometry and Trigger Method on the Risks Associated with Thermal Runaway of Lithium-Ion Batteries

Consideration of thermal runaway heat output variability is paramount for the development of safe lithium-ion battery assemblies. This study utilizes data gathered from fractional thermal runaway calorimetry (FTRC) experiments to conduct a comparative analysis of thermal runaway heat output for three cell formats (18650, 21700, and 33600) as a function of trigger method (heaters, internal short-circuiting device, and nail penetration). The analysis is based on comparisons for the calculated total energy yield, fractional energy yield, heat rate, and heat flux. This study reveals that nail penetration tends to result in higher thermal runaway heat output for larger cells (21700 & 33600); these experiments also tended to result in higher fractions of the total energy being released through the cell body. The smaller cells (18650) did not appear to have significant variation in heat output as a function of trigger method. This finding suggests that, for this cell type, worst-case scenario heat output could be achievable in assembly level testing regardless of the utilized trigger method. This study also demonstrates successful translation of FTRC results, as recorded in the Battery Failure Databank, into meaningful analysis that breaks down the influence of specific conditions on thermal runaway heat output.

calorimetry↗
DOE OSTI2025

Current interrupt method for calculating the electrochemical impedance in a solid oxide electrolysis stack

Here, in this work the time domain response of Solid Oxide Electrolysis Cells (SOEC) to a current interruption was transformed into the frequency domain using a carrier function Laplace transform, which is fit to the experimental data using a MATLAB Complex Nonlinear Least Squares (CNLS) solver. The hardware implementation, consisting principally of a high-speed switch and a fast-logging Analog to Digital Converter (ADC), was assembled and tested using a calibration module to assess the accuracy, repeatability, and speed of acquisition of the prototype device as compared against a calibrated commercial impedance spectrometer. Additionally, the current interrupt device and commercial FRA were used to acquire the impedance spectra of a four cell SOEC stack with a large, 300 cm 2 , active cell area.

SOEC↗
DOE OSTI2022

Rationalizing nitrogen-doped secondary carbon particles for practical lithium-sulfur batteries

Nanostructured carbon host materials are widely used to improve both sulfur utilization rate and reaction kinetics in lithium-sulfur (Li-S) batteries. However, high complexity/cost of materials synthesis and difficulty in processing nano-materials into high-mass-loading electrodes are still significant barriers to the development of low-cost and high-energy Li-S batteries. In this study, we reported a generic and scalable synthesis approach to prepare nitrogen-doped secondary carbon particles. By using nitrogen-containing precursor as an integration reagent, the nanosized Ketjen Black particles were integrated into micron-size secondary ones and nitrogen-doped (NKB) simultaneously through a one-step heat treatment. With NKB as an example material, the effects of particle integration degree on the secondary particles’ structures, pore volume and connectivity, sulfur loading capability, and cell performance were studied and discussed. At an optimal integration condition, the NKB particles had significantly improved particle dimensions with well-maintained high specific surface area and pore volume. Here, contributed by the micron size and high pore volume, the NKB/S were successfully used for high-sulfur-loading cathodes (4–7 mg s /cm -2 ) and were able to deliver a specific capacity of ~1100 mAh g -1 at a low-porosity (50%) and lean-electrolyte conditions (E/S =4 µL/mg -1 ). Feasibility of the materials for practical use was validated through scaling up synthesis (40 g/batch), large-area electrode coating, and practical pouch cell (1.6 Ah) assembly and test.

25 ENERGY STORAGE↗
DOE OSTI2024

Building a Simplistic Automatic Extruder: Instrument Development Opportunities for the Laboratory

This work presents an automatic extruder as a research experience for undergraduate students. The system offers a user-friendly approach to preparing vesicles, such as liposomes or polymersomes, with a defined size and polydispersity properties crucial for research in biology and macromolecules. It comprises two syringe pumps connected by a membrane filter. The setup is controlled by software. Compared to manual extrusion, this automated system provides advantages, such as precisely controlled variables. The project describes a tool to enhance undergraduate learning in science and engineering laboratories. Building an automatic extruder serves as a simplified model of a complex industrial process. It offers a clear advantage: automating a well-understood manual extrusion process. To make this project accessible, it is broken down into three manageable tasks: software development, hardware assembly, and testing procedures. This breakdown describes the software created, the hardware components used, and the testing procedures conducted for this project. All project data, including software code, testing data, and procedures, are freely available online. This allows undergraduate students to not only begin their own projects but also contribute to this educational instrument’s ongoing development.

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

Boosting the interfacial superionic conduction of halide solid electrolytes for all-solid-state batteries

Designing highly conductive and (electro)chemical stable inorganic solid electrolytes using cost-effective materials is crucial for developing all-solid-state batteries. Here, we report halide nanocomposite solid electrolytes (HNSEs) ZrO 2 (-ACl)-A 2 ZrCl 6 (A = Li or Na) that demonstrate improved ionic conductivities at 30 °C, from 0.40 to 1.3 mS cm -1 and from 0.011 to 0.11 mS cm -1 for Li + and Na + , respectively, compared to A 2 ZrCl 6 , and improved compatibility with sulfide solid electrolytes. The mechanochemical method employing Li 2 O for the HNSEs synthesis enables the formation of nanostructured networks that promote interfacial superionic conduction. Via density functional theory calculations combined with synchrotron X-ray and 6 Li nuclear magnetic resonance measurements and analyses, we demonstrate that interfacial oxygen-substituted compounds are responsible for the boosted interfacial conduction mechanism. Compared to state-of-the-art Li 2 ZrCl 6 , the fluorinated ZrO 2 -2Li 2 ZrCl 5 F HNSE shows improved high-voltage stability and interfacial compatibility with Li 6 PS 5 Cl and layered lithium transition metal oxide-based positive electrodes without detrimentally affecting Li + conductivity. We also report the assembly and testing of a Li-In||LiNi 0.88 Co 0.11 Mn 0.01 O 2 all-solid-state lab-scale cell operating at 30 °C and 70 MPa and capable of delivering a specific discharge of 115 mAh g -1 after almost 2000 cycles at 400 mA g -1 .

36 MATERIALS SCIENCE↗
DOE OSTI2023

High spatial resolution direct conversion amorphous selenium X-ray detectors with monolithically integrated CMOS readout

Recent progress in the field of micron-scale spatial resolution direct conversion X-ray detectors for high-energy synchrotron light sources serve applications ranging from nondestructive and noninvasive microscopy techniques which provide insight into the structure and morphology of crystals, to medical diagnostic measurement devices. Amorphous selenium ( a -Se) as a wide-bandgap thermally evaporated photoconductor exhibits ultra-low thermal generation rates for dark carriers and has been extensively used in X-ray medical imaging. Being an amorphous material, it can further be deposited over large areas at room temperatures and at substantially lower costs as compared to crystalline semiconductors. Here, to address the demands for a high-energy and high spatial resolution X-ray detector for synchrotron light source applications, we have thermally evaporated a -Se on a Mixed-Mode Pixel Array Detector (MM-PAD) Application Specific Integrated Circuit (ASIC). The ASIC format consists of 128 × 128 square pixels each 150 μm on a side. A 200 μm a -Se layer was directly deposited on the ASIC followed by a metal top electrode. The completed detector assembly was tested with 45 kV Ag and 23 kV Cu X-ray tube sources. The detector fabrication, performances, Modulation Transfer Function (MTF) measurements, and simulations are reported.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The LED calibration systems for the mDOM and D-Egg sensor modules of the IceCube Upgrade: Design, production, testing and use in module calibration

The IceCube Neutrino Observatory, instrumenting about 1 km 3 of deep, glacial ice at the geographic South Pole, is due to be enhanced with the IceCube Upgrade. The IceCube Upgrade, to be deployed during the 2025/26 Antarctic summer season, will consist of seven new strings of photosensors, densely embedded near the bottom center of the existing array. Aside from a world-leading sensitivity to neutrino oscillations, a primary goal is the improvement of the calibration of the optical properties of the instrumented ice. This calibration will be applied to the entire archive of IceCube data, improving the angular and energy resolution of the detected neutrino events. For this purpose, the Upgrade strings include a host of new calibration devices. Aside from dedicated calibration modules, several thousand LED flashers have been incorporated into the photosensor modules. We describe the design, production, and testing of these LED flashers before their integration into the sensor modules as well as the use of the LED flashers during lab testing of assembled sensor modules.

Analogue electronic circuits↗
DOE OSTI2021

Mechanical Comparison of Short Models of Nb$_3$ Sn Low-$\beta$ Quadrupole for the Hi-Lumi LHC

MQXF is the Nb 3 Sn Low-β quadrupole magnet that the HL-LHC project is planning to install in the LHC interaction regions in 2026 to increase the LHC integrated luminosity. The magnet will be fabricated in two different lengths: 4.2 m for MQXFA, built in the US by the Accelerator Upgrade Project (AUP), and 7.15 m for MQXFB, fabricated by CERN. In order to qualify the magnet design and characterize its performance with different conductors, cable geometries and pre-load configurations, five short model magnets, called MQXFS, were fabricated, assembled and tested. We compare the mechanical behavior of short model magnets using experimental data and new numerical models that take into account the measured coil sizes as a function of position.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Analysis of the Mechanical Performance of the 4.2-m-Long MQXFA Magnets for the Hi-Lumi LHC Upgrade

Under the U.S. High Luminosity LHC Accelerator Upgrade Project (HL-LHC AUP), the 150 mm bore, high-field Nb 3 Sn low-{eta}_MQXFA quadrupole magnets are being fabricated, assembled and tested, in the context of the CERN Hi-Luminosity LHC (HL-LHC) upgrade. These magnets have 4.2 m magnetic length and 4.56 m long iron yoke. To date, eight MQXFA magnets have been tested. One of the magnets additionally underwent a successful endurance test with 40 triggered quenches, and two magnets did not perform as expected. This work summarizes for the first time the available strain gauge data from eight identical Nb 3 Sn MQXFA tested magnets, focusing on the endurance test, and on a possible cause of underperformance of the two magnets that did not pass the vertical test. Here we applied methods to prevent this from happening in future MQXFA magnets, which shown to be effective for last two tested magnets.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Hybrid Li-S pouch cell with a reinforced sulfide glass solid-state electrolyte film separator

Here, in this paper, sulfide glass electrolyte powder with a nominal composition of (Li 2 S) 60 (SiS 2 ) 28 (P 2 S 5 ) 12 is hot pressed at a 330°C and 12 MPa into separator films using non-woven fiberglass reinforcement. The reinforced separator films are 93% dense, bendable, and have an ionic conductivity of 0.7 mS/cm at room temperature. When integrated into hybrid Li-S coin cells with liquid electrolyte, these reinforced glass separators blocked the parasitic polysulfide shuttle sufficiently to enable reversible cycling without LiNO 3 co-salt. Furthermore, the scalability of the reinforced glass separator technology is demonstrated by assembling and testing a hybrid single-layer pouch cell.

25 ENERGY STORAGE↗
DOE OSTI2022

CEA Contribution to the PIP-II Linear Accelerator

The Proton Improvement Plan II (PIP-II) that will be installed at Fermilab is the first U.S. accelerator project that will have significant contributions from international partners. CEA joined the international collaboration in 2018, and will deliver 10 low-beta cryomodules as In-Kind Contribution to the PIP-II project, with cavities supplied by LASA-INFN and power couplers and tuning systems supplied by Fermilab. This paper presents the CEA scope of work that includes the design, manufacturing, assembly and tests of the cryomodules and the upgrade of the existing infrastructures to the PIP-II requirements.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Design of the PIP-II 650 MHz Low Beta Cryomodule

The Proton Improvement Plan II (PIP-II) that will be installed at Fermilab is the first U.S. accelerator project that will have significant contributions from international partners. CEA joined the international collaboration in 2018, and is responsible of the 650 MHz low-beta section made of 9 cryomodules, with the design of the cryostat (i.e the cryomodule without the cavities, the power couplers and the frequency tuning systems) and the manufacturing of its components, the assembly and tests of the pre-production cryomodule and the 9 series ones. This paper will present the design of the 650 MHz low-beta cryomodule.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Final Design of the LB650 Cryomodule for the PIP-II Linear Accelerator

The Proton Improvement Plan II (PIP-II) that will be installed at Fermilab is the first U.S. accelerator project that will have significant contributions from international partners. CEA joined the international collaboration in 2018, and its scope covers the supply of the 650 MHz low-beta cryomodule section, with the design of the cryostat (i.e the cryomodule without the cavities, the power couplers and the frequency tuning systems) and the manufacturing of its components, the assembly and tests of the pre-production cryomodule and 9 production modules. An important milestone was reached in April 2023 with the Final Design Review. This paper presents the detailed design of the 650 MHz low-beta cryomodules.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Impact of Solenoid Induced Residual Magnetic Fields on The Prototype SSR1 CM Performance

A prototype cryomodule containing eight Single Spoke Resonators type-1 (SSR1) operating at 325 MHz and four superconducting focusing lenses was successfully assembled, cold tested, and accelerated beam in the framework of the PIP-II project at Fermilab. The impact of induced residual magnetic fields from the solenoids on performance of cavities is presented in this contribution. In addition, design optimizations for the production cryomodules as a result of this impact are highlighted.

43 PARTICLE ACCELERATORS↗