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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 OSTI2026

Wireless High-Temperature Sensor Network for smart boiler systems

This final project report describes the research data and findings. This project aims to develop a new wireless high-temperature sensor network for real-time continuous boiler condition monitoring in harsh environments. Such a wireless high-temperature sensor network enables network-based automatic temperature sensing and data collection, which combined with artificial intelligent (AI) algorithms allow the construction of smart boiler systems with boiling condition management and optimization for significant energy-saving and reliability improvement

42 ENGINEERING↗

DOE OSTI2024

Embedded High-Temperature Sensors: Enhancing Thermoelectrical Performance with Refractory Composites Gradient Layers

To monitor the stability of various energy and manufacturing systems, sensors capable of operating at temperatures exceeding 1000 °C in diverse environments for extended durations are essential. However, under harsh conditions, degradation of sensing materials is a concern that can be controlled by embedding the sensors into refractory oxides. Doped-LaCrO3 based composites are excellent candidates for high-temperature sensing applications due to their good thermoelectrical properties. However, chemical reactivity between the conductive phase and the refractory oxides can decrease the performance of the sensors. In this work, it was devised gradient-type protective layers safeguarding conductive phases within embedded thermocouples, which were fabricated and characterized by X-Ray Diffraction for phase development analysis, Scanning Electron Microscopy and Energy-dispersive X-ray spectroscopy for microstructure and cationic interdiffusion kinetics, long-term thermoelectric testing was completed up to 1400 °C. The enhanced performance of these novel sensors addresses a critical limitation, rendering them viable for long-term high-temperature applications.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Passive Wireless Sensors for Realtime Temperature and Corrosion Monitoring of Coal Boiler Components Under Flexible Operation (Final Technical Report)

Researchers at West Virginia University (WVU) propose to demonstrate inexpensive wireless, high-temperature sensors for real-time monitoring of the temperature and corrosion of metal components, which are commonly used in coal-fired boilers. This study presents the development of cost-effective wireless high-temperature sensors for real-time temperature and corrosion monitoring in coal-fired boilers' metal components. The focus is on fabricating and evaluating chipless radio-frequency identification (RFID) sensors capable of operating between 25-1300 ºC. Efforts were directed towards designing passive RFID sensor and interrogator antenna with a broad frequency range, optimizing a microstrip patch antenna sensor integrated into a "peel-and-stick" format for efficient application to various metal specimens without altering their geometry. Additionally, this research aimed to assess the sensor responses under accelerated high-temperature conditions, correlating corrosion and cracking mechanisms with sensor data. An investigation of through-wall data acquisition techniques was also planned, facilitating unobtrusive monitoring of sensor responses housed within metal enclosures. Ultimately, this work sought to establish a robust passive wireless sensor system for the continuous health monitoring of metal components in operational settings, thereby contributing to enhanced safety and efficiency in coal-fired power plants.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

Near-Field Passive Wireless Sensors for High- Temperature Metal Corrosion Monitoring

Post-Doc presentation focusing on new developments on passive wireless sensors to monitor metal corrosion at high temperature.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

High-Temperature Gas Sensor Materials with Properties Predicted via First-Principles Calculations with Machine Learning Modeling and Experimental Corroboration

Understanding the temperature dependence of functional properties of sensing materials is vital for their applications in combustion environments. The electron-phonon coupling that derives the electronic structure change with temperatures is a key property of interest as it affects other sensing responses. Herein, we first assess the temperature dependence of band gap renormalization in sensing materials by employing Allen-Heine-Cardona (AHC) theory with density functional theory (DFT) simulations corroborated with experimental observation. As the AHC calculations are impractical for high-throughput screening of materials, we employ data-driven Gaussian process regression to predict the parameters employed in the O’Donnell empirical model from a set of physical features. To mitigate the reliability issues arising from the small size of the dataset, we apply a Bayesian technique to improve the generalizability of the data-driven models as well as to quantify the uncertainty associated with theoretical predictions. These models capture well the overall trend of the O’Donnell parameters with respect to a reduced feature set obtained by transforming the available physical features. Quantifying the associated uncertainty helps us understand the reliability of the predictions and, therefore, the variation of bandgap as a function of temperature for other novel materials. The predicted candidates from machine learning models are further validated by experiments and DFT calculations.

bandgap renormalization↗

DOE OSTI2025

Novel High Resolution High Temperature In-Line Sensors for Steel Manufacturing

To support efficiency, productivity, yield improvements, and future industry 4.0 and SMART manufacturing objectives for a competitive and prosperous steel industry, this program has embarked on an effort to develop, demonstrate and deploy several novel sensing technologies based on fiber optics for use in production steel facilities. Over the duration of this program, our team has successfully demonstrated three of these technologies: (1) near continuous Rayliegh Scattering optical frequency domain reflectometry (OFDR) sensing with single mode silica fibers for temperature sensing to 700 C, (2) semi-distributed fiber Bragg grating (FBG) sensing with multimode sapphire fibers for temperature sensing to >1600 C, and (3) remote in-situ Raman analysis for slag and flux chemistry analysis at steelmaking temperatures >1550 C. Each of these sensor and interrogation systems was developed, refined, and tested in our labs at Missouri S&T and then successfully deployed at SSAB’s production facilities at two sites, one in Montpelier, IA and one in Mobile, AL.

36 MATERIALS SCIENCE↗

DOE OSTI2025

REFRACTORY COMPACT HEAT EXCHANGERS WITH EMBEDDED SENSORS ENABLED BY HYBRID ADVANCED SINTERING AND ADDITIVE APPROACH

Structural health monitoring (SHM) of compact heat exchangers (CHXs) operating in extreme environments is essential for ensuring system reliability, safety, and longevity. This study presents the development of high-temperature sensors fabricated via aerosol jet printing (AJP) using platinum ink, selected for its exceptional thermal stability, oxidation resistance, and electrical conductivity. AJP enables precise deposition of fine-feature sensor patterns onto complex geometries, making it well-suited for integration within CHX architectures. To enhance sensor durability, an alumina-based ceramic protective layer was printed over the platinum sensing elements. The sensors demonstrated stable, repeatable performance up to 900?°C during extended thermal cycling. A custom test setup was developed to evaluate sensor accuracy and robustness under steady-state and transient conditions. Substrate screening identified HG-1 ceramic-coated stainless steel as the most effective platform, offering strong adhesion and low resistance. Furthermore, electric field-assisted sintering (EFAS) was employed to embed the sensors into stainless steel 316L matrices without degrading their functionality. Post-embedding electrical tests confirmed sensor integrity, and initial characterization suggests strong potential for in-situ monitoring. This work provides a scalable strategy for integrating high-performance temperature sensors directly into refractory components, advancing embedded SHM technologies for harsh operating environments.

36 - MATERIALS SCIENCE↗

DOE OSTI2024

Near-Field Passive Wireless Sensor for High-Temperature Metal Corrosion Monitoring

This work focuses on the fabrication and evaluation of a passive wireless sensor for the monitoring of the temperature and corrosion of a metal material at high temperatures. An inductor–capacitor (LC) resonator sensor was fabricated through the screen printing of Ag-based inks on dense polycrystalline Al 2 O 3 substrates. The LC design was modeled using the ANSYS HFSS modeling package, with the LC passive wireless sensors operating at frequencies from 70 to 100 MHz. The wireless response of the LC was interrogated and received by a radio frequency signal generator and spectrum analyzer at temperatures from 50 to 800 °C in real time. The corrosion kinetics of the Cu 110 was characterized through thermogravimetric (TGA) analysis and microscopy images, and the oxide thickness growth was then correlated to the wireless sensor signal under isothermal conditions at 800 °C. The results showed that the wireless signal was consistent with the corrosion kinetics and temperature, indicating that these two characteristics can be further deconvoluted in the future. In addition, the sensor also showed a magnitude- and frequency-dependent response to crack/spallation events in the oxide corrosion layer, permitting the in situ wireless identification of these catastrophic events on the metal surface at high temperatures.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Enabling The Next Generation of Smart Sensors in Coal Fired Power Plants using Cellular 5G Technology

Ohio University (OHIO), West Virginia University (WVU), and American Electric Power (AEP) proposed to study and report on the benefits of 5G wireless cellular technologies for coal-fired power plants. The significant advantages, cost savings, and potential of 5G wireless data communications based sensors promised to usher in a new era of reliable, inexpensive, and powerful embedded systems that had not previously been available for coal-fired power plants. The team built upon existing experience with cellular-based systems, power plant water quality sensing, and high temperature sensors developed during past projects. Principal Investigator Wilhelm had been developing cellular-based sensor data systems with a commercial partner for 10 years, pioneering innovative solar-powered devices that began with 2G technology. The lessons and knowledge gained served as a foundation to demonstrate innovations and potential impacts specific to coal fired power plants enabled by 5G technology, along with integration with existing sensors and systems.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

Inaugural Molten Salt Technologies Workshop Powering the Future

The inaugural “Molten Salt Technologies – Powering the Future” Workshop marked a significant convergence of minds from diverse industries, each harnessing molten-salt technologies in innovative ways. Participants from sectors such as solar, geothermal, and advanced nuclear energy, as well as those involved in cutting-edge applications like thermal transport and rare-earth metals extraction, gathered to discuss their shared technical challenges and opportunities. Industry leaders in metal extraction and recycling, alongside experts in high-temperature sensor technology and advanced material manufacturing, also brought their unique perspectives to the table. This workshop served as a crucial platform for these varied industries to delve into the engineering intricacies that molten salt technologies entail. Common challenges such as understanding the thermophysical properties of salts, tackling corrosion mechanisms in harsh environments, and enhancing material resilience under extreme conditions were at the forefront of discussions. These technical sessions highlighted the critical need for cross-industry collaboration to address issues like salt life-cycle process engineering, impurity mitigation, and the development of durable, high-performance materials. By bringing together academia, industry, and representatives from national laboratories and the U.S. Department of Energy (DOE), the workshop facilitated a rich exchange of knowledge and experiences. This interaction not only fostered new partnerships but also strengthened the network among existing collaborators, setting the stage for joint solutions to the complex problems faced by all sectors using molten salt technologies. The event underscored the importance of collaborative efforts in overcoming common engineering challenges and advancing the application of molten-salt technologies across various industries. The workshop not only provided an essential forum for networking and idea exchange but also highlighted the collective drive towards innovative solutions that could benefit multiple fields.

Department of Energy↗

DOE OSTI2024

Inaugural Molten Salt Technologies Workshop Powering the Future

Department of Energy↗

DOE OSTI2025

A high-temperature heat flux sensor using the transverse Seebeck effect in elemental rhenium

Heat flux sensors compatible with hot environments are critical to advance aerospace, materials, and energy generation technologies that cope with extreme thermal conditions. In this work, we report on the development and characterization of a high-temperature heat flux sensor using the transverse Seebeck effect in rhenium single crystals. The sensor leverages refractory alloys and ceramics compatible with temperatures exceeding 1000 °C. The heat flux sensor was characterized from room temperature to 500 °C using a temperature-controlled calibration facility. At constant temperature, the sensor’s voltage output is linear with respect to the absorbed heat flux. The responsivity of the sensor varies with temperature, from 1.3 μV/(W/cm 2 ) at room temperature to −3.2 μV/(W/cm 2 ) at 500 °C, increasing monotonically in magnitude after changing sign from positive to negative at approximately 300 °C. The experimental results are in good agreement with analytical predictions of the sensor’s temperature-dependent responsivity, which suggest a further increase in magnitude up to −7.4 μV/(W/cm 2 ) at 1000 °C. These results highlight the unique characteristics of rhenium as a TSE transducer. The design offers compatibility with a wide range of operating temperatures and yields a measurement sensitivity that increases as the environmental conditions become more challenging.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Cold Spray Cobalt Magnetostrictive Electromagnetic Acoustic Transducers for High Temperature Structure Monitoring

The Department of Energy’s Advanced Sensors and Instrumentation program seeks to develop and qualify advanced sensors for the nuclear industry. Reliable high temperature and high radiation sensors for detection and characterization of structural flaws in pipes, vessels, and structurally critical components is a weakness for both conventional light water reactors with coolant T-hot approaching 350oC, and for advanced reactors with T-hot temperatures in excess of 500 to 800oC. Magnetostrictive Electromagnetic Acoustic Transducers using a cold spray cobalt coating have been proposed as a sensor design that can withstand these kinds of temperatures and radiation levels to serve as online sensors to detect flaws before cracks, pits, or erosion/corrosion flaws progress to through-wall failures. This report tests cold spray cobalt as part of a magnetostrictive EMAT for high temperature service. Cobalt is known to have strong magnetostrictive properties however the effect of cold spray application is not well studied. This program was surprised to discover that cold sprayed cobalt exhibited little or no magnetostrictive behavior until it was thermally annealed. Following annealing to 650oC however, cold spray cobalt did exhibit a magnetostrictive response. Work to date prior to this milestone report publication showed that magnetostrictive EMAT was successfully tested to 400oC with an alnico permanent magnet. The program plans to extend testing with an electromagnet to higher temperatures. This follow-on work will be reported under subsequent publications or as a revision to this report.

Glass, Samuel W.↗

DOE OSTI2025

Improving high temperature resilience of fiber sensor embedded smart components through laser shock peening

This study explores the use of laser shock peening (LSP) to enhance material properties and high-temperature performance of fiber-sensor-fused smart parts fabricated by additive manufacturing (AM) methods. Using embedded fiber sensors as distributed strain gauges, the study demonstrates that LSP can induce compressive strains of up to 130 µε on fiber embedded 1-mm below metal surfaces. The electron backscatter diffraction (EBSD) analysis shows that, with optimized LSP parameters, the metallic matrix undergoes substantial microstructural refinement, resulting in denser structures. Thermal cycling tests showed that the LSP process can increase fiber slippage temperatures by more than 50 °C. This work shows that the LSP process is an effective room-temperature process for enhancing both surface quality and increasing fiber slippage threshold under both thermal and mechanical stress.

Zhong, Shuda [University of Pittsburgh, PA (United↗

DOE OSTI2026

High-Accuracy and High-Stability Fiber-Optic Temperature Sensors for Coal Fired Advanced Energy

A research team at Michigan State University, led by Dr. Ming Han, has developed a revolutionary fiber-optic thermometer for use in next-generation coal-fired power plants. Funded by the U.S. Department of Energy, this new sensor is designed to measure extremely high temperatures with unmatched accuracy and long-term stability. Unlike conventional optical sensors that can give false readings due to mechanical strain and often drift out of calibration at high heat, this new technology uses a sealed gas chamber as its core. By measuring the temperature-dependent properties of the gas (air or argon), the sensor’s readings remain absolute and reliable, completely unaffected by the physical stresses on the surrounding equipment. The breakthrough design eliminates the need for complex and costly correction systems. It represents a fundamental shift in sensing technology, paving the way for a primary thermometer that maintains calibration and provides foundational accuracy essential for advanced energy systems.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Test and Validate Distributed Coaxial Cable Sensors for in situ Condition Monitoring of Coal-Fired Boiler Tubes

This project aims to test, validate, and advance the technology readiness level (from TRL5 to TRL7) of a novel low-cost distributed stainless-steel/ceramic coaxial cable sensing (SSC-CCS) technology for in situ monitoring of the boiler tube temperature in existing coal-fired power plants. The novel SSC-CCS sensing technology and associated condition-based monitoring (CBM) software to be demonstrated in this project will lead to an improved understanding of the boiler tube failure mechanisms and a prognostic system to improve the overall performance, reliability, and flexibility of the nation’s coal-fired power plant fleet. A boiler tube monitoring system with distributed coaxial cable temperature sensors and a sensor acquisition system was constructed. The high-temperature coaxial cable sensor with a length of 1.3m was made by using a quartz tube (1mm inner diameter (ID) and 6mm outer diameter (OD)) to concentrically separate a 304 stainless-steel (SS) rod (1mm OD) and SS tube (7.94mm OD and 6.16mm ID). The sensor acquisition system includes a vector network analyzer (VNA), a radio frequency (RF) power amplifier, multiple switches and a USB hub. The distributed stainless-steel quartz coaxial cable sensor (SSQ-CCS) had a linear response to temperature with a resolution uncertainty of σ = 0.77℃. To withstand the harsh conditions of 3,300 steam pressures and 800℃ high temperatures, the sensor was shielded by a protective tube made of the same material as the boiler tube. The protection tube had an OD of 1.5 inches and a thickness of 0.25 inches. In the laboratory tests, the sensor showed good sensitivity and fast response. The drift was bounded between +0.33% and -0.67% during a test at 600℃ for 350 hours, indicating good stability of the sensor. A field test was conducted where four sensors were welded on four superheat tubes (SH-Ts) at a coal-fired power station over 400 days. Conventional thermocouples were welded to the superheater tubes alongside the coaxial cable sensors for the purpose of comparison. Two sensors were capable of distributed sensing, with three multiplexed sensing sections. The other two sensors were single section. During the 400-day test period, the power plant experienced startups and shutdowns. At the steady state operations, the temperature of the boiler tube is about 600℃ (1112°F). The sensors recorded the entire coal-firing processes (start-up, steady state, and shut-down) and the glitch event. A GSM modem and a Watchdog were added to the system to ensure reliable data recording. The GSM modem sent daily messages to plant managers and Clemson team to inform the status of the sensor system. If the system was not normally working, the Watchdog would reboot the system automatically. The new coaxial cable based distributed sensing technology has been proven to be successful in both laboratory and field tests. A comprehensive four-stage multi-physics computational framework has been developed to assist the design, optimization, installation, and operation of SSQ-CCS. With the consideration of various operation conditions, we predict the distributions of flue gas temperatures within coal-fired boilers, the temperature correlation between the boiler tube and SSQ-CCS, and the safety of SSQ-CCS. A conditional-based monitoring system is implemented as well. The computational framework developed in this work can guide the future operation of coal-fired plants and other power plants for the safety prediction of boiler operations.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2026

Near-field passive sensor for the monitoring of high-temperature oxidative corrosion of metals

This study reports on the development and testing of a passive wireless device designed to track temperature and corrosion behavior in SS304H stainless steel under elevated temperatures. The ANSYS HFSS software was utilized to model and optimize the design of an inductor-capacitor (LC) resonator passive wireless sensors fabricated using platinum designs printed onto an aluminum oxide support operating at frequencies between (50–190 MHz). The optimal LC wireless sensor designs were then fabricated using screen-printing and sintering methods. Here, the sensors were tested by placing the sensor onto polished SS304H flat substrates and heated to 900–1050 °C in air. Wireless acquisition of sensor data during heating, cooling, and isothermal stages was achieved through a Pt loop antenna connected to an RF signal generator and a network analyzer.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Enhanced Design of Radiation Tolerant High-Temperature Structural Health Monitoring Sensors

Acoustic emission sensors are vital in the nuclear industry for real-time structural health monitoring and early detection of material degradation. By capturing high-frequency stress waves emitted from defects like cracks, corrosion, or fatigue, acoustic emission sensors enable non-invasive monitoring of critical components such as reactor vessels, piping, and containment structures. This technology supports predictive maintenance, enhances safety, and ensures regulatory compliance by providing early warnings of potential failures. It is also instrumental in research, particularly in material testing reactors, where it is used to monitor the behavior of fuels and materials under irradiation, by allowing the detection of cracking or other acoustic signals in real time. This enables the evaluation of performance and accident behavior of advanced fuel concepts.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗