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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Recent Progress in Developing Nb 3 Sn Conductors With Increased Specific Heat

A possible approach to reducing Nb 3 Sn magnet training is to increase the energy margin of Nb 3 Sn conductors by enhancing their specific heat (C p ). For this study, we have been developing Nb 3 Sn conductors with increased C p by incorporating substances with high C p at 2-10 K based on a conductor design that is compatible with standard Nb 3 Sn strand production. In the past couple of years our efforts have been mainly focused on improving strand design (e.g., position of high- C p filaments, thickness of the Cu tube for the high-C p filaments, ratio of the Cu powder to the high-C p substance, filament spacing, etc.) in order to obtain good strand drawability and to reduce degradation after rolling, which is needed for production of Rutherford cables. We also tried a new high-C p substance, Gd 2 O 2 S, and verified that it has much higher C p over the whole magnetic field range than the Gd 2 O 3 we used before. With that development work we can now produce high-C p strands with good drawability and low levels of degradation after rolling. This paper reports our findings and the current status of the development of high-C p Nb 3 Sn conductors.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2022

Bearing Fault Detection on Wind Turbine Gearbox Vibrations Using Generalized Likelihood Ratio-Based Indicators

Studies in condition monitoring literature often aim to detect rolling element bearing faults because they have one of the biggest shares among defects in turbo machinery. Accordingly, several prognosis and diagnosis methods have been devised to identify fault signatures from vibration signals. A recently proposed method to capture the rolling element bearing degradation provides the groundwork for new indicator families utilizing the generalized likelihood ratio test. This novel approach exploits the cyclostationarity and the impulsiveness of vibration signals independently in order to estimate the most suitable indicators for a given fault. However, the method has yet to be tested on complex experimental vibration signals such as those of a wind turbine gearbox. In this study, the approach is applied to the National Renewable Energy Laboratory Wind Turbine Gearbox Condition Monitoring Round Robin Study data set for bearing fault detection purposes. The data set is measured on an experimental test rig of a wind turbine gearbox; hence the complexity of the vibration signals is similar to a real case. The outcome demonstrates that the proposed method is capable of distinguishing between healthy and damaged vibration signals measured on a complex wind turbine gearbox.

condition monitoring↗
DOE OSTI2023

Multi-layered Energy Management Framework for Extreme Fast Charging Stations Considering Demand Charges, Battery Degradation, and Forecast Uncertainties

To achieve a cost-effective and expeditious charging experience for extreme fast charging station (XFCS) owners and electric vehicle (EV) users, the optimal operation of XFCS is crucial. It is however challenging to simultaneously manage the profit from energy arbitrage, the cost of demand charges, and the degradation of a battery energy storage system (BESS) under uncertainties. This paper, therefore, proposes a multi-layered multi-time scale energy flow management framework for an XFCS by considering long- and short-term forecast uncertainties, monthly demand charges reduction, and BESS life degradation. In the proposed approach, an upper scheduling layer (USL) ensures the overall operation economy and yields optimal scheduling of the energy resources on a rolling horizon basis, thereby considering the long-term forecast errors. A lower dispatch layer (LDL) takes the short-term forecast errors into account during the real-time operation of the XFCS. Per the latest research, monthly demand charges can be as high as 90% of the total monthly bills for EV fast charging stations; to this end, this paper takes the first attempt at the reduction of demand charges cost by considering the trade-off between the energy cost and monthly demand charges. Contrasting literature, this work allocates an energy reserve in the BESS stored energy to deal with the impact of short-term forecast errors on the optimized real-time operation of the XFCS. Moreover, degradation modeling considers the trade-off between short-term benefits and long-term BESS life degradation. As a result, case studies and a comparative analysis prove the efficacy of the proposed framework.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Control Design for a Marine Hydrokinetic Cycloturbine Vehicle

Abstract Marine Hydrokinetic (MHK) cycloturbines generate sustainable power by exploiting tidal currents. By powering the turbines and using pitching foils for control, a vehicle comprised of MHK cycloturbines also has the ability to station keep and maneuver. The vehicle consists of four counter-rotating cycloturbines, with hydrofoils oriented perpendicular to the flow in a paddlewheel configuration. Lift and drag generated from these foils sum together to produce thrust. An experimentally tuned simulation model that solves the six-degrees-of-freedom rigid body equations of motion for the MHK vehicle subject to hydrodynamic, hydrostatic, and propulsive forces is used to aid the design of vehicle controllers. Global feedback controllers are initially designed by applying classical control methods to an approximate linear model of the system dynamics. A higher performing nonlinear controller is designed using the nonlinear dynamic inversion (NDI) method. NDI accounts for the nonlinearities of the MHK system and therefore is suitable for a wide range of operating conditions. The response of the classical and NDI controllers to speed, depth, roll, pitch, and yaw commands are evaluated and compared in simulation. The classical controller outperforms the NDI controller for small amplitude maneuvers, although the degradation with NDI is minor. However, in the nonlinear operating regime the NDI controller outperforms the classical controller and the classical controller exhibits instability.

Automation & Control Systems↗
DOE OSTI2026

A Holistic Stabilization of the Anode in Lithium‐Sulfur Batteries Through a Ternary Alloy Fusion

The anode in lithium–sulfur batteries (LSBs) is plagued by not only inhomogeneous lithium (Li) deposition, but also by parasitic side-reactions. Often, a thick anode (∼400 µm) is used to compensate for these drawbacks, lowering gravimetric and volumetric energy densities. In this work, we demonstrate a ternary alloy anode fabricated via scalable thermal fusion of Li with aluminum (Al) and tellurium (Te) to cohesively address these issues. The Al–Li skeleton serves to homogenize Li deposition as well as reinforce the anode, allowing it to be rolled down to low thicknesses. Te incorporation suppresses the reaction of Li with polysulfides (Li 2 Sn) to form lithium sulfide (Li 2 S) and electrolyte degradation. It can also facilitate the formation of polytellurosulfides (Li 2 Te x Sy), which are far more conducive to Li + -ion diffusion. Even under a lean electrolyte/sulfur (E/S) ratio of 8 µL mg −1 and a low negative/positive (N/P) ratio of 3, capacities over 900 mA h g −1 at a C/5 rate are obtained in cells with Li–Te–Al anodes with a capacity retention of 80% after 70 cycles. In comparison, the baseline lithium-metal anode retains only 35% after 50 cycles. Furthermore, the Li–Te–Al anodes confer a 24% boost to gravimetric energy density at the pouch cell level.

25 ENERGY STORAGE↗
DOE OSTI2025

Seismic Performance of Conventional and Additively Manufactured U-Shaped Flexural Plates

U-shape flexural plates (UFPs) have gained significant attention in seismic structural design due to their ability to provide stable hysteresis behaviour and serve as effective energy-dissipating devices. Concurrently, Additive Manufacturing (AM) has advanced significantly, enabling the production of metallic components with mechanical properties comparable to those of conventionally manufactured cold-rolled materials. This study aims to explore the seismic response of single and double UFP fabricated through Laser Powder Based Fusion (LPBF) and conventional cold rolled 316L stainless steel (SS). The experimental results are evaluated based on force-displacement hysteresis behaviour, energy dissipation capacity, load-carrying capacity, and stiffness degradation. The findings confirm the efficacy of AM-fabricated UFPs for seismic energy dissipation. Additionally, the results suggest the potential for further improvement through the optimization of AM process parameters, such as laser scan speed, hatch spacing, and layer thickness, to enhance hysteretic performance and energy dissipation characteristics.

Risal, Kshitiz [Idaho State University]↗
DOE OSTI2023

The Influence of Strain Path and Heat Treatment Variations on Recrystallization in Cold-Rolled High-Purity Niobium Polycrystals

With the standard material and cavity production guidelines, the properties and performance of industrially produced high-purity niobium superconducting radiofrequency (SRF) cavities are unpredictably variable. Currently, assembled niobium SRF cavities undergo post-purification vacuum heat treatment at 800 °C for three hours to remove hydrogen and increase performance; however, recent work has shown significant improvements in cavity performance when annealed between 900–1000 °C, causing recrystallization (Rx). Increasing the annealing temperature and/or the heating rate should facilitate the onset of Rx, resulting in a greater reduction in the density of geometrically necessary dislocations (GNDs) that are strongly associated with the degradation of cavity performance via trapped magnetic flux. Improving the SRF community's understanding of the influence of both heat treatment and deformation history on the resulting microstructure and Rx behavior in high-purity niobium is needed. This fundamental metallurgy is critical for identifying improved specifications for the consistent production of high-performing niobium SRF cavities. This research investigates variations in deformation paths, heating rates, and annealing temperatures on Rx of deformed samples of polycrystalline high-purity niobium. To assess the effects of strain path, samples were cold-rolled to ~30% reduction prior to annealing, with half of the sample set rolled parallel to the as-received niobium sheet and the other half in the transverse direction.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Impact of Rubin Observatory Cadence Choices on Supernovae Photometric Classification

The Vera C. Rubin Observatory's Legacy Survey of Space and Time (LSST) will discover an unprecedented number of supernovae (SNe), making spectroscopic classification for all the events infeasible. LSST will thus rely on photometric classification, whose accuracy depends on the not-yet-finalized LSST observing strategy. In this work, we analyze the impact of cadence choices on classification performance using simulated multiband light curves. First, we simulate SNe with an LSST baseline cadence, a nonrolling cadence, and a presto-color cadence, which observes each sky location three times per night instead of twice. Each simulated data set includes a spectroscopically confirmed training set, which we augment to be representative of the test set as part of the classification pipeline. Then we use the photometric transient classification library snmachine to build classifiers. We find that the active region of the rolling cadence used in the baseline observing strategy yields a 25% improvement in classification performance relative to the background region. This improvement in performance in the actively rolling region is also associated with an increase of up to a factor of 2.7 in the number of cosmologically useful Type Ia SNe relative to the background region. However, adding a third visit per night as implemented in presto-color degrades classification performance due to more irregularly sampled light curves. Overall, our results establish desiderata on the observing cadence related to classification of full SNe light curves, which in turn impacts photometric SNe cosmology with LSST.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Robust constrained tension control for high-precision roll-to-roll processes

Tension control is critical for maintaining good product quality in most roll-to-roll (R2R) production systems. Previous work has primarily focused on improving the disturbance rejection performance of tension controllers. Here, a robust linear parameter-varying model predictive control (LPV-MPC) scheme is designed to enhance the tension tracking performance of a pilot R2R system for deposition of materials used in flexible thin film applications. The performance of a tension controller may degrade due to disturbances associated with model uncertainties and the slowly-changing dynamics in R2R systems. We introduce a method that separately treats these two sources of disturbance. The controller utilizes an incremental model to eliminate the errors caused by the mismatch between the nominal model and the actual system. A tube-based MPC formulation combined with scheduled parameters adequately updates models and corrects for the time-varying dynamics. Constraints on the rated motor torque are incorporated in the MPC to maintain the controller reliability and avoid machine failures. We illustrate the operation of our control algorithm through simulation of an actual R2R system. The controller outperforms the benchmarks in terms of fast transient response and offset-free tension tracking. Furthermore, it also demonstrates immunity from variations due to parametric uncertainties.

42 ENGINEERING↗
DOE OSTI2022

Modelling and Experimental Validation of Improved Performance of Lithium-Ion Batteries Having Thick Electrodes with Laser-Ablated Micro-Structures

For widespread adoption of electric vehicles, lithium-ion batteries (LiBs) need to achieve energy densities of >275 Wh/kg, cost less than $100/Wh, and charge to more than 80% capacity within 15 minutes. Increasing the battery electrode thicknesses is one way to increase cell energy densities while also saving on cell manufacturing cost by increasing the ratio of electrode active material to inactive material within each cell. However, increased electrode loading is often accompanied by decreased Li+-ion diffusion across the full thick electrodes. This leads to significant cell polarization that prevents full capacity utilization and accelerates cell degradation, especially at fast charging/discharging rates. The introduction of secondary pore networks in thick battery electrodes alleviates some of the trade-offs between energy and power performance. These microstructures provide low tortuosity pathways for facile Li+-ion diffusion deep into the thick electrodes, diminishing detrimental concentration gradients within the cell. Ultrafast-pulsed laser ablation is a promising method to introduce micro pores or channels in thick battery electrodes as it allows for precise control of pattern geometries, results in minimal damage to the electrode and can be introduced into existing roll-to-roll electrode manufacturing lines. Herein, the limitations of thick planer electrodes and the advanced predictive models to identify optimal electrode patterns for improved cycling performance will be presented. The impact of electrode laser patterning to create secondary pore networks also will be discussed. Materials characterization techniques (SEM-EDS, XRD) were used to explore the affect ultrafast laser ablation had on the electrode materials’ morphology and structure. The improvements in the patterned electrodes’ electrochemical cycling performances and degrees of wetting will be compared to a pristine baseline case. Finally, the discrepancies between experimentally obtained data and model predictions will be explained.

DIRECT ENERGY CONVERSION,ENERGY STORAGE↗
DOE OSTI2024

Spot size measurement of a deuterium–tritium dense plasma focus using neutron radiography

Neutron radiography is a technique uniquely suited to applications in nuclear diagnostics, non-destructive testing, and subcritical experiments. The spatial resolution of neutron radiographs is degraded by optical blur in the imaging system and the neutron source size, where the ideal source is point-like to optimize the point-spread function. A potential neutron source for radiography is the dense plasma focus (DPF), a coaxial Z-pinch that produces thermonuclear and beam-target neutrons. To assess if the source size is suitable for radiography, a neutron imaging system was used to measure the source size of the 4 MA Sodium DPF at the Nevada National Security Site operating with deuterium–tritium gas-fill. The source size was measured using the edge-spread function of tungsten objects, each having a rolled (convex) edge. The spot size was found to be 7–12 mm full-width at half-max (FWHM) assuming a Gaussian source, though comparison is presented for Lorentzian and Bennett distributions. The average FWHM was found to be 8.6 ± 1.2 mm vertically and 10.8 ± 1.2 mm horizontally with respect to the image plane, averaging over varied edges and alignments. The results were sensitive to source alignment and edge metrology, which introduced notable uncertainties. These results are consistent with separate experimental measurements as well as magnetohydrodynamics simulations of this DPF, which suggest that neutron production can originate from pinches ∼5–7 mm off-axis. These results suggest that the DPF should be used for radiography at low magnification (M < 1) where spot size does not dominate spatial blur.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Impact of survey spatial variability on galaxy redshift distributions and the cosmological 3 × 2-point statistics for the Rubin Legacy Survey of Space and Time (LSST)

We investigate the impact of spatial survey non-uniformity on the galaxy redshift distributions for forthcoming data releases of the Rubin Observatory Legacy Survey of Space and Time (LSST). Specifically, we construct a mock photometry data set degraded by the Rubin OpSim observing conditions, and estimate photometric redshifts of the sample using a template-fitting photo-z estimator, BPZ, and a machine learning method, FlexZBoost. We select the Gold sample, defined as $i\lt 25.3$ for 10 yr LSST data, with an adjusted magnitude cut for each year and divide it into five tomographic redshift bins for the weak lensing lens and source samples. We quantify the change in the number of objects, mean redshift, and width of each tomographic bin as a function of the coadd i-band depth for 1-yr (Y1), 3-yr (Y3), and 5-yr (Y5) data. In particular, Y3 and Y5 have large non-uniformity due to the rolling cadence of LSST, hence provide a worst-case scenario of the impact from non-uniformity. We find that these quantities typically increase with depth, and the variation can be $10\!-\!40~{{\rm per\ cent}}$ at extreme depth values. Using Y3 as an example, we propagate the variable depth effect to the weak lensing $3\times 2$ pt analysis, and assess the impact on cosmological parameters via a Fisher forecast. We find that galaxy clustering is most susceptible to variable depth, and non-uniformity needs to be mitigated below 3 per cent to recover unbiased cosmological constraints. There is little impact on galaxy–shear and shear–shear power spectra, given the expected LSST Y3 noise.

cosmology↗
DOE OSTI2026

Mechanical characterization of fine-grain dispersion-strengthened tungsten as a plasma facing material

Field-Assisted Sintering Technology (FAST) was used to produce fine-grained, dispersion-strengthened tungsten (W) materials. Investigated materials 4138, 4353, and 4355 composed of 3 wt% ZrC sintered at 1800 °C, 5 wt% ZrC sintered at 1800 °C, and 3 wt% ZrC sintered at 2000 °C, respectively. They were compared against ITER-grade W. A series of mechanical and thermal property testing and microstructure studies were conducted to study them as a potential plasma facing material (PFM) for fusion reactors. Hardness testing showed that manufacturing conditions substantially altered hardness. Material 4355 had an average HV10 value of 497.2 ± 16.8, slightly higher than ITER-grade at 378.5 ± 40.3. However, material 4353 was substantially higher with an HV10 value of 738.9 ± 31.7 over the investigated temperature range. Electron Backscatter Diffraction (EBSD) analysis showed that FAST produced substantially smaller grains than the hot-rolled ITER-grade W material, offering notable control over grain size. Materials 4353 and 4355 had grain sizes of 0.44 ± 0.20 µm and 3.67 ± 0.89 µm, respectively, whereas ITER-grade 27.14 ± 19.76 µm at room temperature. The fine grain structures showed no net coarsening after 1 hr. anneals up to 1800 °C, several hundred degrees above the 1100 – 1500 °C recrystallization range reported for conventional W. Inverse application of the Zener pinning relationship to the measured grain sizes indicates that these two FAST sintering conditions produce markedly different effective dispersoid populations, with effective particle diameters of approximately 90 nm at a peak sintering temperature of 1800 °C and approximately 460 nm at 2000 °C, respectively. This result demonstrates that the FAST thermal condition itself, and not the nominal ZrC content alone, governs the pinning effectiveness of the dispersion. Thermal diffusivity measurements support this finding independently. Materials of identical composition sintered at different temperatures differ by approximately 19% in measured thermal diffusivity with statistically indistinguishable density, while materials of different composition and sintering temperature converge to within approximately 2%. At a representative divertor heat flux of 10 MW/m², the lower thermal conductivity of the fine-grained materials corresponds to approximately 28 to 33 °C per millimeter of armor thickness relative to ITER-grade W, traded against a substantially larger margin to recrystallization-driven degradation. While high temperature tensile testing revealed likely contamination that motivates refinement of the manufacturing process, FAST-produced, fine-grained, dispersion-strengthened W offers process-controlled microstructural stability well above the operating temperatures of conventional W and supports its continued development as a PFM for economically viable commercial fusion power.

Parker, Gabe [ORNL] (ORCID:0000000190394100)↗