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DOE OSTI2024

Effects of processing temperature, pressure, and fiber volume fraction on mechanical and morphological behaviors of fully-recyclable uni-directional thermoplastic polymer-fiber-reinforced polymers

This work explores a type of composite called thermoplastic polymer-fiber-reinforced polymers (PFRPs), often referred to as self-reinforced composites (SRCs). A representative PFRP was exemplified using unidirectional (UD) ultra-high-molecular-weight polyethylene (UHMWPE) fibers embedded in a high-density polyethylene (HDPE) matrix. The effects of compression molding temperature and pressure on the mechanical and morphological behaviors of the filament-wound PFRPs with various fiber volume fractions (V f ) were experimentally investigated. The results elucidate the evolution of morphologies and tensile properties of the PFRPs due to thermal melting, fiber misalignment from pressure, and (V f )-induced structural variance, which has not been comprehensively reported yet. The highest specific tensile strength and modulus of the PFRP laminae reach 600 MPa/(g/cm 3 ) and 31 GPa/(g/cm 3 ), respectively. These properties are comparable to glass-/aramid-fiber-reinforced polymers (GFRPs, GFRTPs, AFRPs, and AFRTPs), with PFRPs exhibiting better ductility (specific strain at peak load ≈ 4%/(g/cm 3 )) than other common polymer composites. The motivation for this work was the high recyclability of PFRPs, which can be recycled by melting both the fibers and the matrix, and then reshaped them for re-manufacturing composites to maximize the efficiency in material reuse. This process simplifies the implementation of closed-loop recycling, re-manufacturing, and reuse to support sustainability in composites. This work aims to contribute to advancing thermoplastic PFRPs for their potential applications in various industries.

36 MATERIALS SCIENCE↗

DOE OSTI2026

High pressure effects on EBC systems in high temperature environments

Environmental barrier coatings (EBCs) are designed to protect SiCfiber/SiCmatrix ceramic matrix composites (CMCs) in turbine engines by mitigating wear in high-temperature water vapor environments. The failure of EBCs is frequently attributed to the accelerated oxidation of the silicon bond coating layer when exposed to high-temperature steam, leading to the formation of a thickened thermally grown oxide (TGO). TGO growth increases interfacial stress, weakens adhesion, and results in coating spallation. Understanding the impact of high-temperature oxidation of EBC systems is essential for developing accurate lifespan models for turbine components, although pressurized oxidation testing is extremely sparse in the open literature. In this work, oxidation tests were performed on rare earth silicate EBCs coated onto SiC substrates under increased pressure conditions. The coated specimens were tested at 1100°C, 1200°C, and 1300°C at both 1 atm and 10 atm total pressure in steam environments. Subsequent characterization focused on the microstructural evolution of the EBC/Si/SiC system. The experimental findings indicated that TGO behavior is dependent on high-pressure conditions, with elevated pressure leading to an increase in oxide scale thickness and modifications in its morphology.

Ardrey, Kristyn [ORNL] (ORCID:0000000184407796)↗

DOE OSTI2021

Investigation of δ zirconium hydride morphology in a single crystal using quantitative phase field simulations supported by experiments

In light water nuclear reactors, waterside corrosion of the cladding material leads to the production of hydrogen, a fraction of which is picked up by the zirconium cladding and precipitates into brittle hydride particles. These nanoscale hydride particles aggregate into mesoscale hydride clusters. The principal stacking direction of the nanoscale hydrides precipitated in the cladding tube changes from circumferential in the absence of applied stress to radial under circumferential applied stress. A quantitative phase field model has been developed to predict the hydride morphology observed experimentally and identify the mechanisms responsible for nanoscale hydride stacking. The model focuses on nanoscale hydride precipitation in a single zirconium grain with a detailed description of the anisotropic elastic contribution. The model predictions concerning the shape, orientation, and stacking behavior of nanoscale hydride are analyzed and compared with experimental observations. The model accurately accounts for the experimentally observed elongated nanoscale hydride shape and the stacking of hydrides along the basal plane of the hexagonal zirconium matrix. When investigating the role of applied stress in hydride morphology, the model challenges some of the mechanisms previously proposed to explain hydride reorientation. Finally, although hydride reorientation has been hypothesized to be caused by a change in nanoscale hydride shape, the current study shows that these mechanisms are unlikely to occur.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

Chemical beneficiation of cobaltiferous pyrite: a thermodynamic and parametric study

Despite ongoing efforts to identify substitute materials, cobalt remains indispensable for the production of rechargeable batteries essential to the global energy transition. Currently, most cobalt is sourced as a by-product of nickel and copper extraction from politically and ethically unstable regions. To address this vulnerability, certain primary cobalt deposits—where cobalt occurs within the crystal lattice of pyrite (FeS 2 )—have been identified as potential alternatives. Nonetheless, conventional beneficiation methods have proven largely ineffective for the potential processing of these minerals. This study investigated the thermal decomposition of cobaltiferous pyrite contained in flotation concentrates as a subsequent chemical beneficiation stage aimed at (i) selectively removing sulfur to further increase cobalt grades and (ii) producing a ferromagnetic product suitable for downstream magnetic separation. A thermodynamic analysis was first conducted to evaluate the feasibility of the decomposition reactions and the temperature-dependent evolution of sulfur species. A parametric experimental study then assessed the influence of temperature, residence time, and gas flow rate under N 2 and CO 2 atmospheres. Under the most favorable experimental conditions tested (650 °C, 15 min), cobalt grades increased by up to 15% with negligible cobalt losses and the co-production of high-purity sulfur (>95%). Magnetic separation of the resulting calcine yielded a final concentrate containing 2.09% cobalt at 82.5% recovery, representing a 16–74% improvement over previous baseline studies on similar feedstocks.

Beneficiation↗

DOE OSTI2025

Strain-Based Assessment of Shale Caprock during Cyclic Underground Hydrogen Storage

Successful large-scale underground hydrogen storage (UHS) in depleted gas reservoirs depends on the integrity of the overlying caprock to prevent hydrogen loss during cyclic injection and depletion. Prior studies on crushed Marcellus shale, a potential caprock, indicate that cyclic hydrogen injection and depletion induces microstructural changes, increasing porosity and permeability. However, the extent of these changes in intact shale remains unclear. This study presents a strain-based experimental approach to quantify volumetric strain evolution in intact Marcellus shale matrix under unconstrained stress conditions. A quadrant-shaped shale sample without visible fractures underwent eight hydrostatic pore-pressure cycles (injection to 1500 psi and depletion to 500 psi in 250 psi steps). Linear strain gauges measured strain in three orthogonal directions. Results indicate progressive plastic strain accumulation, leading to an ∼12% increase in matrix porosity after eight cycles, with an estimated 19% increase after 30 cycles. This porosity increase follows a logarithmic trend, suggesting a diminishing effect in later cycles. Additionally, permeability and diffusive mass flux are projected to rise by ∼70% over 30 cycles, enhancing hydrogen migration risk. The shale matrix also exhibited mechanical stiffening over successive cycles, limiting large-scale deformation but not preventing porosity enhancement. A new parameter, α, was introduced to characterize shale sensitivity to cyclic loading, aiding UHS caprock assessments. These findings underscore the necessity of incorporating cyclic loading effects in UHS site selection and operational strategies to ensure long-term storage integrity.

08 HYDROGEN↗

DOE OSTI2025

A comparative analysis of YOLOv8 and U-Net image segmentation approaches for transmission electron micrographs of polycrystalline thin films

Metallic thin films offer a platform to experimentally study the dynamics of microstructural evolution, but the required transmission electron microscopy (TEM)-based imaging generates complex images that are challenging to segment and quantify. This work provides a comparative analysis of a new YOLOv8 model and an established U-Net model for bright-field TEM images of polycrystals, employing a framework leveraging physical observables to evaluate performance against two hand-traced benchmark datasets. This methodology obviates the comparison of large, diversely structured, and manually labeled datasets that are required to assess performance on a per-image/per-pixel basis. It is found that the YOLOv8 model, adapted for real-time instance segmentation, has up to 43× faster inferencing (NVIDIA GeForce RTX 4090) compared to U-Net and reconstructs hand-traced grain size distributions (GSDs) with excellent fidelity, finding mean diameter within 3% for grains near an optimal magnification; for grains that deviate from the optimal pixel-diameter, the size of small- (large)-diameter grains is systematically over- (under)-estimated. This is partially mitigated by including scale-aware augmentations during training. Moreover, when the bias is corrected post-inference by a rigid shift in distribution, the YOLOv8 model reproduces ground truth GSDs with exceptional fidelity, with statistical tests indicating <5% probability that the distributions are distinct. Based on ground truth data, calibration curves pertaining to this shift can be constructed for a given model. This issue is not present in the U-Net model’s results, indicating that for quantitative measurements where the true size of objects is of interest, special procedures must be implemented for YOLO-based models.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Peptide Control of Electrocatalyst Surface Environment and Catalyst Structure: A Design Platform to Enable Mechanistic Understanding and Synthesis of Active and Selective N2 Reduction Catalysts

Low-temperature electrochemical ammonia synthesis with heterogeneous catalysts suffers from extremely low Faradaic efficiencies (< 1%). The hydrogen evolution reaction (HER) is predicted and experimentally demonstrated to outcompete the nitrogen reduction reaction (N2RR). Meanwhile, the nitrogenase enzymes found in nature enable selective N2RR at Fe/Mo metal centers. Montoya and co-authors suggest that a successful transition metal N2RR catalyst will deviate from or completely circumvent current linear scaling relationships. We propose an approach where short-chain peptides (3-20 amino acids) will be used to control the local surface environment of catalysts. This peptide-based design strategy will be used to overcome HER selectivity and the limitations of *NxHy adsorbate scaling.

08 HYDROGEN↗

DOE OSTI2023

Recent In Situ Experimental and Theoretical Advances in Severe Plastic Deformations, Strain-Induced Phase Transformations, and Microstructure Evolution under High Pressure

Not provided.

Materials Science↗

NASA NTRS1989

Molecular and mass spectroscopic analysis of isotopically labeled organic residues

Experimental studies aimed at understanding the evolution of complex organic molecules on interstellar grains were performed. The photolysis of frozen gas mixtures of various compositions containing H2O, CO, NH3, and CH4 was studied. These species were chosen because of their astrophysical importance as deducted from observational as well as theoretical studies of ice mantles on interstellar grains. These ultraviolet photolyzed ices were warmed up in order to produce refractory organic molecules like the ones formed in molecular clouds when the icy mantles are being irradiated and warmed up either by a nearby stellar source or impulsive heating. The laboratory studies give estimates of the efficiency of production of such organic material under interstellar conditions. It is shown that the gradual carbonization of organic mantles in the diffuse cloud phase leads to higher and higher visual absorptivity - yellow residues become brown in the laboratory. The obtained results can be applied to explaining the organic components of comets and their relevance to the origin of life.

Mendoza-Gomez, Celia X.↗

NASA NTRS1991

An experimental investigation of boundary layer transition in an adverse pressure gradient

The evolution of a small perturbation introduced periodically into a boundary layer with a moderately strong adverse pressure gradient (APG) was investigated experimentally using the hot-wire method. The magnitude of the disturbance is found to decay with the streamwise distance in the APG before undergoing rapid growth and triggering transition in a very repetitive manner. The evidence suggests that the laminar layer separates and that the transition mechanism is an inviscid shear-layer type of instability. Contours of spanwise vorticity in the plane of the disturbance show the formation of roll-ups in the initial stages. Subsequent interaction with the wall leads to the formation of large-scale vortex loops which merge into a single vortex loop further downstream.

Watmuff, Jonathan H.↗

NASA NTRS1993

A new technique for in situ measurement of the composition of neutral gas in interplanetary space

Neutral atoms in interplanetary space play an important role in many processes relevant to the formation and evolution of the Solar System. An experimental approach is proposed for in situ atom detection based on the conversion of neutral atoms to negative ions at a specially prepared sensitive surface. Negative ions are subsequently analyzed and detected in an essentially noise-free mode. The use of the technique for in situ study of the composition of neutral interstellar atoms is considered. It is shown that interstellar H, D, and O atoms and possibly H2 molecules can be measured by the proposed technique. The experiment can be performed from a high-apogee Earth-orbiting satellite or from a deep space probe. Possible applications of the technique are discussed.

Gruntman, Michael A.↗

NASA NTRS1998

On the Environmental Realizability of Algebraically Growing Disturbances and Their Relation to Klebanoff Modes

A theoretical explanation of some experimentally observed phenomena associated with the so-called Klebanoff modes is obtained by analyzing the flow over a finite thickness flat plate resulting from a small-amplitude distortion imposed on the upstream mean flow. The analysis shows (among other things) how the stretching of the vortex lines around the plate leads to streamwise vorticity at the plate surface, which then produces a streamwise velocity perturbation within the boundary layer that can be related to the experimentally observed Klebanoff mode. The complete evolution of this flow must be found by solving the boundary-region equations of Kemp (1951) and Davis and Rubin (1980), but a limiting analytical solution can also be obtained. Since the initial growth of the boundary-layer disturbance is nearly algebraic, our results demonstrate how the algebraically growing disturbances promoted by Landahl and others can be generated by a realistic external-disturbance environment. The relationship between these results and various bypass transition mechanisms is discussed.

Goldstein, Marvin E.↗

NASA NTRS1998

On the Environmental Realizability of Algebraically Growing Disturbances and Their Relation to Klebanoff Modes

Goldstein, M. E.↗

NASA NTRS2003

Evaluation of Production Cross Sections of Li, Be, B in CR

Accurate evaluation of the production cross section of light elements is important for models of cosmic ray (CR) propagation, galactic chemical evolution, and cosmological studies. However, the experimental spallation cross section data are scarce and often unavailable to CR community while semi-empirical systematics are frequently wrong by a significant factor. Running sophisticated nuclear codes is not an option of choice for everyone either. We use the Los Alamos versions of the Quark-Gluon String Model code LAQGSM and the improved Cascade-Exciton Model code CEM2k together with all available data from Los Alamos Nuclear Laboratory (LANL) nuclear database to produce evaluated production cross sections of isotopes of Li, Be, and B suitable for astrophysical applications. The LAQGSM and CEM2k models have been shown to reproduce well nuclear reactions and hadronic data in the range 0.01-800 GeV/nucleon.

Moskalenko, I. V.↗

NASA NTRS2005

Lunar and Planetary Science XXXVI, Part 4

Contents include the following: High-Resolution Electron Energy-Loss Spectroscopy (HREELS) Using a Monochromated TEM/STEM. Dynamical Evolution of Planets in Open Clusters. Experimental Petrology of the Basaltic Shergottite Yamato 980459: Implications for the Thermal Structure of the Martian Mantle. Cryogenic Reflectance Spectroscopy of Highly Hydrated Sulfur-bearing Salts. Implications for Core Formation of the Earth from High Pressure-Temperature Au Partitioning Experiments. Uranium-Thorium Cosmochronology. Protracted Core Differentiation in Asteroids from 182Hf-182W Systematics in the Eagle Station Pallasite. Maximizing Mission Science Return Through Use of Spacecraft Autonomy: Active Volcanism and the Autonomous Sciencecraft Experiment. Classification of Volcanic Eruptions on Io and Earth Using Low-Resolution Remote Sensing Data. Isotopic Mass Fractionation Laws and the Initial Solar System (sup26)Al/(sup27)Al Ratio. Catastrophic Disruption of Porous and Solid Ice Bodies (sup187)Re-(sup187)Os Isotope Disturbance in LaPaz Mare Basalt Meteorites. Comparative Petrology and Geochemistry of the LaPaz Mare Basalt Meteorites. A Comparison of the Structure and Bonding of Carbon in Apex Chert Kerogenous Material and Fischer-Tropsch-Type Carbons. Broad Spectrum Characterization of Returned Samples: Orientation Constraints of Small Samples on X-Ray and Other Spectroscopies. Apollo 14 High-Ti Picritic Glass: Oxidation/Reduction by Condensation of Alkali Metals. New Lunar Meteorites from Oman: Dhofar 925, 960 and 961. The First Six Months of Iapetus Observations by the Cassini ISS Camera. First Imaging Results from the Iapetus B/C Flyby of the Cassini Spacecraft. Radiative Transfer Calculations for the Atmosphere of Mars in the 200-900 nm Range. Geomorphologic Map of the Atlantis Basin, Terra Sirenum, Mars. The Meaning of Iron 60: A Nearby Supernova Injected Short-lived Radionuclides into Our Protoplanetary Disk.

Source record↗

NASA NTRS2015

Development and Characterization of a Rate-Dependent Three-Dimensional Macroscopic Plasticity Model Suitable for Use in Composite Impact Problems

Several key capabilities have been identified by the aerospace community as lacking in the material/models for composite materials currently available within commercial transient dynamic finite element codes such as LS-DYNA. Some of the specific desired features that have been identified include the incorporation of both plasticity and damage within the material model, the capability of using the material model to analyze the response of both three-dimensional solid elements and two dimensional shell elements, and the ability to simulate the response of composites composed with a variety of composite architectures, including laminates, weaves and braids. In addition, a need has been expressed to have a material model that utilizes tabulated experimentally based input to define the evolution of plasticity and damage as opposed to utilizing discrete input parameters (such as modulus and strength) and analytical functions based on curve fitting. To begin to address these needs, an orthotropic macroscopic plasticity based model suitable for implementation within LS-DYNA has been developed. Specifically, the Tsai-Wu composite failure model has been generalized and extended to a strain-hardening based orthotropic plasticity model with a non-associative flow rule. The coefficients in the yield function are determined based on tabulated stress-strain curves in the various normal and shear directions, along with selected off-axis curves. Incorporating rate dependence into the yield function is achieved by using a series of tabluated input curves, each at a different constant strain rate. The non-associative flow-rule is used to compute the evolution of the effective plastic strain. Systematic procedures have been developed to determine the values of the various coefficients in the yield function and the flow rule based on the tabulated input data. An algorithm based on the radial return method has been developed to facilitate the numerical implementation of the material model. The presented paper will present in detail the development of the orthotropic plasticity model and the procedures used to obtain the required material parameters. Methods in which a combination of actual testing and selective numerical testing can be combined to yield the appropriate input data for the model will be described. A specific laminated polymer matrix composite will be examined to demonstrate the application of the model.

Impact↗

NASA NTRSDate not supplied

Modeling the Crystallization of Martian Igneous Compositions

The martian crust is dominated by basalts and ultramafic rocks [1]. Understanding the crystallization sequence of martian igneous rocks is critical for constraining the petrologic and geochemical evolution of the crust and mantle. Experimental studies have investigated the parental liquid compositions and crystallization behavior using martian meteorite compositions [2-7], as well as compositions measured by rovers on the martian surface [8,9]. While experiments deliver crucial results, they are often limited by time and resources. Therefore, modeling approaches are an ideal tool to complement experimental results. The application of the MELTS software package [10, 11], to calculate the crystallization of martian compositions, reproduces important compositional details of magma crystallization but significant uncertainties regarding the pressure of the olivine-pyroxene multiple saturation point have been reported [12], and in the temperatures of initial crystallization [12, 13]. Recently, a new melting model, MAGMARS, has been shown to reproduce martian primary melts more accurately [14]. Here, we constrain the applicability of Gibbs free energy minimization software Perple_X [15] for martian compositions by comparing our modeled results to experimentally derived crystallization paths for two martian compositions.

J Semprich↗

DOE OSTI2024

Exploration of Rayleigh-Taylor seeding mechanisms in laser- and pulsed-power-driven inertial fusion

The ubiquitous Rayleigh-Taylor instability (RTI) has been observed in fluids and plasmas in a wide range of parameter regimes from astrophysical to laboratory plasmas. In high-energy-density (HED) laboratory plasmas, such as laser-driven inertial confinement fusion (ICF) plasmas, the RTI can have a detrimental impact on achieving fusion ignition through the generation of hydrodynamic mix. Hence, an understanding of the seeding mechanisms that produce the RTI and identifying ways to mitigate hydrodynamic mix is of critical importance. Appropriately aligned magnetic fields have been known to stabilize short-wavelength RTI. A number of numerical and experimental studies have demonstrated the benefits of using imposed magnetic fields in laser-driven ICF to achieve higher ion temeratures, higher neutron yields, and a relaxation of the ignition criteria. This work addresses seeding mechanisms in laser-driven implosions to understand critical early-stage physics that ultimately leads to substantial growth of the RTI along with mechanisms for mitigation of this growth. Surface perturbations due to machining tolerances and single-feature seeds (for example due to fill tubes) can produce substantial RTI growth in the ignition-relevant high-convergence ratio targets for laser- driven ICF implosions. RTI growth from single-feature seeding in laser-based implosions has the potential to be mitigated through appropriately aligned externally applied magnetic fields and the goal of this work has been to quantify that numerically and experimentally. Resistive-magnetohydrodynamic (MHD) simu- lations are used to study the seeding and evolution of the RTI leveraging previous support from the DOE HEDLP program. Furthermore, experimental data has been obtained and applied towards code validation of unmagnetized and magnetized evolution of single-feature seeded RTI growth.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗