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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

The effect of lignin degradation products on the generation of pseudo-lignin during dilute acid pretreatment

Pseudo-lignin is an insoluble material that tends to deposit on acidic pretreated fiber surface and negatively impacts the biological conversion of biomass to valued added products. Employing a laboratory generated acidic hydrolysate solution from dilute acid pretreatment of bamboo residues, we sought to seek an improved understanding of pseudo-lignin formation from fragmented carbohydrates. In addition, we also performed experiments to investigate how lignin model compounds interact with carbohydrates en route to pseudo-lignin’s formation. The yields of pseudo-lignin generated from xylose (CXPL) were higher than those generated from glucose (CGPL). Gas chromatography-Mass spectrometry and Foloin-Ciocalteau analysis suggested that there were more aromatic compounds in hydrolyzate during CGPL’s formation. The presence of lignin phenolic model compounds had both a positive and negative effect upon quantitative yields of pseudo-lignin. Gel permeation chromatography and NMR analysis ( 31 P and 2D-HSQC NMR) of the pseudo-lignin samples generated in the presence and absence of 4-hydroxybenzoic acid (4-HA), employed as a lignin model compound, revealed drastic differences in molecular weight, changes in hydroxyl group content, and hydrocarbon bonds, suggesting significant differences in the pseudo-lignin reaction pathways when certain lignin model compounds are present. Finally, our findings demonstrate the effects of both hemicellulose carbohydrate makeup and lignin model compound impact on the formation of pseudo-lignin and its chemical properties, suggesting a potential way to minimize pseudo-lignin formation.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Understanding the Transport Properties of Methane–Hydrogen Mixtures under the Interior Conditions of Ice Giants

Inaccuracy in our knowledge of the transport properties of relevant mixtures under planetary interior conditions is a roadblock in predicting the observable properties of planets in our solar system and beyond. In this work, we investigate methane–hydrogen mixtures using data sets obtained from density functional theory calculations for the electronic structure, combined with molecular dynamics simulations for the ions for a wide range of pressure and temperature. Hydrogen concentration significantly affects the equation of state (EOS) but has little influence on transport properties. We provide an analytical expression to model thermal EOS and transport properties as a function of hydrogen content, with the maximum deviation observed at low P–T conditions. These insights are particularly relevant to improve the planetary models and enhance our ability to predict the properties of “ice” giants and beyond.

Methane↗
DOE OSTI2020

Dual frequency comb spectroscopy of solid fuel pyrolysis and combustion: Quantifying the influence of moisture content in Douglas fir

As the fire research community develops multi-scale models to predict the spread of wildland fires, there is a need for well-controlled, small-scale experiments which provide benchmark data and fundamental understanding of the effects of key parameters on the combustion of wildland fuels. Here, we implement a unique suite of non-intrusive, quantitative diagnostics that simultaneously measure mass loss, surface temperature, in situ gas temperature and water vapor concentration, including the first implementation of dual frequency comb spectroscopy for the study of solid fuels. As a demonstration, we examine the effect of fuel moisture content on the burning of Douglas fir wood samples that are ignited under constant radiative heat flux from a cone calorimeter to provide benchmark data for multi-scale models. Peak flame temperatures 3 mm above the sample surface measured with the dual frequency comb laser spectrometer are in excess of 1200 K. The flame temperature decreases by over 150 K as fuel moisture content increases from 0.7% to 40%. This work demonstrates a platform for simultaneous, quantitative measurements of well-controlled small-scale experiments which provide benchmark data for the development of advanced modeling and simulations capable of capturing the complex physics present in wildland fire systems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

A High-Performance Discrete-Element Framework for Simulating Flow and Jamming of Moisture Bearing Biomass Feedstocks

We developed and verified a high-performance open-source discrete element method (DEM) solver with simultaneously-supported feedstock-specific interaction models, including bonded-sphere, liquid bridge, cohesion, and non-linear contact models. Our solver uses parallel data structures on hybrid central and graphics processing unit (CPU/GPU) architectures, with favorable strong scaling performance observed for large problem sizes comprised of (100 M particles), and 4X single-node GPU speedup. The particles for corn stover feedstock were conceptualized and calibrated based on experimental measurements and results. Sensitivity analyses demonstrate that the mass flow rate from a wedge hopper is governed primarily by moisture content, friction coefficient, and cohesion energy density. The model is used to reproduce experimentally observed hopper jamming results, highlighting that the experimental no-flow trends can only be achieved by using non-spherical particles, liquid bridge and cohesion models, highlighting the importance of using concurrent feedstock specialized models for the effective representation of biomass material handling problems.

bioenergy↗
DOE OSTI2023

Explainable AI (XAI)-driven vibration sensing scheme for surface quality monitoring in a smart surface grinding process

Local Interpretable and Model-agnostic Explanation (LIME), an explainable artificial intelligence (XAI) approach is adapted to identify the globally important time-frequency bands for predicting average surface roughness (Ra) in a smart grinding process. The smart grinding setup consisted of a Supertech CNC precision surface grinding machine, instrumented with a Dytran piezoelectric accelerometer attached to the tailstock quill along the tangential direction (Y-axis). For every grinding pass, vibration signatures were captured, and the ground truth surface roughness values were recorded using a Mahr Marsurf M300C portable surface roughness profilometer. The roughness values ranged from 0.06 to 0.14 microns over the complete set of experiments. Time-frequency domain spectrogram frames were extracted for each of the vibration signals collected during the grinding process. Convolutional Neural Networks (CNNs) were modeled to predict the surface roughness based on these spectrogram frames and their image augmentations. The best CNN model was able to predict the roughness values with an overall R2-score of 0.95, training R2-score of 0.99, and testing R2-score of 0.81 with only 80 sets of vibration signals corresponding to 4 experiments with 20 trials each. Although the data size is not large enough to guarantee such performance metrics in real-world scenarios, one can extract statistically consistent explanations underlying the relationships these complex deep learning models capture. Further, the LIME methodology was implemented on the developed surface roughness CNN model to identify the important time-frequency bands (i.e., the superpixels of a spectrogram) influencing the predictions. Based on the identified important regions on the spectrogram frames, the corresponding frequency characteristics were determined that influence the surface roughness predictions. The important frequency range based on LIME results was approximately 11.7 to 19.1 kHz. The power of XAI was demonstrated by cutting down the sampling rate from 160 kHz to 30, 20, 10, and 5 kHz based on the important frequency range and considering Nyquist criteria. Separate CNN models were developed for these ranges by only extracting time-frequency contents below their corresponding Nyquist cut-offs. A proper data acquisition strategy is proposed by comparing the model performances to argue the selection of a sufficient sampling rate to capture the grinding process successfully and robustly.

42 ENGINEERING↗
DOE OSTI2023

Reprint of: Explainable AI (XAI)-driven vibration sensing scheme for surface quality monitoring in a smart surface grinding process

Local Interpretable and Model-agnostic Explanation (LIME), an explainable artificial intelligence (XAI) approach is adapted to identify the globally important time-frequency bands for predicting average surface roughness (Ra) in a smart grinding process. The smart grinding setup consisted of a Supertech CNC precision surface grinding machine, instrumented with a Dytran piezoelectric accelerometer attached to the tailstock quill along the tangential direction (Y-axis). For every grinding pass, vibration signatures were captured, and the ground truth surface roughness values were recorded using a Mahr Marsurf M300C portable surface roughness profilometer. The roughness values ranged from 0.06 to 0.14 microns over the complete set of experiments. Time-frequency domain spectrogram frames were extracted for each of the vibration signals collected during the grinding process. Convolutional Neural Networks (CNNs) were modeled to predict the surface roughness based on these spectrogram frames and their image augmentations. The best CNN model was able to predict the roughness values with an overall R2-score of 0.95, training R2-score of 0.99, and testing R2-score of 0.81 with only 80 sets of vibration signals corresponding to 4 experiments with 20 trials each. Although the data size is not large enough to guarantee such performance metrics in real-world scenarios, one can extract statistically consistent explanations underlying the relationships these complex deep learning models capture. Further, the LIME methodology was implemented on the developed surface roughness CNN model to identify the important time-frequency bands (i.e., the superpixels of a spectrogram) influencing the predictions. Based on the identified important regions on the spectrogram frames, the corresponding frequency characteristics were determined that influence the surface roughness predictions. The important frequency range based on LIME results was approximately 11.7 to 19.1 kHz. The power of XAI was demonstrated by cutting down the sampling rate from 160 kHz to 30, 20, 10, and 5 kHz based on the important frequency range and considering Nyquist criteria. Separate CNN models were developed for these ranges by only extracting time-frequency contents below their corresponding Nyquist cut-offs. A proper data acquisition strategy is proposed by comparing the model performances to argue the selection of a sufficient sampling rate to capture the grinding process successfully and robustly.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Dark Energy Survey Year 3 Results: Constraints on cosmological parameters and galaxy bias models from galaxy clustering and galaxy-galaxy lensing using the redMaGiC sample

We constrain cosmological parameters and galaxy-bias parameters using the combination of galaxy clustering and galaxy-galaxy lensing measurements from the Dark Energy Survey Year-3 data. We describe our modeling framework and choice of scales analyzed, validating their robustness to theoretical uncertainties in small-scale clustering by analyzing simulated data. Using a linear galaxy bias model and redMaGiC galaxy sample, we obtain constraints on the matter content of the universe to be $\Omega_{\rm m} = 0.325^{+0.033}_{-0.034}$. We also implement a non-linear galaxy bias model to probe smaller scales that includes parameterizations based on hybrid perturbation theory, and find that it leads to a 17% gain in cosmological constraining power. Using the redMaGiC galaxy sample as foreground lens galaxies, we find the galaxy clustering and galaxy-galaxy lensing measurements to exhibit significant signals akin to decorrelation between galaxies and mass on large scales, which is not expected in any current models. This likely systematic measurement error biases our constraints on galaxy bias and the $S_8$ parameter. We find that a scale-, redshift- and sky-area-independent phenomenological decorrelation parameter can effectively capture this inconsistency between the galaxy clustering and galaxy-galaxy lensing. We perform robustness tests of our methodology pipeline and demonstrate stability of the constraints to changes in the theory model. After accounting for this decorrelation, we infer the constraints on the mean host halo mass of the redMaGiC galaxies from the large-scale bias constraints, finding the galaxies occupy halos of mass approximately $1.5 \times 10^{13} M_{\odot}/h$.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Steric Sea Level Rise and Relationships with Model Drift and Water Mass Representation in GFDL CM4 and ESM4

Abstract Density-driven steric seawater changes are a leading-order contributor to global mean sea level rise. However, intermodel differences in the magnitude and spatial patterns of steric sea level rise exist at regional scales and often emerge during the spinup and preindustrial control integrations of climate models. Steric sea level results from an eddy-permitting climate model, GFDL CM4, are compared with a lower-resolution counterpart, GFDL-ESM4. The results from both models are examined through basin-scale heat budgets and watermass analysis, and we compare the patterns of ocean heat uptake, redistribution, and sea level differ in ocean-only [i.e., Ocean Model Intercomparison Project (OMIP)] and coupled climate configurations. After correcting for model drift, both GFDL CM4 and GFDL-ESM4 simulate nearly equivalent ocean heat content change and global sea level rise during the historical period. However, the GFDL CM4 model exhibits as much as a 40% increase in surface ocean heat uptake in the Southern Ocean and subsequent increases in horizontal export to other ocean basins after bias correction. The results suggest regional differences in the processes governing Southern Ocean heat export, such as the formation of Antarctic Intermediate Water (AAIW), Subpolar Mode Water (SPMW), and gyre transport between the two models, and that sea level changes in these models cannot be fully bias-corrected. Since the process-level differences between the two models are evident in the preindustrial control simulations of both models, these results suggest that the control simulations are important for identifying and correcting sea level–related model biases.

Krasting, John P. [a NOAA/OAR/Geophysical Fluid Dy↗
DOE OSTI2021

A study of real-world micrograph data quality and machine learning model robustness

Abstract Machine-learning (ML) techniques hold the potential of enabling efficient quantitative micrograph analysis, but the robustness of ML models with respect to real-world micrograph quality variations has not been carefully evaluated. We collected thousands of scanning electron microscopy (SEM) micrographs for molecular solid materials, in which image pixel intensities vary due to both the microstructure content and microscope instrument conditions. We then built ML models to predict the ultimate compressive strength (UCS) of consolidated molecular solids, by encoding micrographs with different image feature descriptors and training a random forest regressor, and by training an end-to-end deep-learning (DL) model. Results show that instrument-induced pixel intensity signals can affect ML model predictions in a consistently negative way. As a remedy, we explored intensity normalization techniques. It is seen that intensity normalization helps to improve micrograph data quality and ML model robustness, but microscope-induced intensity variations can be difficult to eliminate.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Sensitivity of Arctic Clouds to Ice Microphysical Processes in the NorESM2 Climate Model

Abstract Ice formation remains one of the most poorly represented microphysical processes in climate models. While primary ice production (PIP) parameterizations are known to have a large influence on the modeled cloud properties, the representation of secondary ice production (SIP) is incomplete and its corresponding impact is therefore largely unquantified. Furthermore, ice aggregation is another important process for the total cloud ice budget, which also remains largely unconstrained. In this study, we examine the impact of PIP, SIP, and ice aggregation on Arctic clouds, using the Norwegian Earth System Model, version 2 (NorESM2). Simulations with both prognostic and diagnostic PIP show that heterogeneous freezing alone cannot reproduce the observed cloud ice content. The implementation of missing SIP mechanisms (collisional breakup, drop shattering, and sublimation breakup) in NorESM2 improves the modeled ice properties, while improvements in liquid content occur only in simulations with prognostic PIP. However, results are sensitive to the description of collisional breakup. This mechanism, which dominates SIP in the examined conditions, is very sensitive to the treatment of the sublimation correction factor, a poorly constrained parameter that is included in the utilized parameterization. Finally, variations in ice aggregation treatment can also significantly impact cloud properties, mainly through their impact on collisional breakup efficiency. Overall, enhancement in ice production through the addition of SIP mechanisms and the reduction in ice aggregation (in line with radar observations of shallow Arctic clouds) result in enhanced cloud cover and decreased TOA radiation biases, compared to satellite measurements, especially during the cold months. Significance Statement Arctic clouds remain a large source of uncertainty in projections of the future climate due to the poor representation of the microphysical processes that govern their life cycle. Ice formation is among the least understood processes. While it is widely recognized that better constraints on primary ice production (PIP) are needed to improve existing parameterizations, we show that secondary ice production (SIP) and ice aggregation can have also a significant impact on ice number concentrations. Constraining ice formation through the addition of missing SIP mechanisms and reducing ice aggregation can improve the representation of the cloud macrophysical properties and enhance total cloud cover in the Arctic region, which in turn contributes to decreased TOA radiation biases in the cold months.

Meteorology & Atmospheric Sciences↗
DOE OSTI2024

Underestimation of multi-decadal global O 2 loss due to an optimal interpolation method

Abstract. The global ocean's oxygen content has declined significantly over the past several decades and is expected to continue decreasing under global warming, with far-reaching impacts on marine ecosystems and biogeochemical cycling. Determining the oxygen trend, its spatial pattern, and uncertainties from observations is fundamental to our understanding of the changing ocean environment. This study uses a suite of CMIP6 Earth system models to evaluate the biases and uncertainties in oxygen distribution and trends due to sampling sparseness. Model outputs are sub-sampled according to the spatial and temporal distribution of the historical shipboard measurements, and the data gaps are filled by a simple optimal interpolation method using Gaussian covariance with a constant e-folding length scale. Sub-sampled results are compared to full model output, revealing the biases in global and basin-wise oxygen content trends. The simple optimal interpolation underestimates the modeled global deoxygenation trends, capturing approximately two-thirds of the full model trends. The North Atlantic and subpolar North Pacific are relatively well sampled, and the simple optimal interpolation is capable of reconstructing more than 80 % of the oxygen trend in the non-eddying CMIP models. In contrast, pronounced biases are found in the equatorial oceans and the Southern Ocean, where the sampling density is relatively low. The application of the simple optimal interpolation method to the historical dataset estimated the global oxygen loss to be 1.5 % over the past 50 years. However, the ratio of the global oxygen trend between the sub-sampled and full model output has increased the estimated loss rate in the range of 1.7 % to 3.1 % over the past 50 years, which partially overlaps with previous studies. The approach taken in this study can provide a framework for the intercomparison of different statistical gap-filling methods to estimate oxygen content trends and their uncertainties due to sampling sparseness.

Ito, Takamitsu (ORCID:000000019873099X)↗
DOE OSTI2023

Determinants of photochemical characteristics of the photosynthetic electron transport chain of maize

The photosynthetic electron transport chain (ETC) is the bridge that links energy harvesting during the photophysical reactions at one end and energy consumption during the biochemical reactions at the other. Its functioning is thus fundamental for the proper balance between energy supply and demand in photosynthesis. Currently, there is a lack of understanding regarding how the structural properties of the ETC are affected by nutrient availability and plant developmental stages, which is a major roadblock to comprehensive modeling of photosynthesis. Redox parameters reflect the structural controls of ETC on the photochemical reactions and electron transport. We conducted joint measurements of chlorophyll fluorescence (ChlF) and gas exchange under systematically varying environmental conditions and growth stages of maize and sampled foliar nutrient contents. We utilized the recently developed steady-state photochemical model to infer redox parameters of electron transport from these measurements. We found that the inferred values of these photochemical redox parameters varied with leaf macronutrient content. These variations may be caused either directly by these nutrients being components of protein complexes on the ETC or indirectly by their impacts on the structural integrity of the thylakoid and feedback from the biochemical reactions. Also, the redox parameters varied with plant morphology and developmental stage, reflecting seasonal changes in the structural properties of the ETC. Our findings will facilitate the parameterization and simulation of complete models of photosynthesis.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Beyond the visible: Accounting for ultraviolet and far‐red radiation in vegetation productivity and surface energy budgets

Photosynthetically active radiation (PAR) is typically defined as light with a wavelength within 400–700 nm. However, ultra-violet (UV) radiation within 280–400 nm and far-red (FR) radiation within 700–750 nm can also excite photosystems, though not as efficiently as PAR. Vegetation and land surface models (LSMs) typically do not explicitly account for UV's contribution to energy budgets or photosynthesis, nor FR's contribution to photosynthesis. However, whether neglecting UV and FR has significant impacts remains unknown. Here, we explored how canopy radiative transfer (RT) and photosynthesis are impacted when explicitly implementing UV in the canopy RT model and accounting for UV and FR in the photosynthesis models within a next-generation LSM that can simulate hyperspectral canopy RT. We validated our improvements using photosynthesis measurements from plants under different light sources and intensities and surface reflection from an eddy-covariance tower. Our model simulations suggested that at the whole plant level, after accounting for UV and FR explicitly, chlorophyll content, leaf area index (LAI), clumping index, and solar radiation all impact the modeling of gross primary productivity (GPP). At the global scale, mean annual GPP within a grid would increase by up to 7.3% and the increase is proportional to LAI; globally integrated GPP increases by 4.6 PgC year −1 (3.8% of the GPP without accounting for UV + FR). Further, using PAR to proxy UV could overestimate surface albedo by more than 0.1, particularly in the boreal forests. Our results highlight the importance of improving UV and FR in canopy RT and photosynthesis modeling and the necessity to implement hyperspectral or multispectral canopy RT schemes in future vegetation and LSMs.

energy budget↗
DOE OSTI2024

Manufactured solutions for an electromagnetic slot model

The accurate modeling of electromagnetic penetration is an important topic in computational electromagnetics. Electromagnetic penetration occurs through intentional or inadvertent openings in an otherwise closed electromagnetic scatterer, which prevent the contents from being fully shielded from external fields. To efficiently model electromagnetic penetration, aperture or slot models can be used with surface integral equations to solve Maxwell's equations. A necessary step towards establishing the credibility of these models is to assess the correctness of the implementation of the underlying numerical methods through code verification. Surface integral equations and slot models yield multiple interacting sources of numerical error and other challenges, which render traditional code-verification approaches ineffective. In this paper, we provide approaches to separately measure the numerical errors arising from these different error sources for the method-of-moments implementation of the electric-field integral equation with a slot model. Finally, we demonstrate the effectiveness of these approaches for a variety of cases.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Environmental Controls on Water Vapor Deuterium Excess in the Coastal Boundary Layer: An Information Theory Perspective

We use information theory to quantify the environmental controls on water vapor deuterium excess (D-excess) in coastal Southern California from June 2023 through February 2024. Using Shannon entropy, mutual information (MI), and joint mutual information, metrics that capture both linear and nonlinear relationships, we identify the most informative variables and variable combinations governing D-excess across contrasting marine and continental regimes. Relative humidity with respect to sea surface temperature (RHS) is consistently the strongest individual predictor, explaining up to 27% of D-excess variability during marine conditions but only 10% in continental air masses. The Relative humidity(RHS) + sea surface temperature (SST) combination demonstrates synergistic effects, where their joint influence (explaining up to 36% of D-excess variability) exceeds what either variable achieves individually, confirming their coupled influence on deuterium excess. Wind direction complements RHS most effectively during continental conditions. The best three-variable combination (RHS + SST + Planetary Boundary Layer height) explains 38% of D-excess variability in marine air, while no combination exceeds 20% explanatory power during continental periods. Information theory shows that heteroscedasticity in D-excess relationships indicates regime shifts in controlling processes and quantifies fundamental constraints on predictor variables: some environmental factors like surface pressure or water vapor flux contain insufficient information content to explain D-excess variability regardless of their physical relevance. These results highlight the different predictability limits between marine and continental regimes, challenging the adequacy of linear models and providing a rigorous framework for quantifying the information content of isotope-climate relationships with implications for both modern and paleoclimate applications.

information theory↗
DOE OSTI2026

Upper ocean mixing, surface heat fluxes, and heat content variability in the upper 150 m during Hurricane Laura (2020)

Observations (from thermistor sensors and a hurricane glider) and model-based temperature were used to answer questions including the following: 1) What physical and environmental conditions explain the rapid intensification of Hurricane Laura? 2) How did the pre-existing warm mixed layer at Stone mooring (StM) influence the degree of cooling in the mixed layer? 3) How did vertical mixing, surface heat fluxes, and advective processes collectively shape the mixed layer heat evolution at StM? Observations measured by thermistor sensors showed that Hurricane Laura induced a cooling of -1.2oC in the mixed layer when Hurricane Laura’s wind speed increased to 47 m/s on 26 August. This contrasts with the -1.04oC mixed layer temperature change estimated from model-based temperature. At StM, the presence of a 31oC warm mixed layer and elevated heat content (60-80kJ/cm2) effectively preconditioned the upper ocean ahead of Hurricane Laura’s passage. After Hurricane Laura passed, turbulent mixing associated with the storm transported the heat anomalies downward into subsurface layers. In addition, this study shows that a surface heat flux of 5.04 kJ/cm2 supported the intensity of Hurricane Laura as it traversed over the StM. Using a mixed layer heat balance model, this study shows that entrainment flux and surface flux mostly contributed to the observed change in the mixed layer temperature.

Tsai, Senam↗
DOE OSTI2020

A Fluorination Method for Improving Cation-Disordered Rocksalt Cathode Performance

In Li-rich cation-disordered rocksalt oxide cathodes (DRX), partial fluorine substitution in the oxygen anion sublattice can increase the capacity contribution from transition-metal (TM) redox while reducing that from the less reversible oxygen redox. To date, limited fluorination substitution has been achieved by introducing LiF precursor during the solid-state synthesis. To take full advantage of the fluorination effect, however, a higher F content is desired. In the present study, the successful use of a fluorinated polymeric precursor is reported to increase the F solubility in DRX and the incorporation of F content up to 10–12.5 at% into the rocksalt lattice of a model Li-Mn-Nb-O (LMNO) system, largely exceeding the 7.5 at% limit achieved with LiF synthesis. Higher F content in the fluorinated-DRX (F-DRX) significantly improves electrochemical performance, with a reversible discharge capacity of ≈255 mAh g –1 achieved at 10 at% of F substitution. After 30 cycles, up to a 40% increase in capacity retention is achieved through the fluorination. Overall, the study demonstrates the feasibility of using a new and effective fluorination process to synthesize advanced DRX cathode materials.

25 ENERGY STORAGE↗
DOE OSTI2026

Tailoring Thermal and Mechanical Performance Through Multimaterial Laser Powder Directed Energy Deposition of Copper and 17-4PH Stainless Steel

This study investigates the additive manufacturing (AM) processing, microstructural evolution, and resulting mechanical and thermal properties of multimaterial components combining 17-4PH stainless steel and pure copper (Cu) fabricated via laser powder directed energy deposition (LP-DED). Conventional tooling steels exhibit limited thermal conductivity, significantly constraining production throughput in high-volume processes. Incorporating Cu, with its superior thermal conductivity, could significantly enhance tool performance, though Cu and steel present metallurgical incompatibilities when processed via AM. A systematic investigation was conducted across compositions ranging from 0 to 100 wt% Cu, revealing critical thresholds influencing solidification behavior, defect formation, microstructure, hardness, and thermal transport. Optical microscopy, electron backscatter diffraction (EBSD), hardness testing, and thermal conductivity measurements provided comprehensive process–structure–property correlations. Severe hot cracking occurred at low-Cu contents (6–25 wt%), aligning generally well with crack susceptibility modeling, with an unexpected discrepancy at 25 wt%. Porosity remained low (≥99% dense) throughout the compositional spectrum. EBSD analysis revealed a transformation from columnar martensitic structures at low-Cu contents to equiaxed FCC Cu-dominated structures at higher Cu concentrations, highlighting the complex microstructural transitions driven by Cu-induced changes in solidification and phase stability. Hardness decreased from 330 HV (pure 17-4PH) to 62 HV (pure Cu), consistent with microstructural changes. Concurrently, thermal conductivity improved substantially from 13.5 W/m K to 367.9 W/m K, emphasizing Cu’s dominant role in thermal transport. The findings highlight the feasibility of leveraging compositional gradients between 17-4PH and Cu to achieve tailored tooling with optimized thermal and mechanical performance.

17-4PH↗