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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 OSTI2023

Finding simplicity: unsupervised discovery of features, patterns, and order parameters via shift-invariant variational autoencoders *

Abstract Recent advances in scanning tunneling and transmission electron microscopies (STM and STEM) have allowed routine generation of large volumes of imaging data containing information on the structure and functionality of materials. The experimental data sets contain signatures of long-range phenomena such as physical order parameter fields, polarization, and strain gradients in STEM, or standing electronic waves and carrier-mediated exchange interactions in STM, all superimposed onto scanning system distortions and gradual changes of contrast due to drift and/or mis-tilt effects. Correspondingly, while the human eye can readily identify certain patterns in the images such as lattice periodicities, repeating structural elements, or microstructures, their automatic extraction and classification are highly non-trivial and universal pathways to accomplish such analyses are absent. We pose that the most distinctive elements of the patterns observed in STM and (S)TEM images are similarity and (almost-) periodicity, behaviors stemming directly from the parsimony of elementary atomic structures, superimposed on the gradual changes reflective of order parameter distributions. However, the discovery of these elements via global Fourier methods is non-trivial due to variability and lack of ideal discrete translation symmetry. To address this problem, we explore the shift-invariant variational autoencoders (shift-VAEs) that allow disentangling characteristic repeating features in the images, their variations, and shifts that inevitably occur when randomly sampling the image space. Shift-VAEs balance the uncertainty in the position of the object of interest with the uncertainty in shape reconstruction. This approach is illustrated for model 1D data, and further extended to synthetic and experimental STM and STEM 2D data. We further introduce an approach for training shift-VAEs that allows finding the latent variables that comport to known physical behavior. In this specific case, the condition is that the latent variable maps should be smooth on the length scale of the atomic lattice (as expected for physical order parameters), but other conditions can be imposed. The opportunities and limitations of the shift VAE analysis for pattern discovery are elucidated.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

New Capabilities for Sampling Tools

This report will discuss new capabilities that have been added to the sample.py and uniform_sampler.py codes. The codes have been updated to allow for both log-uniform sampling and categorical variables. The categorical variables do not have to be numeric. The different values for a categorical variable are specified in a limits file by having spaces between them. The difference between sample.py and uniform_sampler.py is that sample.py is for generating random samples and uniform_sampler.py is for generating samples or points on a fixed grid. After sourcing a file to set the environment, execute the codes with the commands: sample.py and uniform sampler.py .

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Investigating performance and variability of NIF ICF experiments with deep learning

The parameter space involved in designing an inertial confinement fusion shot at the National Ignition Facility (NIF) is massively multi-dimensional and the cost of a single shot makes a comprehensive set of sensitivity studies in the laboratory impractical. The use of machine learning to overcome these challenges has gained popularity and has had several successful applications by the scientific community. We extend on these efforts by training a neural network (NN) on information about the experimental design, engineering elements, and drive asymmetry to predict with uncertainty the neutron yield of an experiment. We find the measured and model predicted values are in good agreement, with an R 2 value of 0.91 for a randomly selected test dataset. Almost all the predicted 95% credible intervals contain the corresponding measured value for both training and test datasets. We identify correlations picked up by the NN between the shot design, yield, and variability and use them to motivate shot sensitivity studies. The first shot to exceed the Lawson-like ignition criteria (N210808) was conducted at the NIF and subsequent shots studied the design’s robustness. In a follow-up shot to N210808, our model predicts capsule quality to be the main performance degradation mechanism that prevented the shot from repeating previous performance levels. Shot N221204 was the first shot to exceed a target energy gain of 1. Our model predicts increased yield with reduced coast time for a N221204 study and greater variability for designs with lower peak powers at constant yield. The model’s fast prediction speed and uncertainty prediction are useful for identifying interesting design paths that could warrant further investigation with conventional simulations to search for robust high yield designs.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Adaptive Interface-PINNs (AdaI-PINNs) for inverse problems: Determining material properties for heterogeneous systems

Here, we determine spatially varying discontinuous material properties using a domain-decomposition based physics-informed neural networks (PINNs) framework named the Adaptive Interface-PINNs or AdaI-PINNs (Roy et al., 2024). We propose the use of distinct neural networks for the field variables and material properties within each material, utilizing adaptive activation functions. While the neural networks across different materials share the same weights and biases, their activation functions are uniquely tailored using a hyperparameter that influences the slope of the activation function. The proposed framework is tested on several one-dimensional and two-dimensional benchmark examples, and its performance is compared with conventional PINNs and existing domain-decomposition PINNs frameworks, namely, the Multi-domain physics-informed neural network (M-PINN), and the eXtended physics-informed neural networks (XPINNs). The results demonstrate that the proposed approach can determine randomly distributed discontinuous material properties with an L 2 error of $\mathscr{O}$ (10 -3 ) for the material property and the root-mean-square error of $\mathscr{O}$ (10 -3 ) for the primary variable while the other approaches yield errors that are approximately two orders of magnitude larger (that is, $\mathscr{O}$ (10 -1 )). Moreover, the spatial distribution of material properties obtained using the proposed framework is in close agreement with the true distribution, whereas the other approaches fare much worse. Additionally, the proposed approach is approximately 40% faster than its competitors, indicating its potential as a robust alternative for solving inverse problems in heterogeneous materials.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Megadrought: A Series of Unfortunate La Niña Events?

Megadroughts are multidecadal periods of aridity more persistent than most droughts during the instrumental period. Paleoclimate evidence suggests that megadroughts occur in many parts of the world, including North America, Central America, western Europe, eastern Asia, and northern Africa. It remains unclear to what extent such megadroughts require external forcing or whether they can arise from internal climate variability alone. A novel statistical–dynamical approach is used to evaluate the possibility that such events arise solely as a function of interannual tropical sea surface temperature (SST) variations. A statistical emulator of tropical SST variations is constructed by using an empirical moving-blocks bootstrap approach that randomly samples multiyear sequences of the observational SST record. This approach preserves the power spectrum, seasonal cycle, and spatial pattern of El Niño-Southern Oscillation (ENSO) but removes longer timescale fluctuations embedded in the observational record. These resampled SST anomalies are then used to force an atmospheric model (the Community Atmosphere Model Version 5). As megadroughts emerge in this run, they should, therefore, be solely a consequence of La Niña sequences combined with internal atmospheric variability and persistence driven by soil moisture storage and other land-surface processes. We indeed find that megadroughts in this simulation have an amplitude-duration rate that is generally indistinguishable from the rate documented in paleoclimate records of the western United States. Our findings support the idea that megadroughts may occur randomly when the unforced climate system evolves freely over a sufficiently long period of time, implying that an unforced unusual but statistically plausible series of La Niña events may be sufficient to generate megadrought.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Machine learning to predict biomass sorghum yields under future climate scenarios

Crop yield modeling is critical in the design of national strategies for agricultural production, particularly in the context of a changing climate. Forecasting yields of bioenergy crops at fine spatial resolutions can help to evaluate near-term and long-term pathways for scaling up bio-based fuel and chemical production, and for understanding the impacts of abiotic stressors such as severe droughts and temperature extremes on potential biomass supply. In this work we used a large dataset of 28,364 Sorghum bicolor yield samples (uniquely identified by county and year of observation), environmental variables, and multiple approaches to analyze historical trends in sorghum productivity across the USA. We selected the most accurate machine learning approach (a variation of the random forest approach) to predict future trends in sorghum yields under four greenhouse gas (GHG) emission scenarios and two irrigation regimes. We identified irrigation practices, vapor pressure deficit, and time (a proxy for technological improvement) as the most important predictors of sorghum productivity. Our results showed a decreasing trend of sorghum yields over future years (on average 2.7% from 2018 to 2099), with greater decline under a high GHG emissions scenario (3.8%) and in the absence of irrigation (4.6%). Geographically, we observed the steepest predicted declines in the Great Lakes (8.2%), Upper Midwest (7.5%), and Heartland (6.7%) regions. Our study demonstrates the use of machine learning to identify environmental controllers of sorghum biomass yield and predict yields with reasonable accuracy. These results can inform the development of more realistic biomass supply projections for bioenergy if sorghum production is scaled up. (c) 2020 Society of Chemical Industry and John Wiley & Sons, Ltd

09 BIOMASS FUELS↗
DOE OSTI2021

Scale-dependent spatial variabilities of hydrological exchange flows and transit time in a large regulated river

Hydrological exchange flows (HEF) across the river-aquifer interface and the associated residence time of river water in the aquifer have important implications for contaminant plume migration and biogeochemical processes in the river corridor. HEFs and residence time are influenced by both subsurface physical features and hydrologic forcing related to the transport process, which can exhibit complex spatial and temporal variations. In this study, we used a massively parallel subsurface flow model and a particle-tracking model to study the influences of different control factors on spatial variability of HEFs and residence time distributions (RTD) in the Hanford Reach of the Columbia River in Washington State. A total number of 100M particles were randomly injected in time and space and then tracked in a model domain that covers a 51-km 2 area (15.1M model cells). We used hourly river stages and groundwater levels to drive the model to provide dynamic velocity fields for the particle tracking in the simulation period that was longer than 2 years. The groundwater flow simulation and particle-tracking results provide the first comprehensive assessment of the spatial distribution of HEFs and residence time in large complex river corridors. Overall, our results show that the aquifer hydrogeological structure has the strongest correlation with the extent and magnitude of exchange flux. The residence time exhibits complex patterns that are impacted by all the river geomorphologic, hydrodynamic, and hydrogeologic factors and are strongly correlated with the downwelling ratio of exchange flux. The new insights gained through this study can be used to support the development of reduced-order models of HEFs and RTDs for large complex river systems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

An investigation of Newton-Sketch and subsampled Newton methods

Sketching, a dimensionality reduction technique, has received much attention in the statistics community. In this paper, we study sketching in the context of Newton's method for solving finite-sum optimization problems in which the number of variables and data points are both large. In this work, we study two forms of sketching that perform dimensionality reduction in data space: Hessian subsampling and randomized Hadamard transformations. Each has its own advantages, and their relative tradeoffs have not been investigated in the optimization literature. Additionally, our study focuses on practical versions of the two methods in which the resulting linear systems of equations are solved approximately, at every iteration, using an iterative solver. The advantages of using the conjugate gradient method vs. a stochastic gradient iteration are revealed through a set of numerical experiments, and a complexity analysis of the Hessian subsampling method is presented.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Toward Drilling the Perfect Geothermal Well: An International Research Coordination Network for Geothermal Drilling Optimization Supported by Deep Machine Learning and Cloud Based Data Aggregation

The EDGE project, supported by the U.S. Department of Energy Geothermal Technologies Office under award DE-EE0008793, established a data-driven framework for improving the efficiency, cost-effectiveness, and reliability of geothermal well drilling. The project focused on developing scalable data infrastructure, advanced machine learning and probabilistic models, and integrated analytics tools to support continuous drilling optimization. A central objective was to reduce geothermal drilling costs by up to seventy percent while minimizing the risk of well failure through predictive diagnostics and adaptive planning. Over the project period, a comprehensive data repository was designed and deployed, incorporating records from over one hundred geothermal wells across varied geological settings. This repository supported both structured and unstructured data and adhered to FAIR data principles, enabling provenance tracking, quality control, and standardized metadata. The project introduced automated ingestion pipelines and a cloud-hosted platform that facilitated access to raw, processed, and derived datasets. This infrastructure served as the foundation for model development and analysis. Machine learning workflows were developed to predict key drilling metrics including rate of penetration, non-productive time, and total drilling costs. Self-organizing maps and dimensionality reduction methods were used to uncover operational patterns and outliers, while supervised learning algorithms such as random forests and deep neural networks were applied to forecast performance outcomes. The models were validated on heterogeneous datasets from both U.S. and Icelandic fields, demonstrating variable but significant predictive accuracy. The results indicated that finer temporal resolution, inclusion of lithological data, and consistency in operational annotations could substantially improve model performance. The project also implemented process mining techniques to reconstruct state-transition models from drilling event logs. These models enabled the identification of deviations from optimal workflows and provided insights into recurring failure modes. Analysis of non-productive time highlighted the impact of equipment failures, geological challenges, and human factors, offering opportunities for targeted mitigation strategies. The EDGE Dashboard was developed as a web-based expert system integrating data visualization, model outputs, and user-driven queries. It provided an accessible interface for operators to explore historical data, evaluate predicted outcomes, and compare drilling scenarios. Initial feedback from project partners suggested that the dashboard could serve as a foundation for more advanced advisory and optimization tools. Overall, the EDGE project demonstrated the feasibility and value of applying modern data science techniques to geothermal drilling. It delivered a set of interoperable tools and models that can support more efficient, lower-risk well development. The findings point toward a viable path for transitioning from advisory analytics to semi-autonomous drilling systems, contingent on continued collaboration, expanded datasets, and field validation. The project results have immediate relevance for drilling operations, data management practices, and future geothermal R&D efforts aimed at achieving reliable, cost-competitive geothermal energy at scale.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

Understanding the Seismic Ground Motion Spatial Variability Using Network Analysis Community Detection

This project is to explore ground motion spatial distribution using a new approach graph-based network analysis. In this study, we combine a large-N seismic array and graph analytics to explore spatial variability and correlation at a local scale using small local and regional earthquakes. In this method, each seismic station is modeled as a node and the similarities of the waveforms that represent ground motions between two stations are modeled as edges. By analyzing this graph network using the similarity matrices and community detection algorithm, we can group the stations spatially with similar patterns. A random forest algorithm is used to reveal the important features that affect the spatial grouping. The result suggests site conditions, and how they interact with the incident seismic wavefield, strongly condition the spatial correlation of ground motion. Future progress in characterizing ground motion spatial variability will require dense wavefield measurements, either through nodal deployments, or perhaps distributed acoustic sensing measurements of seismic wavefields.

58 GEOSCIENCES↗
DOE OSTI2025

Data-Driven Closures and Assimilation for Stiff Multiscale Random Dynamics

Here, we introduce a data-driven and physics-informed framework for propagating uncertainty in stiff, multiscale random ordinary differential equations (RODEs) driven by correlated (colored) noise. Unlike systems subjected to Gaussian white noise, a deterministic equation for the joint probability density function (PDF) of RODE state variables does not exist in closed form. Moreover, such an equation would require as many phase-space variables as there are states in the RODE system. To alleviate this curse of dimensionality, we instead derive exact, albeit unclosed, reduced-order PDF (RoPDF) equations for low-dimensional observables/quantities of interest. The unclosed terms take the form of state-dependent conditional expectations, which are directly estimated from data at sparse observation times. However, for systems exhibiting stiff, multiscale dynamics, data sparsity introduces regression discrepancies that compound during RoPDF evolution. This is overcome by introducing a kinetic-like defect term to the RoPDF equation, which is learned by assimilating in sparse, low-fidelity RoPDF estimates. Two assimilation methods are considered, namely nudging and deep neural networks, which are successfully tested against Monte Carlo simulations.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

A review of imputation strategies for isobaric labeling-based shotgun proteomics

The throughput efficiency and increased depth of coverage provided by isobaric-labeled proteomics measurements have led to increased usage of these techniques. However, the structure of missing data is uniquely different than unlabeled studies. In this review, we compare the efficacy of nine imputation methods on a CPTAC proteomics iTRAQ dataset. Imputation methods were evaluated with regard to accuracy, variability, statistical hypothesis test inference and run time over datasets consisting of varying number of iTRAQ plexes and percentages of missing data. In general, expectation maximization and random forest imputation methods yielded the best performances, and constant-based methods performed poorly consistently across all dataset sizes and percentages of missing values. For datasets with small sample sizes and higher percentages of missing data, results indicate that statistical inference with no imputation may be preferable. Based on the findings in this review, there are core imputation methods that perform higher for isobaric-labeled proteomics data, but great care and consideration as to whether imputation should be used should be given for datasets comprised of a small number of samples, as well as to factors such as computational time and reproducibility of imputation values.

Bramer, Lisa M.↗
DOE OSTI2025

Denoising Autoencoder for Reconstructing Sensor Observation Data and Predicting Evapotranspiration: Noisy and Missing Values Repair and Uncertainty Quantification

Abstract Machine learning (ML) methods applied in scientific research often deal with interrelated features in high‐dimensional data. Reducing data noise and redundancy is needed to increase prediction accuracy and efficiency especially when dealing with data from field sensors. We explored an unsupervised learning method, the denoising autoencoder (DAE), to extract the underlying data structure from noisy raw data in the context of predicting hydrologic quantities from multiple field sensors. These sensors have intrinsic instrumental noise and occasional malfunctions that cause missing values. Our DAE neural network reconstructed meteorological sensor data containing noise and missing values to predict evapotranspiration in a mountainous watershed. The DAE reconstructed the sensor variables with a mean coefficient of determination value of 0.77 across 15 dimensions representing individual sensors. It reduced variance and bias uncertainties compared to a classical autoencoder model. The reconstruction quality varied across dimensions depending on their cross‐correlation and alignment with the underlying data structure. Uncertainties arising from the model structure were overall higher than those resulting from data corruption. We attached the DAE structure to a downstream ET‐prediction neural network in three formats and achieved reasonably accurate ET predictions . The use of the DAE notably reduced variance uncertainty in ET prediction. However, excessive variance reduction may be accompanied by an increase in bias due to the intrinsic bias‐variance tradeoff. Our method of evaluating and reducing uncertainties in aggregated data from different sources can be used to improve predictive models, process understanding, and uncertainty quantification for better water resource management. Plain Language Summary We present a machine learning method, namely the denoising autoencoder, which reduces the effects of data noise and missing values typically present in scientific data sets collected through sensor measurements. This method selects the most relevant information from noisy raw data collected by the instruments and fills in missing values. To demonstrate the effectiveness of our method, we applied it to predict evapotranspiration, a hydrologic variable that represents the water moved from the land surface to the atmosphere through a combination of evaporation and plant water use (transpiration). We also used a random sampling technique (the Monte Carlo method) to compare the uncertainty in the predictions when using the raw and noisy data versus the reconstructed data. The denoising process produced more accurate predictions of evapotranspiration with less uncertainty. Improved predictions of evapotranspiration can lead to a better understanding and accounting of water budgets. This ML approach is broadly suitable for a wide variety of applications that involve noisy sensor data with missing values. Key Points We used a denoising autoencoder (DAE) neural network to reduce noise in meteorological and soil sensor observations by on average We used Monte Carlo sampling to estimate the bias and variance of all model outputs, including uncertainty sources from data and the model We attached the DAE component to a downstream neural network to predict ET with the variance reduced by , compared to that without the DAE

denoising autoencoder↗
DOE OSTI2020

ROM-Based Surrogate Systems Modeling of EBR-II

We report the System Analysis Module (SAM), developed and maintained by Argonne National Laboratory, is designed to provide whole-plant transient safety analysis capabilities for a number of advanced non-light water reactors, including sodium-cooled fast reactor (SFR), lead-cooled fast reactor (LFR), and molten salt reactor (MSR)/fluoride-salt-cooled high-temperature reactor (FHR) designs. SAM is primarily constructed as a systems-level analysis tool, with the potential to incorporate reduced order models from three-dimensional computational fluid dynamics (CFD) simulations to improve characterization of complex, multidimensional physics. It is recognized that the computational expense associated with CFD can be intractable for various engineering analyses, such as uncertainty quantification, inference, and design optimization. This paper explores the reducibility of a SAM model using recent advances in randomized linear algebra techniques, which attempt to find recurring patterns in the various realizations generated by a model after randomly perturbing all its input parameters. The reduction is described in terms of fewer degrees of freedom (DOFs), referred to as the active DOFs, for the model variables such as input model parameters and model responses. The results indicate that there is significant room for additional reduction that may be leveraged for additional computational gains when employing SAM for engineering-intensive analyses that require repeated model executions. Different from physics-based reduction approaches, the proposed approach allows one to estimate upper bounds on the reduction errors, which are rigorously developed in this work. Finally, different methods for surrogate model construction, such as regression and neural network-based training, are employed to correlate the input and output active DOFs, which are related back to the original variables using matrix-based linear transformations.

42 ENGINEERING↗
DOE OSTI2023

Quantification and prediction of error in MIMO tests

Dynamic testing of systems is most realistic of real-world conditions when multiple input and multiple output (MIMO) techniques are used. To replicate measured environmental conditions, a series of desired outputs (responses) on the system must be realized by inverting the frequency response functions (FRF) matrix for input estimation. System identification is dependent on the number of inputs and outputs, which affect the type of solutions. In input estimation, the auto spectra of the determined inputs are affected by both the auto spectra and cross spectra of the desired outputs. This research evaluates errors and investigates two sources in an experimental setting. The first significant error source is test-to-test variability in FRFs from system identification tests, quantified by magnitude variability from long-duration tests. The second significant error source is the realization of time histories from frequency domain inputs. The spectral content of the realized random process deviates from the desired content and is also quantified. The structure is a linear three-story frame fixed at the base; two inputs are provided uniaxially with the use of suspended electrodynamic shakers. The proposed model for error sources was found to be effective in predicting errors in a SISO (single-input single-output) and a square (2-input 2-output) MIMO test.

Yousef, Odey↗
DOE OSTI2022

Model-Form Epistemic Uncertainty Quantification for Modeling with Differential Equations: Application to Epidemiology

Modeling real-world phenomena to any degree of accuracy is a challenge that the scientific research community has navigated since its foundation. Lack of information and limited computational and observational resources necessitate modeling assumptions which, when invalid, lead to model-form error (MFE). The work reported herein explored a novel method to represent model-form uncertainty (MFU) that combines Bayesian statistics with the emerging field of universal differential equations (UDEs). The fundamental principle behind UDEs is simple: use known equational forms that govern a dynamical system when you have them; then incorporate data-driven approaches – in this case neural networks (NNs) – embedded within the governing equations to learn the interacting terms that were underrepresented. Utilizing epidemiology as our motivating exemplar, this report will highlight the challenges of modeling novel infectious diseases while introducing ways to incorporate NN approximations to MFE. Prior to embarking on a Bayesian calibration, we first explored methods to augment the standard (non-Bayesian) UDE training procedure to account for uncertainty and increase robustness of training. In addition, it is often the case that uncertainty in observations is significant; this may be due to randomness or lack of precision in the measurement process. This uncertainty typically manifests as “noisy” observations which deviate from a true underlying signal. To account for such variability, the NN approximation to MFE is endowed with a probabilistic representation and is updated using available observational data in a Bayesian framework. By representing the MFU explicitly and deploying an embedded, data-driven model, this approach enables an agile, expressive, and interpretable method for representing MFU. In this report we will provide evidence that Bayesian UDEs show promise as a novel framework for any science-based, data-driven MFU representation; while emphasizing that significant advances must be made in the calibration of Bayesian NNs to ensure a robust calibration procedure.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Process Variability Effects on Tensile Response in Injection Molded, Fluorinated Thermoplastics

The mechanical properties of fluorinated thermoplastics (i.e., tensile strength and elongation) can vary with changes in injection molding processing parameters. Four fluoropolymers are examined: poly(vinylidene fluoride) (PVDF) and random poly(vinylidene fluoride-co-chlorotrifluoroethylene) (PVDF-CTFE) with three CTFE concentrations. Dog bones were manufactured with various cylinder dwell times and mold cooling times to assess the manufacturing sensitivity to the tensile response. Dwell and cooling times increasingly impact mechanical performance as CTFE concentration increases. Specimens exhibit higher tensile strength as a function of injection order. The first injected specimen exhibits the lowest tensile strength and highest elongation in all copolymers. This trend becomes more pronounced among fluoropolymers with higher CTFE concentration and lower weight-averaged molecular weight. Parallel plate rheology was used to obtain the zero-shear viscosity as a function of material type, process, and injection order. We found that in the copolymers, the first injected sample exhibited a lower zero-shear viscosity than the next, which indicates a lower molecular weight in the first injected specimen. This phenomenon was not presented for the PVDF homopolymer. Copolymer mechanical uncertainties are hypothesized to result from the shorter molecular weight chains extruding out of the specimens' sides as a flash due to higher mobility with CTFE segments.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Process Variability Effects on Tensile Response in Injection Molded, Fluorinated Thermoplastics

The mechanical properties of fluorinated thermoplastics (i.e., tensile strength and elongation) can vary with changes in injection molding processing parameters. Four fluoropolymers are examined: poly(vinylidene fluoride) (PVDF) and random poly(vinylidene fluoride-co-chlorotrifluoroethylene) (PVDF-CTFE) with three CTFE concentrations. Dog bones were manufactured with various cylinder dwell times and mold cooling times to assess the manufacturing sensitivity to the tensile response. Dwell and cooling times increasingly impact mechanical performance as CTFE concentration increases. Specimens exhibit higher tensile strength as a function of injection order. The first injected specimen exhibits the lowest tensile strength and highest elongation in all copolymers. This trend becomes more pronounced among fluoropolymers with higher CTFE concentration and lower weight-averaged molecular weight. Parallel plate rheology was used to obtain the zero-shear viscosity as a function of material type, process, and injection order. We found that in the copolymers, the first injected sample exhibited a lower zero-shear viscosity than the next, which indicates a lower molecular weight in the first injected specimen. This phenomenon was not present for the PVDF homopolymer. Copolymer mechanical uncertainties are hypothesized to result from the shorter molecular weight chains extruding out of the specimens’ sides as a flash due to higher mobility with CTFE segments.

36 MATERIALS SCIENCE↗