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At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

CoSn-type NiIn1–xSbx (0 ≤ x ≤ 0.17): Site-Selective Substitution, Electronic Structure, Chemical Bonding, and Structural Transformation

CoSn-type intermetallic compounds have emerged as a model platform for Kagome-derived flat-band physics, where subtle chemical perturbations can strongly influence electronic structure and phase stability. Here, we present a combined experimental and theoretical study of Sb-substitution in CoSn-type NiIn1–xSbx (0 ≤ x ≤ 0.17) to elucidate the interplay between site selectivity, solubility limit, chemical bonding, and electronic structure. Rietveld refinements on Neutron powder diffraction data confirmed the selective Sb-substitution at the electron-rich In2 (2d) site forming the honeycomb substructure, while the In1 (1a) site within the Kagome layer remains exclusively occupied by In. Density functional theory (DFT) calculations revealed that pristine CoSn-type NiIn hosts Ni 3d-dominated flat bands near the Fermi level (EF), originating from the Kagome-like Ni substructure. Partial replacement of In by Sb within the honeycomb layer alters these flat-band features below EF, reducing the density of states and suppressing the flat-band topology near the Fermi level. Orbital-resolved electronic structure and chemical-bonding analyses show that Sb-substitution enhances Ni-p-block (In/Sb) covalency and optimizes charge compensation, stabilizing the CoSn-type structure up to the solubility limit x ≈ 0.17. Beyond the limit, the higher-Sb compositions show satellite reflections consistent with an incommensurately modulated phase. These results establish a link between site-selective chemical substitution, bonding optimization, and flat-band electronic structure evolution, providing fundamental insights into how chemical substitution influences the electronic properties of Kagome-based intermetallic compounds.

Roy, Nilanjan [National Institute of Technology Si↗
DOE OSTI2022

Illuminating the Photophysics of Oxygen Atom Transfer in Rare Earth Metal-Organic Complexes

Industrial separations of rare earth metals are reliant on selectivity based on ionic radii, which are time, energy, and resource consuming.1 The unique and discontinuous manifold of energy states associated with the f-electron configurations of the rare earth ions2 offer an opportunity to overcome some of these limitations by incorporating light into the separation process. Here, we use transient absorption spectroscopy to understand the differences in mechanism of light-initiated oxygen atom transfer (OAT) in yttrium (Y) and dysprosium (Dy) rare earth complexes. These metal-organic complexes are functionalized with hexfluoroacetyl-acetonate (hfac) and 4-methylmorpholine-N-oxide (NMMO). After light absorption in the presence of triphenyl phosphine (TPP), the NMMO in the Y-NMMO complex is replaced by the TPPO OAT reaction product. Because the Dy f-electron manifold is accessible to the ligand excited states, while there are no accessible states associated with f-electrons for Y, there are significant differences in reactivity. Transient absorption spectroscopy (TAS) was used to monitor changes after 340 nm photoexcitation of Dy/Y-NMMO or the product complex Dy/Y-TPPO. TAS is a pump-probe technique where a white light probe pulse is delayed relative to a visible pump pulse, which photoexcites a sample. Differences between the ground and excited states are monitored over time. With TAS, we access time scales from 100 fs-400 us to determine the photophysics of the complexes of interest. Photoexcitation of Y-NMMO (Fig. 1A) creates a broad photoinduced absorption (PIA) that evolves into a sharp positive feature over 4.2 ps centered at 450 nm. A secondary feature centered at 550 nm grows in with a 200 ps time constant and remains through the 5 ns time window of our experiment. Control experiments for Y-TPPO reveal that the feature at 450 nm is due to internal dynamics of the hfac ligand, while the 550 nm shoulder is due to the presence of the NMMO. Comparing kinetics at 550 nm for Y-NMMO and Dy-NMMO (Fig. 1B) shows that while Y exhibits a distinct growth in the NMMO feature, the Dy decays almost completely within 5 ns. Control experiments with Dy-TPPO prove that the ligand excited states centered on the hfac ligand are deactivated via energy transfer to the Dy manifold within 200 ps. This deactivation leads to significant differences in OAT reactivity between Y and Dy.

CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSICS↗
DOE OSTI2025

The Fermi function and the neutron's lifetime

The traditional Fermi function ansatz for nuclear beta decay describes enhanced perturbative effects in the limit of large nuclear charge Z and/or small electron velocity β. We define and compute the quantum field theory object that replaces this ansatz for neutron beta decay, where neither of these limits hold. We present a new factorization formula that applies in the limit of small electron mass, analyze the components of this formula through two loop order, and resum perturbative corrections that are enhanced by large logarithms. We apply our results to the neutron lifetime, supplying the first two-loop input to the long-distance corrections. Our result can be summarized as τ n x |V ud | 2 [1 + 3λ 2 ] [1 + Δ R ] = $\frac{5263.284(17) s}{1 + 27.04(7) x 10^{-3}}$ with |V ud | the up-down quark mixing parameter, τ n the neutron's lifetime, λ the ratio of axial to vector charge, and Δ R the short-distance matching correction. We find a shift in the long-distance radiative corrections compared to previous work, and discuss implications for extractions of |V ud | and tests of the Standard Model.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2026

Advancing density functional tight-binding method for large organic molecules through equivariant neural networks

Semi-empirical quantum-mechanical (QM) methods have become valuable tools for studying complex (bio)molecular systems due to their balance between computational efficiency and accuracy. A key aspect of these methods is their parameterization, which not only governs the reliability of the results but also provides an opportunity to enhance their overall performance. In our previous work [J. Phys. Chem. Lett., 2021, 11, 16], we advanced the third-order semi-empirical density functional tight-binding (DFTB3) method for computing multiple properties of small molecules by developing the machine learning (ML) potential NN rep to bridge the gap between DFTB3 electronic components and those of the hybrid DFT-PBE0 functional. To overcome the limitations of NN rep , we introduce the EquiDTB framework, which leverages physics-inspired equivariant neural networks (NN) to parameterize scalable and transferable many-body Δ TB potentials, replacing the standard pairwise DFTB repulsive potential. This advancement extends the applicability of our ML-corrected DFTB approach to larger molecules and non-covalent systems (including only C, N, O, and H atoms), going beyond the chemical space represented in the training QM datasets. The enhanced performance of EquiDTB over the standard TB methods is demonstrated by the accurate computation of the atomic forces of S66x8 molecular dimers, as well as their interaction energies. Moreover, EquiDTB can be effectively employed to explore the potential energy surfaces of large and flexible drug-like molecules—for example, to determine the minimum energy path between isomers, analyze structural transitions during dynamical simulations, compute vibrational modes, and investigate energetic rankings. The performance for single molecules slightly decreases when the DFTB electronic energy is reduced to first-order but remains superior to standard TB methods. Our work thus demonstrates that an optimal integration of an equivariant NN with QM datasets can advance the DFTB method while maintaining high efficiency, paving the way for reliable (bio)molecular simulations.

Medrano Sandonas, Leonardo [Technische Universität↗
DOE OSTI2024

A magnetic analog of pressure–strain interaction

We study the evolution equation for magnetic energy density for a non-relativistic magnetized plasma in the (Lagrangian) reference frame comoving with the electron bulk velocity. Analyzing the terms that arise due to the ideal electric field, namely, perpendicular electron compression and magnetic field line bending, we recast them to reveal a quantity with a functional form analogous to the often-studied pressure–strain interaction term that describes one piece of internal energy density evolution of the species in a plasma, except with the species pressure tensor replaced by the magnetic stress tensor. We dub it the “magnetic stress–strain interaction.” We discuss decompositions of the magnetic stress–strain interaction analogous to those used for pressure–strain interaction. These analogies facilitate the interpretation of the evolution of the various forms of energy in magnetized plasmas and should be useful for a wide array of applications, including magnetic reconnection, turbulence, collisionless shocks, and wave–particle interactions. We display and analyze all the terms that can change magnetic energy density in the Lagrangian reference frame of the electrons using a particle-in-cell simulation of magnetic reconnection.

Barbhuiya, M. Hasan (ORCID:0000000163301650)↗
DOE OSTI2022

Single-Atomic Site Catalyst Enhanced Lateral Flow Immunoassay for Point-of-Care Detection of Herbicide

Point-of-care (POC) detection of herbicides is of great importance due to their impact on the environment and potential risks to human health. Here, we design a single-atomic site catalyst (SASC) with excellent peroxidase-like (POD-like) catalytic activity, which enhances the detection performance of corresponding lateral flow immunoassay (LFIA). The iron single-atomic site catalyst (Fe-SASC) is synthesized from hemin-doped ZIF-8, creating active sites that mimic the Fe active center coordination environment of natural enzyme and their functions. Due to its atomically dispersed iron active sites that result in maximum utilization of active metal atoms, the Fe-SASC exhibits superior POD-like activity, which has great potential to replace its natural counterparts. Also, the catalytic mechanism of Fe-SASC is systematically investigated. Utilizing its outstanding catalytic activity, the Fe-SASC is used as label to construct LFIA (Fe-SASC-LFIA) for herbicide detection. The 2,4-dichlorophenoxyacetic acid (2,4-D) is selected as a target here, since it is a commonly used herbicide as well as a biomarker for herbicide exposure evaluation. A linear detection range of 1-250 ng/mL with a low limit of detection (LOD) of 0.82 ng/mL has been achieved. Meanwhile, excellent specificity and selectivity towards 2,4-D have been obtained. The outstanding detection performance of the Fe-SASC-LFIA has also been demonstrated in the detection of human urine samples, indicating the practicability of this POC detection platform for analyzing the 2,4-D exposure level of a person. We believe this proposed Fe-SASC-LFIA has potential as a portable, rapid, and high-sensitive POC detection strategy for pesticide exposure evaluation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Supervised learning and the finite-temperature string method for computing committor functions and reaction rates

A central object in the computational studies of rare events is the committor function. Though costly to compute, the committor function encodes complete mechanistic information of the processes involving rare events, including reaction rates and transition-state ensembles. Under the framework of transition path theory, Rotskoff et al. [Proceedings of the 2nd Mathematical and Scientific Machine Learning Conference, Proceedings of Machine Learning Research (PLMR, 2022), Vol. 145, pp. 757–780] proposes an algorithm where a feedback loop couples a neural network that models the committor function with importance sampling, mainly umbrella sampling, which collects data needed for adaptive training. Here, in this work, we show additional modifications are needed to improve the accuracy of the algorithm. The first modification adds elements of supervised learning, which allows the neural network to improve its prediction by fitting to sample-mean estimates of committor values obtained from short molecular dynamics trajectories. The second modification replaces the committor-based umbrella sampling with the finite-temperature string (FTS) method, which enables homogeneous sampling in regions where transition pathways are located. We test our modifications on low-dimensional systems with non-convex potential energy where reference solutions can be found via analytical or finite element methods, and show how combining supervised learning and the FTS method yields accurate computation of committor functions and reaction rates. We also provide an error analysis for algorithms that use the FTS method, using which reaction rates can be accurately estimated during training with a small number of samples. The methods are then applied to a molecular system in which no reference solution is known, where accurate computations of committor functions and reaction rates can still be obtained.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

A rigorous physics-based enhanced parameter estimation (EPE) methodology for calibration of building energy simulations

Buildings rarely perform as designed/simulated and there are numerous tangible benefits if this gap is reconciled. A new scientifically rigorous yet pragmatic methodology for calibrating building energy simulations - called Enhanced Parameter Estimation (EPE) - is proposed that allows physically relevant parameter estimation rather than a blind force-fit to energy use data. Starting with a rapidly created simulation model, calibration is performed in two stages: (a) building shell calibration with the HVAC system replaced by an ideal system that meets the loads (b) HVAC system calibration with the building shell and all internal loads replaced by a box with only process loads. In the first stage, EPE identifies a small number of high-level heat flows in the energy balance, calculates them with specifically tailored individual driving functions, introduces physically significant parameters to best accomplish energy balance, and, estimates the parameters and their uncertainty bounds. Calibration is thus done with corrective heat flows without any arbitrary tuning of input parameters. Calibration accuracy is enhanced by machine learning of the residual errors. The EPE methodology is demonstrated by means of: a synthetic building and an actual 75,000 sq. ft. building in Pennsylvania. Future work needed for widespread application is discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

3D printed lignin/polymer composite with enhanced mechanical and anti-thermal-aging performance

Lignin is the most abundant natural aromatic polymer globally but is still underutilized as a renewable material, even with its versatile properties. One approach to using lignin is to incorporate it in polymer composites, but this application is often limited by the poor mechanical performance of the resultant composite due to the poor interfacial adhesion. Following the structure–property relationship, stronger interactions were designed to be enhanced by alternating the functional groups of lignin. Here, this study applied a demethylation method to hardwood lignin (Ori-Lig) to introduce more phenolic hydroxyl groups. Research studies with rheology behavior and molecular simulations demonstrated that an increased phenolic hydroxyl content could improve the adhesion between the modified lignin (OH-Lig) and the polymer matrix at the interface. The tensile performance of the samples from the fused depositional modeling (FDM) 3D printing technique was also improved due to the improved interfacial adhesion. Specifically, by adding 10 wt% of the modified lignin, the tensile strength of the 3D printed samples could reach 46.1 MPa (40.2 MPa of Polyamide 12, PA12), and Young’s Modulus could be improved to 1.73 GPa (1.48 GPa of PA12). OH-Lig also improved anti-aging performance so that the tensile strength of the OH-Lig composite after thermo-aging (100 h at 140 °C) remained ~48MPa. The enhanced mechanical performance with anti-aging properties indicated that the OH-Lig composite may replace PA12 to reduce the use of petrol-based materials. This work showed the method of purposefully designing and modifying lignin structures to fulfill the interaction requirements between lignin and polymer matrix. The as-prepared lignin could be used to prepare functional composites to achieve improved mechanical performance and targeted functions at the same time.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Development and field demonstration of residential air source integrated heat pump using a three-stage compressor

To promote decarbonization and all electrification at residential sectors, it is necessary to use air source heat pumps (ASHPs) to replace natural gas for space heating and water heating. ASHPs are widely utilized for residential space cooling, heating, and water heating due to their simplicity and cost-effectiveness. However, their performance can be compromised in cold climates, where they may experience reduced heating capacity. A multi-functional heat pump, using a single compressor, to meet all home space conditioning and water heating demands, is an emerging technology. To address this limitation, we have developed and demonstrated an air source integrated heat pump to fulfill comprehensive home comfort requirements. This system employs a three-stage compressor and a single set of heat exchangers and valves, optimizing functionality while minimizing costs. The performance of the developed system was rigorously evaluated in both laboratory and field settings. In laboratory conditions, the system achieved a Seasonal Energy Efficiency Ratio of 17.0 (average COP of 4.98) and a Heating Seasonal Performance Factor of 11.0 (3.22). Additionally, in its most efficient operational mode—combining space cooling and water heating—the unit attained a total energy efficiency exceeding 7.0 seasonal COP in the field and could heat a 189-liter tank of water in just 25 min. The field study corroborated the laboratory findings, validating the system’s performance in real-world conditions. Here, this integrated heat pump represents an ideal solution for decarbonizing homes in northern climates by providing efficient space heating and water heating, thereby replacing the need for natural gas.

Integrated heat pump↗
DOE OSTI2022

Implantable photoelectronic charging (I-PEC) for medical implants

Medical implants with functionalities such as sensing, health monitoring, stimulation, diagnosis, and physiological treatment are rapidly growing. With the increasing functional sophistication and addition of modules such as data transmission, on-chip processing, and data storage, energy demand of the implantable system is also growing. Using implantable energy harvester either to recharge or ultimately replace hazardous battery is essential to provide a long-term sustainable solution. Furthermore, energy harvesting techniques using piezoelectric, thermoelectric, radio frequency power transmission, biofuel, and photoelectronic (or sometimes termed as “photovoltaic” in terms of solar light harvesting, i.e., PV) conversion, have been attempted for the implantable, but these methods are currently limited by insufficient power output, large footprint, and low efficiency. Nevertheless, the planar PV with potential of lighter weight, higher energy density, and higher efficiency, provides promising power solution for in-body medical implants. In this short review, we will discuss the potential opportunities and challenges associated with PV's for medical implants, covering materials, to devices, and to system level requirements.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

Introducing bioderived solvents for safer and more sustainable 19 F benchtop NMR analysis of pyrolysis oils

The development of increasingly sustainable analytical chemistry techniques is a growing area of research. Detailed knowledge of bio-oil composition is crucial for the wider use of this alternative, sustainable fuel product, whether by guiding and optimising the pyrolysis processes or for indicating appropriate upgrading methods. The oxygen-containing species in the oil are most important to analyse as they are key to the long-term stability and further processing of the oil. A common analytical method is derivatisation, inserting 19 F nuclei only into specific compounds in the sample, so that a sparser NMR spectrum of a subset of the compounds present can be acquired with even a benchtop NMR spectrometer. However, the derivatisation reactions themselves are not benign, with the most commonly used method relying on DMF throughout. While DMF is highly effective in facilitating the derivatisation reaction, it is not only harmful but increasingly restricted in use. By substituting DMF with ethyl lactate, the reaction is rendered safer and more sustainable. The change in solvent does not affect the NMR results, with estimates of total carbonyl content comparable with those produced by titration. The spectra acquired are detailed enough to also allow the quantification of the different carbonyl functional groups present. By switching to ethyl lactate, it is possible to increase the amount of water in the solvent mixture, further reducing the environmental impact, user risks and cost of the analytical method. By replacing harmful solvents with greener alternatives, benchtop NMR analyses of pyrolysis oils are increasingly safer to run, increasingly cheaper to run, and increasingly more accessible to a wide range of different users.

Tang, Bridget [Aston University, Birmingham (Unite↗
DOE OSTI2024

CDL2PLC translator v0.1.0

The CDL-PLC translator aims at translating control sequences for building energy systems from the CDL CXF format to the PLCopen XML format. The CDL CXF developed at LBL within the OpenBuildingControl project, and now being standardized via ASHRAE Standard 231P, enables expressing control sequences developed in the simulation environment Modelica in a JSON format. The PLCopen XML is an existing exchange format standardized in IEC 61131-10 for Programmable Logic Controllers (PLCs) following the IEC 61131 standard as one target system of CDL among others. The translation from the CDL CXF to the PLCopen XML contributes to a seamless workflow from the model-based development of control sequences in simulation environments, which is not building practice today, and their digital implementation on building controllers, which replaces graphical and textual documents used for this purpose today. The translator is at a prototypical stage and enables, as a proof of concept, the translation of very simple control sequences composed of 4 selected function blocks out of 137 function blocks defined in CDL. The translation includes the connection of inputs and outputs of function blocks and the expression of a control function in CDL to the equivalent code in IEC 61131-3.

Walther, Karl↗
DOE OSTI2025

Sigma: Uncertainty Propagation for C++

Sigma is a header-only C++-17 library for uncertainty propagation, inspired by uncertainties for Python and Measurements.jl for Julia. The library tracks the functional correlation between dependent and independent variables, ensuring that the uncertainty of the independent variables is properly considered in the calculation of the dependent variables’ uncertainties. It is intended as a near drop-in replacement for the standard floating point types (aside from uncertainty specification), and aims to be easily interoperable with the existing standard types.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2020

The N–terminal zinc finger of CELLULOSE SYNTHASE6 is critical in defining its functional properties by determining the level of homodimerization in Arabidopsis

Primary cell wall cellulose is synthesized by the cellulose synthase complex (CSC) containing CELLULOSE SYNTHASE1 (CESA1), CESA3 and one of four CESA6–like proteins in Arabidopsis. It has been proposed that the CESA6–like proteins occupy the same position in the CSC, but their underlying selection mechanism remains unclear. We produced a chimeric CESA5 by replacing its N–terminal zinc finger with its CESA6 counterpart to investigate the consequences for its homodimerization, a crucial step in forming higher–order structures during assembly of the CSC. We found that the mutant phenotypes of prc1–1, a cesa6 null mutant, were rescued by the chimeric CESA5, and became comparable to the wild type (WT) and prc1–1 complemented by WT CESA6 in regard to plant growth, cellulose content, cellulose microfibril organization, CSC dynamics and subcellular localization. Bimolecular fluorescence complementation assays were employed to evaluate pairwise interactions between the N–terminal regions of CESA1, CESA3, CESA5, CESA6 and the chimeric CESA5. We verified that the chimeric CESA5 explicitly interacted with all the other CESA partners, comparable to CESA6, whereas interaction between CESA5 with itself was significantly weaker than that of all other CESA pairs. Furthermore, our findings suggest that the homodimerization of CESA6 through its N–terminal zinc finger is critical in defining its functional properties, and possibly determines its intrinsic roles in facilitating higher–order structures in CSCs.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Fragment-based determination of a proteinase K structure from MicroED data using ARCIMBOLDO_SHREDDER

Structure determination of novel biological macromolecules by X-ray crystallography can be facilitated by the use of small structural fragments, some of only a few residues in length, as effective search models for molecular replacement to overcome the phase problem. Independence from the need for a complete pre-existing model with sequence similarity to the crystallized molecule is the primary appeal of ARCIMBOLDO , a suite of programs which employs this ab initio algorithm for phase determination. Here, the use of ARCIMBOLDO is investigated to overcome the phase problem with the electron cryomicroscopy (cryoEM) method known as microcrystal electron diffraction (MicroED). The results support the use of the ARCIMBOLDO_SHREDDER pipeline to provide phasing solutions for a structure of proteinase K from 1.6 Å resolution data using model fragments derived from the structures of proteins sharing a sequence identity of as low as 20%. ARCIMBOLDO_SHREDDER identified the most accurate polyalanine fragments from a set of distantly related sequence homologues. Alternatively, such templates were extracted in spherical volumes and given internal degrees of freedom to refine towards the target structure. Both modes relied on the rotation function in Phaser to identify or refine fragment models and its translation function to place them. Model completion from the placed fragments proceeded through phase combination of partial solutions and/or density modification and main-chain autotracing using SHELXE . The combined set of fragments was sufficient to arrive at a solution that resembled that determined by conventional molecular replacement using the known target structure as a search model. This approach obviates the need for a single, complete and highly accurate search model when phasing MicroED data, and permits the evaluation of large fragment libraries for this purpose.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

A CRISPRi-dCas9 System for Archaea and Its Use To Examine Gene Function during Nitrogen Fixation by Methanosarcina acetivorans

CRISPR-based systems are emerging as the premier method to manipulate many cellular processes. In this study, a simple and efficient CRISPR interference (CRISPRi) system for targeted gene repression in archaea was developed. The Methanosarcina acetivorans CRISPR-Cas9 system was repurposed by replacing Cas9 with the catalytically dead Cas9 (dCas9) to generate a CRISPRi-dCas9 system for targeted gene repression. To test the utility of the system, genes involved in nitrogen (N2) fixation were targeted for dCas9-mediated repression. First, the nif operon (nifHI 1 I 2 DKEN) that encodes molybdenum nitrogenase was targeted by separate guide RNAs (gRNAs), one targeting the promoter and the other targeting nifD. Remarkably, growth of M. acetivorans with N 2 was abolished by dCas9-mediated repression of the nif operon with each gRNA. The abundance of nif transcripts was >90% reduced in both strains expressing the gRNAs, and NifD was not detected in cell lysate. Next, we targeted NifB, which is required for nitrogenase cofactor biogenesis. Expression of a gRNA targeting the coding sequence of NifB decreased nifB transcript abundance >85% and impaired but did not abolish growth of M. acetivorans with N2. Finally, to ascertain the ability to study gene regulation using CRISPRi-dCas9, nrpR1, encoding a subunit of the repressor of the nif operon, was targeted. The nrpR1 repression strain grew normally with N2 but had increased nif operon transcript abundance, consistent with NrpR1 acting as a repressor. Furthermore, these results highlight the utility of the system, whereby a single gRNA when expressed with dCas9 can block transcription of targeted genes and operons in M. acetivorans.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Achieving clean production with nanostructured coated milling tools dry machining low carbon steel

The advancement of clean production using nanostructured materials in subtractive manufacturing processes has focused on replacing the use of liquid lubrication with solid lubricants coated to conventional cutting tools machining low carbon steel (~ 0.2 wt. % carbon). However, little is known about the wear mechanisms that dominate such tools when coated with functional graded nanostructured coatings. The present study follows an international standard for characterizing such wear (ISO 8688) but uses advanced measurement techniques such as x-ray fluorescence technology to measure the diffusion of chemical species from tool to workpiece and vice versa, that contributes to tool wear with the view to enhance the principles of cleaner production. The results show that when commercially-available tools coated with the appropriate functionally graded industrial coating, diffusion does not take place and creates an effective chemical barrier during machining. The experimental methods used in the study include machining workpieces using a CNC milling machine, tachometer for measuring spindle speed, dynamometer for measuring cutting forces, infra-red camera for measuring cutting temperatures, chemical species diffusion wear using x-ray florescence detector, and an optical microscope for measuring tool wear. Coupled with the physical measurement of wear, it is concluded that mechanical wear dominates the milling of a low carbon steel and that thermal properties of the coatings do not correlate with such wear. It is also concluded that flank wear as a function of volume of workpiece removed and machining duration (machining index) is a sound method for assessing the transition of the stages of wear during clean machining operations. The present study not only has implication for the design of better cutting tools, but also advances dry machining processes that eliminate the use of liquid lubricants making subtractive production processes cleaner. The main conclusions drawn from this study show that coated tools have a longer life under dry conditions compared to uncoated tools and that there is no correlation between coating properties and tool wear. In conclusion, diffusion of chemical species into the cut chips did not occur because of the lack of thermally induced chemical wear of the cutting tool and that wear is caused by the gradual erosion of the flank face due to the chip abrading the cutting tool.

36 MATERIALS SCIENCE↗