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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Distribution of rare earth and other critical elements in lignites from the Eocene Jackson Group, Texas

Coal is increasingly evaluated as a source of rare earth elements (REEs) in the United States to address the overreliance on imported REEs. The objective of this study was to assess the distribution of REEs in lignites from selected mining areas in the Texas Gulf Coastal Plain region. Thirty-one archived lignite and rock samples previously collected by the U.S. Geological Survey were analyzed for their rare earth element and critical mineral content. These include samples from one core (5400 and 5500 lignite horizons) and two opencast lignite mines (Gibbons Creek 3500 and 4500 horizons, and San Miguel horizons A to D) in the Eocene Jackson Group of the Texas Gulf of Mexico Coastal Plain. Some lithologies in the Gibbons Creek 3500 and 4500 lignite-bearing sections have high total rare earth, yttrium (Y), and scandium (Sc) (REYSc) values, up to 7800 ppm (ash basis) REYSc. The lignite lithologies show an enrichment in rare earths, [samarium (Sm) through gadolinium (Gd)]. The basal Gibbons Creek 3500 lignite bench shows a heavy rare earth element enrichment pattern resembling that often seen in peats through high volatile A bituminous coals. The 5500 lignite sequence, overlying the latter lignite sections, shows a light rare earth enrichment. The San Miguel lignite benches have heavy rare earth enrichments with a negative europium (Eu) anomaly.

58 GEOSCIENCES↗
DOE OSTI2022

Production of Very Light Elements and Strontium in the Early Ejecta of Neutron Star Mergers

Abstract We study the production of very light elements ( Z < 20) in the dynamical and spiral-wave wind ejecta of binary neutron star mergers by combining detailed nucleosynthesis calculations with the outcome of numerical relativity merger simulations. All our models are targeted to GW170817 and include neutrino radiation. We explore different finite-temperature, composition-dependent nuclear equations of state, and binary mass ratios, and find that hydrogen and helium are the most abundant light elements. For both elements, the decay of free neutrons is the driving nuclear reaction. In particular, ∼0.5–2 × 10 −6 M ⊙ of hydrogen are produced in the fast expanding tail of the dynamical ejecta, while ∼1.5–11 × 10 −6 M ⊙ of helium are synthesized in the bulk of the dynamical ejecta, usually in association with heavy r -process elements. By computing synthetic spectra, we find that the possibility of detecting hydrogen and helium features in kilonova spectra is very unlikely for fiducial masses and luminosities, even when including nonlocal thermodynamic equilibrium effects. The latter could be crucial to observe helium lines a few days after merger for faint kilonovae or for luminous kilonovae ejecting large masses of helium. Finally, we compute the amount of strontium synthesized in the dynamical and spiral-wave wind ejecta, and find that it is consistent with (or even larger than, in the case of a long-lived remnant) the one required to explain early spectral features in the kilonova of GW170817.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Digestion processes and elemental analysis of oxide and sulfide solid electrolytes

Detailed elemental analysis is essential for a successful development and optimization of material systems and synthesis methods. This is especially relevant for Li- and Na-containing compounds, found in state-of-the-art and next-generation battery systems. Their materials’ properties and thus the final device performance strongly depend on the crystal structure, the stoichiometry, and defect chemistry, e.g., influencing charge carrier concentration and activation energies for vacancy transport. However, a detailed quantitative analysis of light elements in a heavy matrix, featuring a broad range of solubilities and vapor pressures, is often difficult and associated with large uncertainties and thus neglected in favor of just reporting the stoichiometry as “weighed in.” Here, in this work, we report several approaches to digest and dissolve various oxide and sulfide-based materials, used in next-generation Li batteries, for elemental analysis via optical emission spectroscopy. These include the most common solid electrolytes Li-La-Ti–O, a perovskite material (LLTO), and Li-La-Zr-O which has garnet structure (LLZO). Additionally, a facile thermal digestion process is reported for a surrogate sulfide solid electrolyte (Na 2 S). The digestion procedures reported here are suitable for almost any laboratory environment and, when applied, will improve understanding of the synthesis-structure–property correlations needed to advanced batteries with all solid-state configurations.

Malkowski, Thomas F.↗
DOE OSTI2021

Distribution of rare earth elements in the pilot-scale processing of fly ashes derived from eastern Kentucky coals: Comparisons of the feed and processed ashes

Beneficiated fly ash from the combustion of Central Appalachian high volatile bituminous coals was extracted with HNO 3 in a pilot-scale processing plant. Several major oxides (notably CaO and SO 3 , but also including Fe 2 O 3 , MgO, K 2 O, and P 2 O 5 ) and minor elements (Mn, As, Sr, Ba, and Pb) are depleted in the post-HNO 3 -extraction spent ash. The total lanthanides, Y, and Sc concentration is reduced by about 20% in the spent ash, with Gd showing the greatest decrease. Along with Gd, Nd and Dy are also well differentiated between the feed and spent ashes, with La and Sm showing minimal partitioning. The Gd decrease is correlated with the depletion of Fe 2 O 3 . The heavy rare earth elements (REE heavier than Eu) and Y are disproportionately concentrated in the HNO 3 -leachate compared to the light REE. For the ashes studied, Sc did not partition between the feed and spent ashes. Pozzolanicity tests show that the compressive strength and strength activity indices of the spent ash + ordinary Portland cement (OPC) mixes are comparable to 100% OPC, indicating that the spent ashes produced in the pilot-scale runs have the potential to be sold as a Class F fly ash. Finally, the beneficiated ash chemistry influences the chemistry of the post-HNO 3 -extraction spent ash and the HNO 3 -leachate. A 500-ppm-REE fly ash will presumably be a more economically favorable feedstock than an ash with a significantly lesser concentration.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Low-energy measurement of the 25 Mg ⁢(𝛼,𝑛)⁢ 28 Si reaction via neutron spectroscopy

During core helium and carbon burning in massive stars, neutrons are produced mainly by the 22 Ne⁢ (𝛼,𝑛) ⁢25 Mg reaction. Some of these released neutrons are captured by heavy seed nuclei from previous nucleosynthesis events, resulting in the slow production of many of the elements between masses 60 ≤ 𝐴 ≤ 90 via the weak 𝑠 process. Determining the overall neutron flux available in this environment is one of the main challenges in modeling its contributions to heavy element production. Not only must the reaction rate be well defined for the primary neutron source, but the rates of neutron poison and recycling reactions must also be well determined. One critical reaction in the simulation network is 25 Mg ⁢(𝛼,𝑛) ⁢ 28 Si. This reaction, together with 25 Mg ⁢(𝑛,𝛾)⁢ 26 Mg and 25 Mg⁢ (𝛼,𝛾) ⁢ 29 Si, determine how 25 Mg nuclei affect the available neutron flux. Past attempts to measure the 25 Mg ⁢(𝛼,𝑛)⁢ 28 Si cross section using neutron moderator counters have been greatly hindered by lower-𝑍 background reactions. Here, in the present work, neutron spectroscopy with deuterated liquid scintillator detectors has been used. The experimental spectra have been analyzed by applying spectrum unfolding techniques to achieve improved background discrimination for the 25 Mg⁢ (𝛼,𝑛)⁢ 28 Si reaction at low energies, down to 𝐸 𝛼 = 1.75 MeV. The separation of the different background contributions gives further insight into the results of previous moderator counter measurements and the measurements lead to a revised and more reliable determination of the reaction rate.

hydrostatic stellar nucleosynthesis↗
DOE OSTI2024

Advances in heavy alkaline earth chemistry provide insight into complexation of weakly polarizing Ra 2+ , Ba 2+ , and Sr 2+ cations

Numerous technologies—with catalytic, therapeutic, and diagnostic applications—would benefit from improved chelation strategies for heavy alkaline earth elements: Ra 2+ , Ba 2+ , and Sr 2+ . Unfortunately, chelating these metals is challenging because of their large size and weak polarizing power. We found 18-crown-6-tetracarboxylic acid (H 4 COCO) bound Ra 2+ , Ba 2+ , and Sr 2+ to form M(H x COCO) x–2 . Upon isolating radioactive 223 Ra from its parent radionuclides ( 227 Ac and 227 Th), 223 Ra 2+ reacted with the fully deprotonated COCO 4- chelator to generate Ra(COCO) 2- (aq) (log K Ra(COCO)2- = 5.97 ± 0.01), a rare example of a molecular radium complex. Comparative analyses with Sr 2+ and Ba 2+ congeners informed on what attributes engendered success in heavy alkaline earth complexation. Chelators with high negative charge [-4 for Ra(COCO) 2- (aq) ] and many donor atoms [≥11 in Ra(COCO) 2- (aq) ] provided a framework for stable complex formation. These conditions achieved steric saturation and overcame the weak polarization powers associated with these large dicationic metals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Removal of Iron from Pyrite-Rich Coal Refuse by Calcination and Magnetic Separation for Hydrometallurgical Extraction of Rare Earth Elements

In the metallurgical extraction of rare earth elements (REEs), the ratio of contaminant ions to REEs in the leachate dictates the cost and operational efficiency of the downstream processes. The current study investigated the potential iron contamination removal from the feed to the hydrometallurgical process by calcination followed by magnetic separation. The 2.20 specific gravity sink fraction of Baker coal seam coarse refuse was pulverized to finer than 180 μm, calcined at various temperatures, and separated into magnetic and non-magnetic fractions using a wet high-intensity magnetic separator at different field strengths. The untreated feed, calcined products, and their subsequent magnetic and non-magnetic fractions were subjected to acid leaching tests with 1.2 M sulfuric acid at 75 °C and 1% w/v solids concentration. The recovery of light and heavy rare earth elements (LREEs and HREEs, respectively) along with the concentration of common contaminant ions (Al, Ca, and Fe) were measured as output variables. The weight percent of magnetic material was maximized at approximately 29% by calcination at a temperature of 400 °C. Magnetic removal of this fraction using a field strength of 1.15 Tesla resulted in the rejection of 81% of the iron. Leaching of the magnetic fraction provided significantly higher Fe recovery relative to untreated feed material and the non-magnetic fraction. The non-magnetic fraction was subsequently calcined at 600 °C to dehydroxylate the clays and released the REE minerals in the same manner as the treatment of the original coarse refuse material. A comparison of the leachate elemental concentrations resulting from the leaching of both the calcined non-magnetic and original coarse refuse showed only a slight reduction in the iron content from the non-magnetic material. This finding combined with the REE loss in the magnetic fraction resulted in the conclusion that the magnetic removal step was unfavorable.

58 GEOSCIENCES↗
DOE OSTI2023

Ultra-low concentration terbium (Tb) adsorption on garlic peels biosorbent and its application for $\mathrm{Nd}$-$\mathrm{Fe}$-$\mathrm{B}$ scraps recovery

Motivated by the strategic value of middle-heavy rare earth elements (MHREEs), we proposed a bio-adsorption method to recover ultra-low concentration terbium (Tb(Ⅲ)) from industrial wastewater that originated from the Nd-Fe-B scraps recovery process. It could be found that Tb(Ⅲ) ions as low as 5.34 ng·mL -1 (ppb) could be adsorbed onto Ca(Ⅱ)-modified garlic peels (Ca-GP) within 10 min with the adsorption efficiency of 99.2% at pH 3.5. The adsorption behavior of Tb(Ⅲ) onto Ca-GP conformed the Langmuir isotherm model and pseudo-second-order kinetic model. Attenuated total reflection Fourier Transform Infrared Spectroscopy (ATR-FTIR), X-ray photoelectron spectroscopy (XPS) and density-functional theory (DFT) calculations results showed that Tb(Ⅲ) ions could be ion-exchanged with cations in Ca-GP such as Ca(Ⅱ) and -COOH. In application, column experiment results showed that the maximum bed adsorption capacity for Tb, praseodymium (Pr), neodymium (Nd), dysprosium (Dy), and Total rare earth elements (REEs) ions calculated by the Thomas model was 0.06, 3.50, 9.65, 7.34, and 27.37 µg·g -1 , respectively, with the initial concentration of 0.37 ng·mL -1 Tb, 20 ng·mL -1 Pr, 44 ng·mL -1 Nd, 67 ng·mL -1 Dy and 170 ng·mL -1 total REEs ions of actual solutions (below the solubility of rare-earth hydroxide). Here this manuscript thus provided a novel cost-effective and efficient approach to the enrichment and recovery of MHREEs from ultra-low concentration REEs ions-containing solutions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Machine learning molecular dynamics simulations toward exploration of high-temperature properties of nuclear fuel materials: case study of thorium dioxide

Predicting materials properties of nuclear fuel compounds is a challenging task in materials science. Their thermodynamical behaviors around and above the operational temperature are essential for the design of nuclear reactors. However, they are not easy to measure, because the target temperature range is too high to perform various standard experiments safely and accurately. Moreover, theoretical methods such as first-principles calculations also suffer from the computational limitations in calculating thermodynamical properties due to their high calculation-costs and complicated electronic structures stemming from f-orbital occupations of valence electrons in actinide elements. Here, we demonstrate, for the first time, machine-learning molecular-dynamics to theoretically explore high-temperature thermodynamical properties of a nuclear fuel material, thorium dioxide. The target compound satisfies first-principles calculation accuracy because f-electron occupation coincidentally diminishes and the scheme meets sampling sufficiency because it works at the computational cost of classical molecular-dynamics levels. We prepare a set of training data using first-principles molecular dynamics with small number of atoms, which cannot directly evaluate thermodynamical properties but captures essential atomistic dynamics at the high temperature range. Then, we construct a machine-learning molecular-dynamics potential and carry out large-scale molecular-dynamics calculations. Consequently, we successfully access two kinds of thermodynamic phase transitions, namely the melting and the anomalous λ transition induced by large diffusions of oxygen atoms. Furthermore, we quantitatively reproduce various experimental data in the best agreement manner by selecting a density functional scheme known as SCAN. Our results suggest that the present scale-up simulation-scheme using machine-learning techniques opens up a new pathway on theoretical studies of not only nuclear fuel compounds, but also a variety of similar materials that contain both heavy and light elements, like thorium dioxide.

74 ATOMIC AND MOLECULAR PHYSICS↗
DOE OSTI2024

Hot-Roll Fabrication of Anisotropic Nanograin Nd-Fe-B Magnet

Nd-Fe-B based magnets have the highest energy product among all permanent magnets, which is required for numerous clean energy technologies. For higher temperature applications (T > 150°C), additions of heavy rare earth elements (HREEs) such as Dy are required to maintain sufficient coercivity during operation. Additions of Dy are expensive. Thus, it is desirable to reduce the need for HREEs by reducing the grain size to the nanoscale, which increases the coercivity and decreases its temperature dependence. Here, we report a novel nanograin Nd-Fe-B magnet fabrication method that is continuous and inexpensive. The process uses mechanically milled Nd-Fe-B melt-spun flakes as feedstock powder that is packed into a metal vessel and then hot rolled to form a fully dense and highly textured strip magnet with tailored thicknesses, down to 800 µm. Finally, using this process, fully dense nanograin bulk magnets can be synthesized in minutes compared to the traditional multi-step processes that are typically low throughput.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Performance of concrete under accelerated physical salt attack and carbonation

Conventional testing of physical salt attack (PSA) on concrete does not consider concomitant factors that may exist in service and alter the mechanisms and kinetics of PSA. This study adopted a combined testing approach where concrete was concurrently investigated under accelerated PSA and carbonation, simulating elements serving in heavy traffic and industrial zones, while implementing ambient conditions similar to that in geographic locations with previous cases of PSA. Based on the tested mixture design parameters [water-to-binder ratio, cement type, and supplementary cementitious materials], potential performance improvement and risks were identified. Thermal, mineralogical, and microscopy analyses elucidated the co-occurrence of complex degradation processes in concrete subjected to accelerated PSA and carbonation, which were distinctive from that induced by the single-factor PSA exposure. The synoptic results from this study may informatively improve guidance on mixture design of concrete when dual exposure to PSA and carbonation is expected in the field.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Contrasting Trivalent Lanthanide and Actinide Complexation by Polyoxometalates via Solution-State NMR

Deciphering the solution chemistry and speciation of actinides is inherently difficult due to radioactivity, rarity, and cost constraints, especially for transplutonium elements. In this context, the development of new chelating platforms for actinides and associated spectroscopic techniques is particularly important. In this study, we investigate a relatively overlooked class of chelators for actinide binding, namely, polyoxometalates (POMs). We provide the first NMR measurements on americium–POM and curium–POM complexes, using one-dimensional (1D) 31 P NMR, variable-temperature NMR, and spin-lattice relaxation time (T 1 ) experiments. The proposed POM–NMR approach allows for the study of trivalent f-elements even when only microgram amounts are available and in phosphate-containing solutions where f-elements are typically insoluble. The solution-state speciation of trivalent americium, curium, plus multiple lanthanide ions (La 3+ , Nd 3+ , Sm 3+ , Eu 3+ , Yb 3+ , and Lu 3+ ), in the presence of the model POM ligand PW 11 O 39 7– was elucidated and revealed the concurrent formation of two stable complexes, [M III (PW 11 O 39 )(H 2 O) x ] 4– and [M III (PW 11 O 39 ) 2 ] 11– . Interconversion reaction constants, reaction enthalpies, and reaction entropies were derived from the NMR data. The NMR results also provide experimental evidence of the weakly paramagnetic nature of the Am 3+ and Cm 3+ ions in solution. Furthermore, the study reveals a previously unnoticed periodicity break along the f-element series with the reversal of T 1 relaxation times of the 1:1 and 1:2 complexes and the preferential formation of the long T 1 species for the early lanthanides versus the short T 1 species for the late lanthanides, americium, and curium. Furthermore, given the broad variety of POM ligands that exist, with many of them containing NMR-active nuclei, the combined POM–NMR approach reported here opens a new avenue to investigate difficult-to-study elements such as heavy actinides and other radionuclides.

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

Electron–Nucleus Hyperfine Coupling Calculated from Restricted Active Space Wavefunctions and an Exact Two-Component Hamiltonian

Exact two-component (X2C) relativistic nuclear hyperfine magnetic field operators were incorporated in X2C ab-initio wavefunction calculations at the multi-reference restricted active space (RAS) level for calculations of nuclear hyperfine magnetic properties. Spin-orbit coupling was treated via RAS state interaction (SO-RASSI). The method was tested by calculations of electron – nucleus hyperfine coupling constants. The approach, implemented in the OpenMolcas program, overcomes a major limitation of a previous SO-RASSI implementation for hyperfine coupling that relied on non-relativistic hyperfine operators [J. Chem. Theor. Comput. 2015, 11, 538–549] and therefore had only limited applicability. Furthermore, results from calculations on systems with light and heavy main group elements, transition metals, lanthanides, and one actinide complex, demonstrate reasonably good agreement with experimental data, where available, as long as the active space can generate sufficient spin polarization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Pnictogen-Bonding Catalysis: Copolymerization of CO 2 and Epoxides on Antimony(V) Platforms

The copolymerization of CO 2 and epoxides to access polycarbonates represents a promising strategy for CO 2 utilization and for the production of useful polymers. Aiming to explore alternative transition-metal-free approaches that support this chemistry, we have investigated a series of triaryl-catecholatostiboranes as pnictogen-bonding platforms for the copolymerization of CO 2 and cyclohexene oxide (CHO). Our survey of these antimony species has identified motifs that promote this polymerization reaction efficiently, provided that bis(triphenylphosphine)iminium chloride is administered as an activator. By coupling these polymerization studies with a careful assessment of the structure, electronic attributes and Lewis acidity of the catecholatostiboranes, this work shows that high activity is generally observed with the weakest pnictogen-bond donors or Lewis acids investigated. Mechanistic studies, which indicate that the polymerization reaction is first order in stiborane, reveal a nonlinear dependence on the CO 2 pressure. This nonlinear dependence could be satisfactorily modeled based on a pre-equilibrium process involving the reversible insertion of the gaseous monomer into the growing chain. Altogether these findings greatly expand the reach of pnictogen bond catalysis while also providing an entry for the use of heavy group 15 elements as competent platforms for CO 2 utilization.

antimony↗
DOE OSTI2025

Predicted Ferromagnetism in Discovered Co–Bi Binary Phases

Binary solid-state materials offer unique insight into how the interplay of factors such as stoichiometry and bonding interactions affects magnetism and electronic properties. In this work, we considered systems where a transition metal provides the spin moment and a heavy main group element bolsters strong spin–orbit coupling. Within this context, cobalt, a known component of permanent magnets, and bismuth, functionally the heaviest element stable to radioactive decay, form a compelling combination. The Co–Bi system has been previously shown to exhibit superconductivity in a phase recovered from high pressure. We expected the Co−Bi system could also be ferromagnetic, resulting in two sets of compounds within one chemical system, one superconducting and one ferromagnetic. Subsequently, we investigated the Co–Bi system through both experimental and theoretical approaches to discover new candidates for permanent magnets. Ab initio random structure searching calculations identified five new compounds with diverse structural motifs that may form at higher pressures than previously reported. Experimental high-pressure synthesis yielded four compounds: α-CoBi, α-CoBi 2 , β-CoBi, and β-CoBi 2 . Three of these phases, α-CoBi 2 , β-CoBi, and β-CoBi 2 , were consistent with the calculated structures, corresponding to a 60% success rate for our structure search and underscoring the strength of combining computation with experiment. Theory predicts β-CoBi and β-CoBi2 are ferromagnetic, with β-CoBi possessing larger magnetocrystalline anisotropy energy than familiar permanent magnets such as CoPt and Nd–Fe–B. These results suggest the Co–Bi system could be a platform for understanding the factors that underpin magnetism and, to an extent, superconductivity in a chemically simple binary system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Hydration structure and water exchange kinetics at xenotime–water interfaces: implications for rare earth minerals separation

Hydration of surface ions gives rise to structural heterogeneity and variable exchange kinetics of water at complex mineral–water interfaces. In this work, we employ ab initio molecular dynamics (AIMD) simulations and water adsorption calorimetry to examine the aqueous interfaces of xenotime, a phosphate mineral that contains predominantly Y 3+ and heavy rare earth elements. Consistent with natural crystal morphology, xenotime is predicted to have a tetragonal prismatic shape, dominated by the {100} surface. Hydration of this surface induces multilayer interfacial water structures with distinct OH orientations, which agrees with recent crystal truncation rod measurements. The exchange kinetics between two adjacent water layers exhibits a wide range of underlying timescales (5–180 picoseconds), dictated by ion–water electrostatics. Adsorption of a bidentate hydroxamate ligand reveals that {100} xenotime surface can only accommodate monodentate coordination with water exchange kinetics strongly depending on specific ligand orientation, prompting us to reconsider traditional strategies for selective separation of rare-earth minerals.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

2023 Critical Materials Strategy

The global effort to curb carbon emissions is accelerating demand for clean energy technologies and the materials they rely on. Demand for these materials will only continue to grow, especially as some nations aim to achieve net zero emissions by 2050. While some major materials like steel, copper, and aluminum are already powering the fossil fuel economy, others are more minor materials with potential supply risks. These risks could jeopardize the ability to reduce greenhouse gas emissions within the desirable timeframe to avoid significant climate change. In some cases, it may be necessary to take action to improve the resilience of material supply chains and mitigate supply risks. Understanding the importance of individual materials to clean energy and the supply risks associated with them is necessary to identify which materials may serve as potential roadblocks to a clean energy future. The U.S. Department of Energy (DOE) issued a series of 13 supply chain deep dive assessment reports on various energy technologies in 2022 in response to President Biden’s Executive Order on America’s Supply Chains (E.O. 14017). These reports emphasized that supply chain bottlenecks can occur at any stage of the value chain from mining and refining to component and even sub-system manufacturing. The bottlenecks are a combination of factors such as material availability, equipment availability, work force availability and quality, logistics, regulatory framework, and market conditions. These bottlenecks were worsened during the global Covid-19 pandemic. Its lingering impacts have hindered capacity expansion for material supply chains and prevented product lead-time recovery. One approach to reduce supply chain risks for the United States is to have a strong domestic manufacturing sector with a diverse set of producers. Boosting responsible domestic production would require leveraging the latest science not only in material extraction but also in developing substitutes, recycling, reuse, and remanufacturing. This report is an updated analysis of previous Critical Materials Strategy (CMS) reports published by the DOE in 2010, 2011, and 2019 based on national and global priorities, technology advancement, and technology adoption trends. Like the CMS reports, this analysis presents the results of a formal material criticality assessment to identify which materials are critical to the continued deployment of clean energy technologies globally. The analysis in this report leveraged the DOE supply chain deep dive assessments to develop the initial list of materials to evaluate. This DOE Critical Materials Assessment (CMA) is conducted independently of criticality assessments performed by other U.S. government agencies, such as that conducted by the U.S. Geological Survey (USGS). This analysis complements the USGS critical minerals determination in three aspects. First, the DOE assessment is performed from a global perspective, while the USGS analysis focusses on the importance of minerals to the U.S. economy. Second, this report focuses on the importance of materials to clean energy technologies, rather than to the economy in general. Lastly, this study is forward looking to 2035 based on clean energy deployment scenarios, whereas the USGS assessment is retrospective. Materials evaluated in this report that do not appear in the USGS Critical Minerals List include copper, uranium, electrical steel, and SiC. A draft version of this report received ~80 public comments related to supporting data and methodological improvement. Those comments have been incorporated as much as possible where appropriate. Highlights of findings from this 2023 CMA include: Rare earth materials (neodymium, praseodymium, dysprosium, and terbium) used in magnets in electric vehicle (EV) motors and wind turbine generators continue to be critical. While dysprosium (Dy) and terbium (Tb) are both heavy rare earth elements that serve the same function in magnets, the criticality of Tb is slightly lower than that for Dy in the short term due to the widespread use of Dy in high-grade magnets and Tb’s present role as a substitute. Similarly, praseodymium (Pr) is critical in the medium term but only near critical in the short term because it is more substitutable in magnets than neodymium (Nd); Materials used in batteries for EVs and stationary storage are now considered to be critical. While cobalt (Co) was found to be critical in this and previous reports, lithium (Li) becomes critical in the medium term due to its broader use in various battery chemistries and the rampant growth of the EV industry. Natural graphite is a new addition in this assessment and is also found to be critical; Platinum group metals used in hydrogen electrolyzers, such as platinum (Pr) and iridium (Ir), are critical due to an increased focus on hydrogen technologies to achieve net zero carbon emissions, while those used in catalytic converters, such as rhodium (Rh) and palladium (Pd), were screened out due to the decreased importance of catalytic converters in the medium term; Gallium (Ga) continues to be critical due to its use in light-emitting diodes (LEDs). In addition, the use of Ga has increased in magnet manufacturing and in semiconductor in forms such as gallium arsenide (GaAs) or gallium nitride (GaN); Major materials like Aluminum (Al), copper (Cu), nickel (Ni), and silicon (Si) move from noncritical in the short term to near critical in the medium term due to their importance in electrification; Electrical steel is near critical due to its use in transformers for the grid and electric motors in EVs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Jump-Start U.S. Manufacturing of High-Performance Permanent Magnets

Gas atomized feedstock powders for Nd-Fe-B based magnets are more robust and cost effective than the strip-cast sheet currently used as feedstock for milling by the magnet industry. However, gas atomized powder’s crystallinity and grain boundary phases are less ideal than the strip cast flake. We proposed to optimize the atomization process as well as the powder chemistry to address this issue and to eliminate heavy rare earth elements from these magnet alloys. Our goal is to help GKN-Hoeganaes, a US metal powder company, who used to make Nd-Fe-B magnets, to bring back US manufacturing of these high energy density permanent magnets.

36 MATERIALS SCIENCE↗