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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

A Computational Framework to design 3D stiffness gradient acoustic metamaterials for impedance matching

Acoustic waves play a crucial role in various applications, including medical imaging, non-destructive testing, and sonar systems. One of the significant challenges in these applications is impedance matching, which is essential for minimizing reflections and maximizing the transfer of acoustic energy between different media. Acoustic metamaterials offer a promising solution to this challenge. In addition to impedance control, gradient stiffness can enhance structural efficiency and enable spatial control of wave propagation, making it a valuable feature in acoustic metamaterial design. In this pa- per, we present our developed computational method to design 3D stiffness gradient acoustic metamaterials for impedance matching. The key steps in our approach include generating initial designs using a periodic covariance function to provide unit cells that are both periodic on the boundaries and randomly formed inside the unit cell. Furthermore, we integrated manufacturing constraints into the design process, ensuring that the structures are interconnected for fabrication. We propose two computational optimization algorithms: GenUnit, based on a non-dominated sorting genetic algorithm (NSGA-II), and MLMatch, which leverages differentiable machine learning. The two approaches are not separate contributions but complementary com- ponents of a unified framework. GenUnit requires no training data and directly interfaces with physics-based simulations, making it highly accurate but slower for large-scale exploration. In contrast, MLMatch is data-hungry during training but, once trained, enables near-instantaneous inference and broad design-space coverage. Together, they form a hybrid strategy: ML- Match rapidly explores the global design space, and GenUnit provides local refinement with high-fidelity accuracy. This balance between training cost, inference time, and precision is the motivation for including both methods in the same study. We applied this dual-algorithm framework to generate two metallic-based metamaterial designs that match the acoustic impedance of water while exhibiting a controlled gradient in stiffness (from stiff to soft). The stiffness gradient is particularly advantageous in applications where one side of the structure must interface with soft or sensitive surfaces, such as human tissue or delicate components. Here, this work paves the way for improved materials in various acoustic applications, particularly in ultrasound devices, by providing better impedance.

Metamaterial↗
DOE OSTI2025

Graph-based design of irregular metamaterials

In the field of metamaterial research, random structures offer a novel and less conventional approach compared to traditional periodic designs. Designing random metamaterials is challenging when it comes to ensuring intercon- nectivity, which is essential for manufacturability. This study introduces an innovative framework for generating random metamaterials using graph al- gorithms, ensuring connectivity and adaptability across various base shapes, including cylinders, triangles, pyramids, and cubes. By employing graph algorithms, our framework enhances the intuitiveness and efficiency of de- sign representation and manipulation, streamlining the design process. The framework generates families of designs that exhibit a wide range of prop- erty magnitudes that can be adjusted intuitively by modifying the input parameters. The rapid design process allows many designs to be generated, offering the user a multitude of solutions around the target property range. The designs can be effectively implemented in various fields and subjected to diverse analytical studies, including static, dynamic, and eigenfrequency assessments. We illustrate computational results for two key properties (stiff- ness and acoustic impedance), showcasing the method’s effectiveness through examples ranging from rod-based to cube-based designs. Here, the framework not only advances metamaterial research but also creates new opportunities for innovation in fields requiring customized material properties.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Observation of polarization density waves in SrTiO 3

The nature of the incipient ferroelectric transition in SrTiO 3 has been a long-standing puzzle in condensed matter physics. One explanation involves the competition between ferroelectricity and an instability characterized by the mesoscopic modulation of the polarization. These polarization density waves, which should intensify near the quantum critical point, break local inversion symmetry and are difficult to characterize with conventional X-ray scattering methods. Here, in this study, we probe inversion symmetry breaking at finite momenta and visualize the instability of the polarization at the nanometre scale in SrTiO3 by combining a femtosecond X-ray free-electron laser with terahertz coherent control methods. We found polar-acoustic collective modes that are soft, particularly at the tens of nanometre scale. These precursor collective excitations provide evidence for the conjectured mesoscopic-modulated phase in SrTiO 3 .

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Journey to Time-Variable Moment Tensors through Inversion of Acoustic and Seismoacoustic Data

We explore the capability of acoustic and seismoacoustic datasets to directly resolve a complex, time-variable source consisting of a buried mechanism, represented as a moment tensor, and a spall mechanism, represented as a vertical force at the surface. Traditionally, each component of a resolved moment tensor assumes one underlying source time function, which likely fails to capture the full evolution of a dynamic source, such as an explosion followed by slip on near-source joints or development of spallation. Specifically, we expand previous work to resolve a time-variable moment tensor using single-modality and joint-modality inversion frameworks through analysis of infrasound and seismoacoustic data recorded as part of the Source Physics Experiment Phase II: Dry Alluvium Geology (DAG). We investigate the impact of including signals from seismic-to-air coupling that are local to each infrasound sensor in comparison to mainly atmosphere-propagating acoustic signals, which occur from coupling of the wavefield from the subsurface to the atmosphere directly above the source. Additionally, we assess the ability of our inversion algorithm to fit observed infrasound data using a variety of time-variable source mechanisms. First, we consider the buried moment tensor source alone, which assumes that the determined Green’s functions incorporate effects from spallation or that the impact from spallation is minimal. Second, we examine the estimated buried moment tensor and vertical surface spallation as terms that must both be resolved in the inversion. Third, we assess the ability for an estimated vertical surface spallation source to fit the acoustic data on its own. Finally, we compare results from the joint inversion of both seismic geophone and infrasound acoustic data for the buried-only source compared to buried and spallation sources. Our results are a preliminary investigation into the applications of the inversion technique to recorded datasets and show the technique has limited capabilities using acoustic data alone. Instead, this method shows promise for seismic and seismoacoustic datasets to resolve the time-variable mechanisms of a buried source.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Source Characterization at Low Yields from Physics Experiment One A

The detonation of a well-recorded coupled explosion at the well-characterized Nevada National Security Site, as part of Physics Experiment One, has provided us with an opportunity to compare and contrast methods and results of yield estimation and other event characterization methods. Yield estimates are made using several methods, including local/regional magnitudes, waveform envelopes, acoustic amplitudes, joint seismoacoustic yield, and moment tensors. We include in our analysis a discussion and comparison of applicability, calibrations, assumptions, and uncertainties involved in each. With the exception of magnitude-based methods, all the techniques were more or less successful in recovering the known yield. It is, however, useful to be cognizant of requirements and calibrations, such as station coverage, emplacement conditions, propagation characterization, and uncertainties, to apply the methods to other areas with less complete information. We demonstrate that we can be successful at monitoring low-yield explosions using a variety of methods assuming that the signal-to-noise ratio is adequate at recording stations, and that the material properties are taken into account. Depth estimates are also important, particularly if one allows the possibility of a surface explosion.

Pasyanos, Michael E. [Lawrence Livermore National ↗
DOE OSTI2025

Machine Learning Approaches to Predicting Induced Seismicity and Imaging Geothermal Reservoir Properties

This project developed machine learning (ML) methods, lab data sets, and field data to advance geothermal exploration and geothermal energy production. The work had three focus areas. One involved the development of ML methods to use microearthquakes (MEQs) for imaging geothermal reservoir properties and improving subsurface characterization – most importantly the evolution of permeability within the evolving reservoir. This part of the work included development of ML approaches for automated MEQ location, focal mechanism determination and identification of earthquake precursors. The second area focused on using MEQ signals generated by geothermal exploration and production to predict the relationship between fluid injection and seismicity. Here, we extended to reservoir scale our success in using ML to predict laboratory earthquakes and fault zone stress state. The third focus area was on lab experiments. Here, we developed new ML models for lab earthquake prediction and identification of precursors to failure to improve earthquake forecasting and early warning in geothermal settings. Major outcomes of our work include ML models that learn from MEQ signals during geothermal exploration and production to predict induced seismicity. MEQs occur naturally in connection with drilling and energy production. We developed ML methods to use the seismic waves from these events to characterize the elastic, hydraulic and poromechanical properties of reservoirs. Our work illuminated fracture geometry and the evolution of fracture permeability by incorporating seismic coda wave analysis and ML methods to relate fluid injection and seismicity. We significantly expanded laboratory earthquake prediction to include methods that use both passive measurements of microearthquakes within the lab fault zones and also active source acoustic measurements of fault zone elastic properties. These methods can now predict fault zone stress state, time to failure and the magnitude of lab earthquakes. Our work showed that repetitive stick- slip failure events during frictional sliding (the lab equivalent of earthquakes) are preceded by a cascade of micro-failure events that radiate energy in a manner that foretells unstable failure – manifest as laboratory MEQs. We documented a mapping between fracture properties and statistical attributes of elastic radiation. We extended existing works to geothermal reservoir scale and developed ML methods to determine reservoir permeability, fracture properties, and their evolution during geothermal energy production. An attractive feature of ML algorithms is their ability to handle big datasets and reveal patterns and correlations that may remain invisible to conventional analyses. Our work connected data from field, laboratory and intermediate scales to study permeability, stress, strength, fracture stiffness and geometry. At the field scale we used data from the Newberry Volcano field site, UtahFORGE, EGS Collab, and also the Bedretto underground research lab in Switzerland. These data sets are bridging the gap between the lab scale, theory, and reservoir scale. Our work produced plain language summaries to improve public understanding of DOE research. We also developed openly distributed ML and seismicity datasets for use by all researchers and we published connections between induced seismicity in geothermal areas and reservoir properties including permeability, fracture properties, and stress state. Our models are designed for the large data sets of induced seismicity typically associated with geothermal sites. We produced labeled event catalogs and used them on geothermal data to assess how ML can facilitate geothermal production and exploration. All datasets are available on the GDR Productivity: The project produced 32 publications in peer reviewed journals (two are in review). It supported the work of 6 PhD students, 40 conference presentations, 6 keynote talks at national meetings, and mentoring and professional development for 4 postdoctoral fellows.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Model-independent measurement of the matter-radiation equality scale in DESI 2024

The peak of the matter power spectrum, known as the turnover (TO) scale, is determined by the horizon size at the time of matter-radiation equality. This scale can serve as a standard ruler, independent of other features in the matter power spectrum, such as baryon acoustic oscillations (BAO). Here, in this work, we present the first detection of the turnover in the galaxy autopower spectrum, utilizing the distribution of quasars and luminous red galaxies (LRG) measured by the Dark Energy Spectroscopic Instrument (DESI) during its first year of survey operations in a model-independent manner. To avoid confirmation bias, we first analyze the data using data blinding methods designed for the DESI baryon acoustic oscillation, redshift space distortion and scale-dependent bias signals. We measure the angle-averaged dilation distance 𝐷 V ⁡(𝑧 = 1.651) = (38.1 ± 2.5)⁢𝑟 H from the quasars and 𝐷 V ⁡(𝑧 = 0.733) = (21.8 ± 1.0)⁢𝑟 H from the LRG sample in units of the horizon 𝑟 H at the matter-radiation-equality epoch. Combining these two constraints and assuming a flat Λ⁢CDM model with three standard neutrino species, we can translate this into a constraint of Ω m ⁢ℎ 2 = 0.13⁢9$^{+0.036}_{−0.046}$. We can break the Ω m −𝐻 0 degeneracy with low-redshift distance measurements from type-Ia supernova (SN) data from Pantheon+, we obtain a sound-horizon free estimate of the Hubble-Lemaître parameter of 𝐻 0 = 65.2$^{+4.9}_{−6.2}$ km/s/Mpc, consistent with sound-horizon dependent DESI measurements. On the other hand, combining the DESI BAO and TO, we find a truly DESI-only measurement of 𝐻 0 = 74.0$^{+7.2}_{−3.5}$ km/s/Mpc, in line with DESI-only full-shape results where the sound-horizon scale is marginalized out. This discrepancy in 𝐻 0 can be reconciled in a 𝑤 0 ⁢𝑤 𝑎 ⁢ CDM cosmology, where the combination of DESI BAO and TO data yields 𝐻 0 = 66.5 ± 7.2 km/s/Mpc.

cosmological parameters↗
DOE OSTI2025

Non-destructive evaluation and machine learning methods for inspection of spent nuclear fuel canisters: A state-of-the-art review

Nuclear energy is among the cleanest and most efficient energy sources currently available. The operation of nuclear power plants (NPPs) produces large amounts of high-level radioactive waste known as spent nuclear fuel (SNF). Currently, large amounts of SNF is stored in dry cask storage systems (DCSSs) for extended interim storage until a permanent disposal solution becomes available. During the extended interim storage, the DCSS, particularly the SNF canisters, may degrade and abnormal conditions may occur. Therefore, non-destructive evaluation (NDE) and machine learning (ML) approaches are necessary for inspection of SNF canisters. This paper presents a state-of-the-art review of literature by summarizing recent progress made on the applications of NDE and ML for inspection of SNF canisters. Sixteen NDE methods are examined and compared: visual inspection, ultrasonic guided waves (UGWs), laser-based approaches, acoustic emission (AE), eddy current testing (ECT), non-invasive acoustic sensing, dynamic modal testing, cosmic ray muons tomography, neutron imaging, gamma rays detection, fiber optical sensors, through-wall communications, X-ray computed tomography (CT), vibrothermography, monoenergetic photon sources, and surface acoustic wave (SAW) sensors. The technology readiness level (TRL) for each method is assessed and compared. Recent publications on ML-enhanced visual inspection, AE, non-invasive acoustic sensing, dynamic modal testing, and neutron imaging for SNF canisters are summarized and future research needs are identified. In conclusion, this review article provides a convenient reference on the state-of-the-art applications of NDE and ML methods for inspection of SNF canisters.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Semi-analytical covariance matrices for two-point correlation function for DESI 2024 data

We present an optimized way of producing the fast semi-analytical covariance matrices for the Legendre moments of the two-point correlation function, taking into account survey geometry and mimicking the non-Gaussian effects. We validate the approach on simulated (mock) catalogs for different galaxy types, representative of the Dark Energy Spectroscopic Instrument (DESI) Data Release 1, used in 2024 analyses. We find only a few percent differences between the mock sample covariance matrix and our results, which can be expected given the approximate nature of the mocks, although we do identify discrepancies between the shot-noise properties of the DESI fiber assignment algorithm and the faster approximation (emulator) used in the mocks. Importantly, we find a close agreement (≤ 8% relative differences) in the projected errorbars for distance scale parameters for the baryon acoustic oscillation measurements. This confirms our method as an attractive alternative to simulation-based covariance matrices, especially for non-standard models or galaxy sample selections, making it particularly relevant to the broad current and future analyses of DESI data.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

FY 2025 End of Year Report: Seismic Monitoring of Underground Vibration Sources using Distributed Acoustic Sensing (DAS) and Seismometers

This end-of-year report summarizes progress on using seismic monitoring to detect, associate, and locate anomalous vibration signals that may indicate potential containment breaches. The work focused on four key tasks: 1. Developing a database of continuous waveforms and ground-truth event data from multiple sensing modalities. 2. Refining and implementing detection and association algorithms to generate a catalog of anomalous underground activities. 3. Testing and improving distributed acoustic sensing amplitude-based geolocation methods to build an event location catalog. 4. Testing and refining seismic array polarization-based geolocation methods to build an event location catalog. This report provides a brief recap of results from the FY25 midyear report (Tasks 1 and 2) and presents new findings from geolocation methods (Tasks 3 and 4).

58 GEOSCIENCES↗
DOE OSTI2025

Atmospheric Profile Builder

APBuilder is a software tool designed to generate atmospheric profiles for use with AC2Dr by downloading weather model data and transforming it into 1D or 2D binary profiles. These binary profiles serve as required inputs for AC2Dr, an LLNL-developed, open source, two-dimensional numerical solver for the acoustic wave equation based on the finite difference method.

Kim, Keehoon [Lawrence Livermore National Laborato↗
DOE OSTI2024

Investigation of acoustic waves under subsurface conditions to improve the predictions of rock mechanical properties and natural fracture characteristics

Mechanical properties and natural fracture characteristics are critical to investigate for subsurface engineering applications, including carbon storage, well drilling, and stimulation, as they govern rock stability, fluid flow, and mechanical behavior under stress. This dissertation integrates experimental and machine learning approaches to enhance the prediction and understanding of these properties by analyzing acoustic wave behavior under varied subsurface conditions. First, the influence of temperature, pore pressure, and supercritical CO2 (scCO2) saturation on poroelastic properties is examined using Gray Berea sandstone samples. The results show that temperature and pore pressure significantly affect the bulk modulus and Biot’s coefficient, while scCO2 saturation impacts rock compressibility, informing strategies for effective geological carbon storage. The study extends this understanding by experimentally evaluating the impact of reservoir depletion on the dynamic mechanical properties of the emerging Caney shale in South Oklahoma with the employment of unsupervised machine learning to predict static mechanical properties across the Caney shale. Integrating petrophysical data and chemostratigraphy, the workflow—featuring K-means clustering, principal component analysis (PCA), and inverse distance weighting (IDW)—improves stratigraphic characterization and the estimation of static-to-dynamic modulus ratios, which is vital for optimizing drilling and stimulation strategies. Finally, the work explores how natural fracture characteristics in shale influence acoustic waveforms and shear wave splitting (SWS) analysis. Experimental data on fractured samples under different stress and temperature conditions, combined with machine learning models such as K-nearest neighbors (KNN) and extreme gradient boosting (XGBoost), reveal key fracture properties impacting SWS and wave propagation. Together, these studies provide a comprehensive framework for linking acoustic wave behavior with rock properties, advancing the methods for monitoring and predicting geomechanical changes. The insights offered valuable implications for safer, more efficient CO2 injection, hydrocarbon extraction, and subsurface management.

Elkholy, Sherif↗
DOE OSTI2025

Suppressing the sample variance of DESI-like galaxy clustering with fast simulations

Ongoing and upcoming galaxy redshift surveys, such as the Dark Energy Spectroscopic Instrument (DESI) survey, will observe vast regions of sky and a wide range of redshifts. In order to model the observations and address various systematic uncertainties, N-body simulations are routinely adopted, however, the number of large simulations with sufficiently high mass resolution is usually limited by available computing time. Therefore, achieving a simulation volume with the effective statistical errors significantly smaller than those of the observations becomes prohibitively expensive. In this study, we apply the Convergence Acceleration by Regression and Pooling (CARPool) method to mitigate the sample variance of the DESI-like galaxy clustering in the AbacusSummit simulations, with the assistance of the quasi-N-body simulations FastPM. Based on the halo occupation distribution (HOD) models, we construct different FastPM galaxy catalogs, including the luminous red galaxies (LRGs), emission line galaxies (ELGs), and quasars, with their number densities and two-point clustering statistics well matched to those of AbacusSummit. We also employ the same initial conditions between AbacusSummit and FastPM to achieve high cross-correlation, as it is useful in effectively suppressing the variance. Our method of reducing noise in clustering is equivalent to performing a simulation with volume larger by a factor of 5 and 4 for LRGs and ELGs, respectively. We also mitigate the standard deviation of the LRG bispectrum with the triangular configurations k 2 = 2k 1 = 0.2 h Mpc -1 by a factor of 1.6. With smaller sample variance on galaxy clustering, we are able to constrain the baryon acoustic oscillations (BAO) scale parameters to higher precision. The CARPool method will be beneficial to better constrain the theoretical systematics of BAO, redshift space distortions (RSD) and primordial non-Gaussianity (NG).

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Polaron catastrophe within quantum acoustics

The quantum acoustic framework has recently emerged as a nonperturbative, coherent approach to electron–lattice interactions, uncovering rich physics often obscured by perturbative methods with incoherent scattering events. Here, we model the strongly coupled dynamics of electrons and acoustic lattice vibrations within this framework, representing lattice vibrations as coherent states and electrons as quantum wave packets, in a manner distinctively different from tight-binding or discrete hopping-based approaches. We derive and numerically implement electron backaction on the lattice, providing both visual and quantitative insights into electron wave packet evolution and the formation of acoustic polarons. We investigate polaron binding energies across varying material parameters and compute key observables—including mean square displacement, kinetic energy, potential energy, and vibrational energy—over time. Our findings reveal the conditions that favor polaron formation, which is enhanced by low temperatures, high deformation potential constants, slow sound velocities, and high effective masses. Additionally, we explore the impact of external electric and magnetic fields, showing that while polaron formation remains robust under moderate fields, it is weakly suppressed at higher field strengths. These results deepen our understanding of polaron dynamics and pave the way for future studies into nontrivial transport behavior in quantum materials.

Science & Technology - Other Topics↗
DOE OSTI2026

In situ quantification of fracture slip induced by hydraulic injections in a deep borehole: A comparison of two different borehole techniques

In situ measurements of fracture deformation during fluid injection are rare, yet essential for understanding the mechanical response of fractured rock. In this study, we evaluate the reliability of two methods by comparing their slip vector estimates: high-resolution borehole acoustic televiewer images captured before and after injection tests, and displacement data from a three-component borehole deformation probe recorded during the injections. Acoustic televiewer images capture only final in-plane displacement, whereas three-component borehole deformation measurements provide full 3D, transient fracture movement. Four injection tests in a fractured granitic rock mass along an inclined borehole at the Bedretto Underground Laboratory (Switzerland), beneath more than 1100 m of overburden, were analyzed. The two methods yielded consistent kinematics and comparable slip magnitudes, typically in the range of 0.2 – 0.6 mm. Angular differences between estimated slip directions ranged from 0.2° to 28°. For two test intervals with pre-existing fractures optimally oriented for slip, the measured slip vectors agreed with forward-modeled slip vectors based on the regional in situ stress field, supporting the Wallace–Bott hypothesis. Measurable shear displacement was identified in two test intervals containing fractures oriented nearly perpendicular to the least principal stress, including a newly formed hydraulic fracture. This demonstrates that even fractures unfavorably oriented for slip can undergo shear due to local stress perturbations around an inclined borehole.

Acoustic televiewer↗
DOE OSTI2026

The Influence of Shallow Subsurface Properties on Particle Motion in Acoustic-Seismic Coupling

Atmospheric acoustic waves transmit energy into the solid Earth through air-to-ground coupling. These waves are recorded by seismic sensors and provide insight into both atmospheric phenomena and subsurface properties. Interpreting these signals is often challenging because they are modulated by subsurface structure and the incidence angle of the acoustic wave. This study examines acoustic--seismic coupling generated by the 2012 Camp Minden Explosion, which was recorded by hundreds of seismoacoustic stations. We apply a novel technique to quantify the seismic particle motion, model coupled waves with a propagator matrix approach, and apply a Bayesian inversion to infer properties of the shallow subsurface. Our analysis reveals that prograde motion is widespread and focused in low shear-wave velocity regions, such as the Mississippi Embayment, and retrograde motion is more common in higher shear-velocity areas. Inversion results at some stations produce plausible subsurface models with strong waveform fits, while inversions at other sites are less successful. These results indicate prograde particle motion in air-to-ground coupled waves is more prevalent than previously recognized and may serve as a diagnostic for shallow velocity structure. Our comprehensive modeling and inversion framework provides a potential method to extract layered near-surface properties from acoustic-seismic coupling observations.

58 GEOSCIENCES↗
DOE OSTI2025

A Weakly Supervised Machine Learning Procedure for Magnet Quench Diagnostics

Voltage taps remain the standard and reliable diagnostic tool for detecting quenches in superconducting magnets. However, they identify a quench only at the time of voltage rise and do not provide information on earlier physical precursors. In this work, we investigate whether acoustic emission data can reveal precursor activity that occurs before conventional voltage detection using machine learning techniques. We introduce an event selection method and a weakly supervised machine learning procedure to learn data-driven criteria for identifying potential acoustic precursors to quenches. Two Convolutional Neural Network (CNN) architectures are trained: one on acoustic sensor events from our selection procedure and one on the Fast Fourier Transforms (FFTs) of these events. Both networks are trained iteratively using confidence-weighted loss functions to associate certain subsets of training data with a precursor label. We evaluate the performance of these models by examining the time distribution of events classified as potential precursors relative to the quench onset. Results indicate that the proposed approach can possibly distinguish acoustic emission events occurring closer to the quench from earlier acoustic activity during ramping, suggesting the potential for flagging quench precursors in acoustic data.

Khan, Maira [Fermilab] (ORCID:0009000891602387)↗
DOE OSTI2025

In‐situ Analysis of Paste Properties in Resonant Acoustic Mixers for Quality Monitoring

Formulation control is key to achieving consistent target properties of energetic materials, as feedstock variations and slight deviations in the ratios of different ingredients can have major effects on final product properties, particularly in dense pastes with high particle loading >65 vol.%. In large‐scale operations, it is imperative to either correct or remove batches of material that perform outside baseline property specifications as early as possible to avoid unnecessary processing of suboptimal material. Quality monitoring is the practice of measuring material properties during processing using process analytical technologies as opposed to only testing the properties of the final product; it is a key principle in the quality‐by‐design frameworks used for designing formulations and manufacturing processes. Herein, a process analytical technology method for correlating material properties of dense pastes directly after mixing in a Resonant Acoustic Mixer to motor data is developed and used to detect differences in the particle content of dense paste formulations. This method was also capable of detecting variations in powder feedstock properties, such as particle packing efficiency, and is sensitive enough to detect changes of 2 wt.% in the total solids content of the formulation. The techniques presented herein show excellent promise for use as a process analytical technology capable of quantifying formulation effects on material movement modes during resonant acoustic mixing.

Materials science↗