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DOE OSTI2025

Automated Image Segmentation and Processing Pipeline Applied to X–Ray Computed Tomography Studies of Pitting Corrosion in Aluminum Wires

Understanding pitting corrosion is critical, yet its kinetics and morphology remain challenging to study from X-ray computed tomography (XCT) due to manual segmentation barriers. To address this, an automated pipeline leveraging deep learning for efficient large-scale XCT analysis is developed, revealing new corrosion insights. The pipeline enables pit segmentation, 3D reconstruction, statistical characterization, and a topological transformation for visualization. Here, the pipeline is applied to 87 648 XCT images capturing commercial purity aluminum (1100 Al) wire exposed to sodium chloride (NaCl) salt particles over a period of 122 h. The pipeline achieves complete feature extraction and statistical quantification across the entire XCT dataset, leveraging distributed computing environment for high efficiency. Global growth kinetics such as high-level stepwise sigmoidal volume loss patterns and granular individual pit developments are both captured for 36 detected pits. By combining automation, computer vision, and extensive XCT datasets, this research accelerates precise corrosion assessment to enable materials science discoveries at scale.

36 MATERIALS SCIENCE↗

NASA NTRS2007

Granular Mechanics and Surface Systems Lab

The cratering of sand under gas jets is observed to further understanding of soil in hopes to further understand lunar soil. Lunar soil is important to understand because it is causing problems with the materials taken into space including the shuttle. Lunar soil is not rounded like beach sand. Lunar soil is sharp like little particles of glass, and some times when blown they can hook on to one another and become bigger particles. The experiments are designed to help to understand some of the basic physics in how the shuttle jets will interact with lunar soil and how to control the lunar soil. These experiments investigate the diameter of the gas jet and the size of the sand grains to determine how these parameters affect the erosion rate and the cratering processes. Therefore, the experiments preformed will point out what is dependent and what is independent.

Randle, Leah↗

DOE OSTI2025

Machine Learning-Driven Optimization of Building Enclosures for Moisture Durability and Thermal Performance

The design of moisture-durable building enclosures with low embodied carbon often involves an iterative process of selecting the materials for the specific exposure conditions to meet the performance requirements. While hygrothermal simulations are commonly used to evaluate moisture durability, they often require advanced expertise for proper implementation. Machine learning (ML) provides a promising alternative by streamlining the design process and minimizing the reliance on complex simulations. This study presents a machine learning-based approach for predicting moisture durability in residential wall assemblies. The ML model was trained to estimate the mold index and maximum moisture content of various layers under typical exposure conditions. The model achieved a high predictive accuracy, with a coefficient of determination (R²) exceeding 0.90 when compared to traditional hygrothermal simulations on materials that were not part of training the ML model. Building on these results, the ML model was developed into a practical tool for optimizing wall assembly designs. This tool allows users to automatically optimize material selections based on energy, moisture, and carbon performance criteria. By incorporating multi-objective optimization, the tool identifies configurations that minimize embodied carbon while maintaining moisture safety and code-compliant thermal performance. Additionally, it provides insights into how material choices influence assembly durability, energy efficiency, and carbon reduction. The tool will be implemented in the Building Science Advisor (BSA) to enhance its performance and provide more granularity on the results. This research highlights the potential for ML-driven tools to simplify the design of high-performance building enclosures, offering architects and engineers a faster, more efficient way to balance critical performance factors.

Salonvaara, Mikael [ORNL] (ORCID:0000000318991554)↗

DOE OSTI2025

A generalizable machine learning-assisted fast Fourier transform algorithm to simulate the large strain phenomena in polycrystalline materials

Machine learning methods have shown initial promise in constitutive modeling for single crystals or homogenized polycrystals, delivering notable computational efficiency. However, existing machine learning-based constitutive models often lack generalizability, limiting their application across diverse boundary value problems. This study introduces a thermodynamics-informed artificial neural network model to accelerate rate-tangent crystal plasticity fast Fourier transform simulations for cross-scale deformation behaviors of polycrystals under complex loading. Our model integrates microstructural variability and local interactions effectively. To address local effects in each grain, we employ K-means clustering to group Gauss points within the microstructure into clusters assumed to be in similar mechanical states. This approach, based on self-clustering analysis, extends model scope from macroscopic stress response to the granular level, capturing mechanical responses and orientation evolution across grains. This reduces the number of nonlinear problems to solve, with cluster responses propagated throughout each group. The thermodynamics-based artificial neural network-extracted features are further processed using local material state clusters to account for history-dependent deformation and evolving microstructures. Additionally, representative volume element simulations with rate-tangent crystal plasticity fast Fourier transform provide reliable datasets for model training. The proposed model demonstrates high efficiency, accuracy, self-consistency, and enhanced generalizability in predicting strain–stress responses and orientation evolution at both individual grain and aggregate scales under complex loading conditions, such as biaxial tension and arbitrary loading scenarios.

36 MATERIALS SCIENCE↗

NASA NTRS1974

Petrography and classification of Apollo 17 non-mare rocks with emphasis on samples from the Station 6 boulder

The Apollo-17 nonmare rock collection consists largely of polymict breccias lithified by impact and characterized by a variety of types of lithic clasts, concentrations of siderophile elements that indicate substantial meteoritic contamination, and contents of metallic iron well above those of mare basalts. These materials may be subdivided into two compositional groups, one with 70-80% feldspar and the other with 50-60% feldspar. The high-feldspar group includes two characteristic textures: coarsely poikilitic and granulitic. The low-feldspar group includes (1) fragmental breccias with the most diverse lithic clast populations of all breccias and (2) crystalline breccias with poikilitic and subophitic to micropoikilitic textures containing tabular feldspar, granular textures with anhedral feldspar, and clast-rich ophitic textures containing less euhedral feldspar. In the poikilitic and subophitic to micropoikilitic textures, the clast population is dominated by the high-feldspar lithologies and An(94-47) plagioclase grains, indicating that these more refractory lithologies were abundant in the material from which the less feldspathic crystalline rocks formed.

Simonds, C. H.↗

DOE OSTI2025

Pseudo-viscous modeling of transport in dense granular flows for thermal energy storage applications

Dense, granular flows were examined to effectively capture and model bulk viscous properties in thin packed beds. A modified Couette cell with particle image velocimetry was used to experimentally determine pseudo-viscosity properties of four particulate media with varying morphologies: (1) iron oxide-coated SiO 2 particles, (2) CARBOBEAD CP30-60 particles, (3) CARBOBEAD CP40-100 particles, and (4) Al 2 O 3 beads. The pseudo-viscosity functions were fitted using a power law to correlate the measured shear stress as a function of measured shear rate. The pseudo-viscous functions were used as inputs to computation fluid dynamics models for a single-phase viscous fluid to predict granular flow profiles. Steady-state free surface velocity profiles at angular velocities <7 rad/s predicted by the model were in good agreement with the experimental particle image velocimetry measurements, resulting in Pearson correlation coefficients of 0.97 for iron-oxide coated SiO 2 particles and 0.95 for CP30-60 particles. As a result, this alternative approach to measuring pseudo-viscous properties under shearing and modeling bulk transport behavior of granular flow using computation fluid dynamics model offered significant reduction in computational load compared to discrete element methods.

14 SOLAR ENERGY↗

DOE OSTI2021

Enhanced van der Waals epitaxy of germanium by out-of-plane dipole moment induced from transferred graphene on TiN/AlN multilayers

We report recent advances in 3D/2D heterostructures have opened up tremendous opportunities in building highly flexible and durable optoelectronic devices. However, the inherit lack of interfacial bonding and low surface energy of van der Waals surfaces limit the nucleation and growth of 3D materials. Enhancing wettability by providing a porous buffer is effective in growing compound semiconductors on graphene while van der Waals epitaxy of Ge remains challenging. Here, the nucleation of Ge has been significantly improved from an islanded mode to granular modes by using a TiN/AlN multilayered buffer prior to Ge/graphene integration. Highly textured Ge growth with dominating (111), (220), and (311) peaks are identified by x-ray diffraction. The microstructure of the buffer TiN/AlN demonstrates a polycrystalline quality with clean interfaces between each interlayer and the substrate. Kelvin probe force microscopy measurements along the lateral TiN/AlN interface identify a potential drop corresponding to the AlN phase. This contact potential difference between TiN and AlN is the key in generating the out-of-plane dipole moment that modifies the surface energy of the monolayer graphene, resulting in enhanced wettability of the Ge adatoms nucleated on top. Surface dipole induced nucleation of 3D semiconductor thin films on 2D materials via the proper design of buffer layer is fundamentally important to enhance the 3D/2D growth toward flexible optoelectronic applications.

36 MATERIALS SCIENCE↗

NASA NTRS2014

Internship Tasks Associated With CIF Icy Regolith Excavation and Volatile Capture Under Vacuum Conditions

Understanding the surface and atmosphere of Mars is critical to current and future development of exploration systems. Dealing with the Martian regolith-the top layer of soil-remains a significant challenge, and much research is still needed. Addressing this need, the Cryogenics Test Lab and Granular Mechanics and Regolith Operations Lab at NASA's Kennedy Space Center are partnering to develop an apparatus that utilizes simulated Martian regolith in an analogous atmospheric environment to gather data about how the material behaves when exposed to water vapor. Martian surface temperatures range from 128 K (-145 C) to 308 K (35 C), and the average pressure is approximately 4.5 Torr; which presents an environment where water can potentially exist in vapor, solid or liquid form. And based on prior Mars missions such as the Phoenix Lander, it is known that water-ice exists just below the surface. This test apparatus will attempt to recreate the conditions that contributed to the Martian ice deposits by exposing a sample to water vapor at low pressure and temperature; thereby forming ice inside the simulant via diffusion. From this, we can better understand the properties and behavior of the regolith, and have more knowledge concerning its ability to store water-and subsequently, how to dig up and extract that water-which will be crucial to sample gathering when the first manned Mars mission takes place.

Thermal-Vacuum Testing↗

DOE OSTI2022

Thermal protection barrier

A thermal protection barrier including a base layer having a high melting temperature granular media having free standing granules disposed within the base layer and a distributor grid layer having a plurality of spaced-apart distributors composed of a high melting temperature material disposed adjacent to the base layer. The spaced-apart distributors are dimensioned and configured to provide load bearing support to the thermal protection barrier prior to a breach of the thermal protection barrier and to divide and disperse a superheated flowing mass to the free standing granules of the base layer upon occurrence of a breach. In certain embodiments, the thermal protection barrier is positioned adjacent to a nuclear system such that, upon occurrence of a loss of containment accident, the distributor grid layer is positioned and configured to divide and disperse a superheated flowing nuclear mass to the free standing granules.

61 RADIATION PROTECTION AND DOSIMETRY↗

NASA NTRS1992

Microgravity fluid physics research in the Space Station Freedom era

Microgravity fluid physics covers an exciting range of established and potential fields of scientific research. Areas in which the Microgravity Science and Applications Division of NASA's Office of Space Science and Applications is currently supporting research include: multiphase flow and phase change heat transfer, behavior of granular media and colloids; and interface dynamics, morphological stability, and contact line phenomena. As they contribute to our knowledge of fluid behavior, advances in these areas will enhance our understanding of materials processing on Earth and in space, and will contribute to technologies as diverse as chemical extraction, the prediction of soil behavior in earthquakes, and the production of oil reservoirs. NASA' s primary platform for research in microgravity fluid physics will soon be the Fluid Physics/Dynamics Facility on Space Station Freedom. This facility shares a rack for control and utilities with the Modular Combustion Facility, and has one rack for experiment-unique instruments. It is planned to change out the content of the experiment-unique rack at intervals on the order of one year. In order to obtain a maximum return on the operation of the facility during these intervals, the research community must carefully plan and coordinate an effort that brings the efforts of many investigators to bear on problems of particular importance. NASA is currently working with the community to identify research areas in which microgravity can make a unique and valuable contribution, and to build a balanced program of research around these areas or thrusts. Selections will soon be made from our first solicitation for research in fluid dynamics and transport phenomena. These solicitations will build the research community that will make Space Station Freedom a catalyst for scientific and technological discovery, and offer U.S. scientists in many disciplines a unique opportunity to participate in space science.

Carpenter, Bradley M.↗

NASA NTRSDate not supplied

Strong Thermoset Regolith UV-Curable Composite Technology (STRUCT) Overview

Future lunar surface missions require construction materials that can be manufactured in situ using lo-cal resources while operating under extreme environmental conditions. Many Lunar material demands can be solved solely with regolith by compacting or sintering. And yet past Lunar missions rely on polymeric materials, and sustained Lunar missions must reduce Earth-supplied polymers dependence. Dual-cure (Ultraviolet (UV) and thermal) polymer-regolith composites offer a promising pathway by leveraging solar UV radiation, moderate thermal in-put, and regolith. Mission mass limits, power availability and energy constraints on the lunar surface further motivate low-energy processing and curing strategies for surface construction materials. The Strong Thermoset Regolith UV-Curable Composite Technology (STRUCT) project has successfully synthesized and demonstrated dual-cure photopolymer resins derivable from in-situ resources [3]. Morphological, thermal, and mechanical characterization show that the newly formulated UV curable resin systems integrates well with lunar regolith simulants. Processing and chemistry changes, and computational analysis advanced the composite design. X-ray CT scanned and computational analysis demonstrate that resin, regolith and additives are well incorporated. The large fraction of regolith, 95% by mass, large char yield (82% mass), low thermal conductivity (0.26 W/m/K), confirm this material as a promising high-performance thermal and structural material.

thermal conductivity↗

DOE OSTI2020

An Overview of the Circular Economy Lifecycle Assessment and VIsualization (CELAVI) Framework

A circular economy emphasizes the efficient use of all resources (e.g., materials, land, water). Despite anticipated overall benefits to society, the transition to a circular economy is likely to create regional differences in impacts. Current tools are unable to fully evaluate these potential externalities, which will be important for informing research prioritization and regional decision making. This presentation will review and contrast nine current impact assessment methods and describe their granularity, scope, data requirements, and capabilities within the context of identifying regional and sectoral transfers of impacts that could result from transitioning to a circular economy for energy systems. The review of current approaches highlights the need for a new hybrid circularity assessment framework that leverages multiple methods. We describe one such approach: the Circular Economy Lifecycle Assessment and VIsualization (CELAVI) framework. CELAVI uses system dynamics to model material flows for multiple circular economy pathways, network theory to track the spatial and sectoral flow of functional units across a graph, and discrete event simulation to to step through time and evaluate lifecycle assessment data at each time step. The framework is designed to be flexible and scalable enough to accommodate multiple energy materials and multiple energy technologies. CELAVI's hybridization of multiple existing methods yields additional capabilities, which may help answer questions about how flows between the technosphere and ecosphere may evolve if the circularity of energy systems is modified.

circular economy↗

NASA NTRS2003

A Method of Estimating Transient-Cavity Diameters for Impact Craters Formed in Dry Sand

Analyses of impact craters formed in laboratory experiments historically have been the source of many fundamental observations and interpretations of the impact-cratering process itself. Due to its ready availability, ease of handling, and lack of strength, dry sand of various types has been the target material of choice in the majority of such experiments. A consequence of its lack of intrinsic strength, however, is dry sand's inability to maintain slopes above its angle of repose. Evidence from field observations of simple terrestrial craters and laboratory craters formed in more cohesive granular media suggests that transient cavities are similar to paraboloids in shape. Cross-sections of craters formed in dry sand, however, are nearly conical with the wall slopes at or near the angle of repose, indicating that the original crater form has been modified by one or more processes, among which is simple slope failure. Because the dimensions and shape of the transient cavity reflect the detailed conditions of a given impact event, its characterization has long been a desired goal in experimentation. A means of estimating the position of the transient cavity's rim is suggested below, relying on determination of velocities of material ejected from the growing cavity.

Cintala, M. J.↗

DOE OSTI2025

Strip-based Scintillation Detector for Dual-readout High-granularity Calorimetry

New calorimeter technology is being developed for future collider experiments. We are developing a calorimeter that integrates two technologies, a high-granularity calorimeter and a dual-readout calorimeter, and has high time resolution at a picosecond level. The proposed calorimeter is a sampling calorimeter based on scintillation and Cherenkov detectors with high-granularity readout. The Cherenkov detector has a picosecond level time resolution. For the high-granularity scintillation detector, scintillator strips of 300mm × 30mm ×3mm-thick are aligned horizontally and vertically to realize an effective 30mm-square-cell segmentation. Prototype strips with different designs and scintillator materials were tested to compare the performance.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2013

Acquisition and Retaining Granular Samples via a Rotating Coring Bit

This device takes advantage of the centrifugal forces that are generated when a coring bit is rotated, and a granular sample is entered into the bit while it is spinning, making it adhere to the internal wall of the bit, where it compacts itself into the wall of the bit. The bit can be specially designed to increase the effectiveness of regolith capturing while turning and penetrating the subsurface. The bit teeth can be oriented such that they direct the regolith toward the bit axis during the rotation of the bit. The bit can be designed with an internal flute that directs the regolith upward inside the bit. The use of both the teeth and flute can be implemented in the same bit. The bit can also be designed with an internal spiral into which the various particles wedge. In another implementation, the bit can be designed to collect regolith primarily from a specific depth. For that implementation, the bit can be designed such that when turning one way, the teeth guide the regolith outward of the bit and when turning in the opposite direction, the teeth will guide the regolith inward into the bit internal section. This mechanism can be implemented with or without an internal flute. The device is based on the use of a spinning coring bit (hollow interior) as a means of retaining granular sample, and the acquisition is done by inserting the bit into the subsurface of a regolith, soil, or powder. To demonstrate the concept, a commercial drill and a coring bit were used. The bit was turned and inserted into the soil that was contained in a bucket. While spinning the bit (at speeds of 600 to 700 RPM), the drill was lifted and the soil was retained inside the bit. To prove this point, the drill was turned horizontally, and the acquired soil was still inside the bit. The basic theory behind the process of retaining unconsolidated mass that can be acquired by the centrifugal forces of the bit is determined by noting that in order to stay inside the interior of the bit, the frictional force must be greater than the weight of the sample. The bit can be designed with an internal sleeve to serve as a container for granular samples. This tube-shaped component can be extracted upon completion of the sampling, and the bottom can be capped by placing the bit onto a corklike component. Then, upon removal of the internal tube, the top section can be sealed. The novel features of this device are: center dot A mechanism of acquiring and retaining granular samples using a coring bit without a closed door. center dot An acquisition bit that has internal structure such as a waffle pattern for compartmentalizing or helical internal flute to propel the sample inside the bit and help in acquiring and retaining granular samples. center dot A bit with an internal spiral into which the various particles wedge. center dot A design that provides a method of testing frictional properties of the granular samples and potentially segregating particles based on size and density. A controlled acceleration or deceleration may be used to drop the least-frictional particles or to eventually shear the unconsolidated material near the bit center.

Bar-Cohen, Yoseph↗

DOE OSTI2020

Long-distance coherence of Majorana wires

Theoretically, a pair of Majorana bound states in a topological superconductor forms a single fermionic level even at large separations, implying that the parity information is stored nonlocally. The nonlocality leads to a long-distance coherence for electrons tunneling through a Coulomb-blockaded Majorana wire, an effect that can be observed, e.g., in an interferometer. Here, we examine theoretically the coherent electron transfer, taking into account that tunneling implies the long-distance transfer of charge, which is carried by one-dimensional plasmons. In this work, we show that the charge dynamics does not affect the coherence of the electron tunneling process in a topological superconductor consisting of a semiconductor wire proximitized by a single bulk superconductor. The coherence may be strongly suppressed, however, if the topological superconductivity derives from a semiconductor wire proximitized by a granular superconductor.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1973

Microwave emission from granular silicates

Experimental finding is that mass absorption coefficient is independent of frequency but highly dependent on moisture content; effective conductivity increases with frequency, and low tangent is independent of frequency. Computed values of electrical properties are in rough numerical agreement with extrapolated laboratory values on other silicate materials.

Conel, J. E.↗

NASA NTRS2010

Granular Flow and Dynamics of Lunar Simulants in Excavating Implements

The exploration of the lunar surface will rely on properly designed excavation equipment for surface preparations and for collection of lunar regolith in In-Situ Resource Utilization (ISRU) processes. Performance efficiency, i.e minimizing loading forces while maximizing material collection, and mass and volume reductions are major design goals. The NASA Glenn Research Center has embarked on an experimental program to determine the flow characteristics and dynamic forces produced by excavation operations using various excavator bucket designs. A new large scale soil bin facility, 2.27 m x 5.94 m x 0.76 m (nominally 8 ft. x 20 ft. x 27 in.) in size, capable of accommodating moderately large test implements was used for the simulations of lunar operations. The soil bin is filled with GRC-3simulant (a mixture of industrial sands and silt with a particle size distribution and the bulk mechanical (shear) strength representative of an average of lunar regolith from different regions) and uses motorized horizontal rails and a vertical actuator to drive the implement through the lunar simulant soil. A six-axis load cell and encoders provide well resolved measurements of the three dimensional forces and torques and motion of the bucket. In addition, simultaneous video allows for the analysis of the flow behavior and structure formation of the regolith during excavation. The data may be useful in anchoring soil mechanic models and to provide engineering data for design consideration.

Agui, Juan H.↗