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DOE OSTI2022

Artificial intelligence inferred microstructural properties from voltage–capacity curves

Abstract The quantification of microstructural properties to optimize battery design and performance, to maintain product quality, or to track the degradation of LIBs remains expensive and slow when performed through currently used characterization approaches. In this paper, a convolution neural network-based deep learning approach (CNN) is reported to infer electrode microstructural properties from the inexpensive, easy to measure cell voltage versus capacity data. The developed framework combines two CNN models to balance the bias and variance of the overall predictions. As an example application, the method was demonstrated against porous electrode theory-generated voltage versus capacity plots. For the graphite|LiMn $$_2$$ 2 O $$_4$$ 4 chemistry, each voltage curve was parameterized as a function of the cathode microstructure tortuosity and area density, delivering CNN predictions of Bruggeman’s exponent and shape factor with 0.97 $$R^2$$ R 2 score within 2 s each, enabling to distinguish between different types of particle morphologies, anisotropies, and particle alignments. The developed neural network model can readily accelerate the processing-properties-performance and degradation characteristics of the existing and emerging LIB chemistries.

25 ENERGY STORAGE↗

DOE OSTI2023

Microstructural evolution and intermetallic formation in Zn-3Mg (wt%) powder mixture processed by high-pressure torsion

Severe plastic deformation (SPD) techniques have been used extensively over the past 40 years for producing strong metals and alloys. High-pressure torsion (HPT) is one of the most promising SPD techniques for achieving high strength through nanoscale grain refinement and phase transformation. In this research, a mixture of pure zinc (Zn) and magnesium (Mg) powders, Zn-3Mg (wt%), was HPT-processed under a pressure of 6 GPa for 1, 5, 10, 20, and 30 turns at room temperature to achieve a high strength biodegradable material. In order to understand the effects of pre-consolidation on the resulting microstructure and hardness, HPT processing was performed on loose powders placed in the die and also on a pre-compacted powder mixture and the resulting HPT disks were characterized by X-ray diffraction, scanning electron microscopy, atom probe tomography, and Vickers microhardness. In both cases, the HPT disk microstructures contained nanoscale grains, and stable and metastable strain-induced intermetallics, but an unusual softening appeared at large shear strains. Grain size, grain morphology, and the formation of different intermetallics were analyzed to explain the unusual hardness distribution, and it was found that an inverse Hall-Petch relationship between hardness and grain size exists. It is suggested that thermally-activated phenomena such as grain boundary sliding contributed to the strain-induced softening of this nano-structured biomaterial due to its low melting point. Finally, the current results are compared with those for HPT-processed cast alloys and hybrids of the same composition.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Theoretical insights into the selective oxidation of methane to methanol in copper-exchanged mordenite

Selective oxidation of methane to methanol is one of the most difficult chemical processes to perform. A potential group of catalysts to achieve CH 4 partial oxidation are Cu-exchanged zeolites mimicking the active structure of the enzyme methane monooxygenase. However, the details of this conversion, including the structure of the active site, are still under debate. In this contribution, periodic density functional theory (DFT) methods were employed to explore the molecular features of the selective oxidation of methane to methanol catalyzed by Cu-exchanged mordenite (Cu-MOR). We focused on two types of previously suggested active species, CuOCu and CuOOCu. Our calculations indicate that the formation of CuOCu is more feasible than that of CuOOCu. In addition, a much lower C–H dissociation barrier is located on the former active site, indicating that C–H bond activation is easily achieved with CuOCu. We calculated the energy barriers of all elementary steps for the entire process, including catalyst activation, CH 4 activation, and CH 3 OH desorption. Finally, our calculations are in agreement with experimental observations and present the first theoretical study examining the entire process of selective oxidation of methane to methanol.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Engineering of holocellulase in biomass-degrading fungi for sustainable biofuel production

Biofuels, such as bioethanol, are a clean and sustainable form of energy and have emerged as a viable alternative to fossil fuels. Plant biomass is an important raw material for the production of clean and renewable energy. The holocellulose contained in the composition of plants may be broken down into simple sugars, such as glucose, which are fermented by yeast to produce bioethanol. The conversion of glucose polymers into fermentable sugars is accomplished by enzymes known as holocellulases, which are produced by lignocellulolytic fungi. These enzymes act synergistically for the efficient degradation of cellulose polymers, and the fine and coordinated regulation of this process is performed by transcription factors (TFs). TFs are regulatory proteins that bind to the promoter region of their target genes (CAZymes, sugar transporters, signaling proteins, other TFs, etc.) to induce or repress their transcription. This review aims to understand the main regulatory mechanisms involved in plant biomass degradation by the most studied lignocellulolytic fungi Trichoderma sp., Aspergillus sp., Penicillium sp., and Neurospora crassa. In this context, the most studied TFs related to holocellulose degradation and genetic modification of TFs or promoters as a valuable tool to improve enzyme production for biotechnological purposes have been discussed. Furthermore, this review enables the expansion of knowledge on the regulation of the cellulolytic system of filamentous fungi and the application of this knowledge to the improvement of numerous bioproducts. Engineering TFs and promoters may yield more efficient strains that may be active in plant biomass hydrolysis. In this way, the technological processes for obtaining ethanol from lignocellulose may become more commercially viable.

09 BIOMASS FUELS↗

DOE OSTI2017

Extension of moment projection method to the fragmentation process

The method of moments is a simple but efficient method of solving the population balance equation which describes particle dynamics. Recently, the moment projection method (MPM) was proposed and validated for particle inception, coagulation, growth and, more importantly, shrinkage; here the method is extended to include the fragmentation process. The performance of MPM is tested for 13 different test cases for different fragmentation kernels, fragment distribution functions and initial conditions. Comparisons are made with the quadrature method of moments (QMOM), hybrid method of moments (HMOM) and a high-precision stochastic solution calculated using the established direct simulation algorithm (DSA) and advantages of MPM are drawn.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2013

Recent developments in DYNSUB: New models, code optimization and parallelization

DYNSUB is a high-fidelity coupled code system consisting of the reactor simulator DYN3D and the sub-channel code SUBCHANFLOW. It describes nuclear reactor core behavior with pin-by-pin resolution for both steady-state and transient scenarios. In the course of the coupled code system's active development, super-homogenization (SPH) and generalized equivalence theory (GET) discontinuity factors may be computed with and employed in DYNSUB to compensate pin level homogenization errors. Because of the largely increased numerical problem size for pin-by-pin simulations, DYNSUB has bene fitted from HPC techniques to improve its numerical performance. DYNSUB's coupling scheme has been structurally revised. Computational bottlenecks have been identified and parallelized for shared memory systems using OpenMP. Comparing the elapsed time for simulating a PWR core with one-eighth symmetry under hot zero power conditions applying the original and the optimized DYNSUB using 8 cores, overall speed up factors greater than 10 have been observed. The corresponding reduction in execution time enables a routine application of DYNSUB to study pin level safety parameters for engineering sized cases in a scientific environment. (authors)

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2015

Optical modeling and physical performances evaluations for the JT-60SA ECRF antenna

The purpose of this work is the optical modeling and physical performances evaluations of the JT-60SA ECRF launcher system. The beams have been simulated with the electromagnetic code GRASP® and used as input for ECCD calculations performed with the beam tracing code GRAY, capable of modeling propagation, absorption and current drive of an EC Gaussion beam with general astigmatism. Full details of the optical analysis has been taken into account to model the launched beams. Inductive and advanced reference scenarios has been analysed for physical evaluations in the full poloidal and toroidal steering ranges for two slightly different layouts of the launcher system.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2014

Interface design of VSOP'94 computer code for safety analysis

Today, most software applications, also in the nuclear field, come with a graphical user interface. VSOP'94 (Very Superior Old Program), was designed to simplify the process of performing reactor simulation. VSOP is a integrated code system to simulate the life history of a nuclear reactor that is devoted in education and research. One advantage of VSOP program is its ability to calculate the neutron spectrum estimation, fuel cycle, 2-D diffusion, resonance integral, estimation of reactors fuel costs, and integrated thermal hydraulics. VSOP also can be used to comparative studies and simulation of reactor safety. However, existing VSOP is a conventional program, which was developed using Fortran 65 and have several problems in using it, for example, it is only operated on Dec Alpha mainframe platforms and provide text-based output, difficult to use, especially in data preparation and interpretation of results. We develop a GUI-VSOP, which is an interface program to facilitate the preparation of data, run the VSOP code and read the results in a more user friendly way and useable on the Personal 'Computer (PC). Modifications include the development of interfaces on preprocessing, processing and postprocessing. GUI-based interface for preprocessing aims to provide a convenience way in preparing data. Processing interface is intended to provide convenience in configuring input files and libraries and do compiling VSOP code. Postprocessing interface designed to visualized the VSOP output in table and graphic forms. GUI-VSOP expected to be useful to simplify and speed up the process and analysis of safety aspects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

LibERI—A portable and performant multi-GPU accelerated library for electron repulsion integrals via OpenMP offloading and standard language parallelism

A portable and performant graphics processing unit (GPU)-accelerated library for electron repulsion integral (ERI) evaluation, named LibERI, has been developed and implemented via directive-based (e.g., OpenMP and OpenACC) and standard language parallelism (e.g., Fortran DO CONCURRENT). Offloaded ERIs consist of integrals over low and high contraction s, p, and d functions using the rotated-axis and Rys quadrature methods. GPU codes are factorized based on previous developments with two layers of integral screening and quartet presorting. In this work, the density screening is moved to the GPU to enhance the computational efficacy for large molecular systems. Here, the L-shells in the Pople basis set are also separated into pure S and P shells to increase the ERI homogeneity and reduce atomic operations and the memory footprint. LibERI is compatible with any quantum chemistry drivers supporting the MolSSI Driver Interface. Benchmark calculations of LibERI interfaced with the GAMESS software package were carried out on various GPU architectures and molecular systems. The results show that the LibERI performance is comparable to other state-of-the-art GPU-accelerated codes (e.g., TeraChem and GMSHPC) and, in some cases, outperforms conventionally developed ERI CUDA kernels (e.g., QUICK) while fully maintaining portability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Validation of the Community Land Model Version 5 over the Contiguous United States (CONUS) using in-situ and remote sensing datasets

The Community Land Model (CLM) is an effective tool to simulate the biophysical and biogeochemical processes and their interactions with the atmosphere. Although CLM Version 5 (CLM5) constitutes various updates in these processes, its performance in simulating energy, water and carbon cycles over the Contiguous United States (CONUS) at scales which land surface changes and hydrometeorological and hydroclimatological applications are more locally relevant is yet to be assessed. In this study, we conducted three simulations at 0.125? during 1979-2018 over the CONUS using different configurations of CLM, namely CLM5-biogeochemistry (CLM5BGC), CLM4.5BGC, and CLM5-satellite phenology (CLM5SP). We validated and compared their simulations against multiple remote-sensed and in-situ datasets. Overall, the parametric and structural updates (e.g., carbon cost for nitrogen uptake, variable soil thickness, dry surface layer) in CLM5 improve its ability in capturing terrestrial biogeochemical dynamics. The low evapotranspiration in CLM5BGC is associated with biases in simulating vegetation phenological characteristics rather than soil water limitations. The mismatch between CLM5BGC-simulated peak leaf area index and reference data can be attributed to CLM5BGC's inability in simulating phenology of trees and grasses. The differences between CLM-simulated irrigation and reference estimates can be attributed to differences between processes represented in models and in reality, and uncertainties in input and validation datasets. Evaluation against observations at small catchments suggest that hydrologic parameters needed to be calibrated to improve simulations of runoff, especially subsurface runoff. Additional efforts are needed to incorporate spatially-distributed plant phenology and physiology parameters and regional-specific agricultural management practices (e.g., planting, harvest).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2015

On the accuracy of coherent modified Redfield theory in simulating excitation energy transfer dynamics

In this study, we investigate the accuracy of a recently developed coherent modified Redfield theory (CMRT) in simulating excitation energy transfer (EET) dynamics. The CMRT is a secular non-Markovian quantum master equation that is derived by extending the modified Redfield theory to treat coherence dynamics in molecular excitonic systems. Herein, we systematically survey the applicability of the CMRT in a large EET parameter space through the comparisons of the CMRT EET dynamics in a dimer system with the numerically exact results. The results confirm that the CMRT exhibits a broad applicable range and allow us to locate the specific parameter regimes where CMRT fails to provide adequate results. Moreover, we propose an accuracy criterion based on the magnitude of second-order perturbation to characterize the applicability of CMRT and show that the criterion summarizes all the benchmark results and the physics described by CMRT. Finally, we employ the accuracy criterion to quantitatively compare the performance of CMRT to that of a small polaron quantum master equation approach. The comparison demonstrates the complementary nature of these two methods, and as a result, the combination of the two methods provides accurate simulations of EET dynamics for the full parameter space investigated in this study. Our results not only delicately evaluate the applicability of the CMRT but also reveal new physical insights for factors controlling the dynamics of EET that should be useful for developing more accurate and efficient methods for simulations of EET dynamics in molecular aggregate systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Proton Beam Emittance Growth due to Centroid Fluctuations in Strongly Disrupted Electron Bunches in the Linac-Ring eRHIC

In the energy recovery linac (ERL) based eRHIC design, the electron beam, accelerated in a superconducting ERL, collides with the proton beam circulating in the RHIC ring ones, undergoing a very strong beam-beam interaction with the protons, which warrants careful examination. Following the analysis of the transverse disruption and linear mismatch effects in the electron beam caused by beam-beam collision discussed in [2], we adopt the beam parameters listed in Table I for the eRHIC linac-ring design. After a review of the electron disruption process, we perform long term strong-strong beam-beam simulations with a modification of K. Ohmi’s strong-strong beam-beam code BBSS, with the modification consisting of the regeneration of the electron beam after every collision with the proton beam. With the parameters listed in Table I, a kink instability is observed in the proton beam. By reducing the proton bunch length, thus decreasing the electron disruption parameter, the kink instability is observed to disappear for a proton bunch length σ z,p < 10 cm, or electron disruption parameter d e < 1.5. The effect of random offsets in the electron bunch centroids on the long term stability of the proton beam is studied next, with a proton bunch length σ z,p = 6.3 cm (d e = 0.9), thus below the kink instability threshold. The random offsets of the electron bunch centroids are assumed to be Gaussian distributed, with standard deviation offs, and "delta-correlated" in time (white noise). Studies to take into account finite time-correlation effects and random offsets generated by non-Gaussian random processes will be considered in the future. The effect from fluctuations in the electron bunch population has been studied analytically and will be discussed numerically in a companion paper.

36 MATERIALS SCIENCE↗

DOE OSTI2013

DISTRIBUTION OF LANTHANIDE AND ACTINIDE ELEMENTS BETWEEN BIS-(2-ETHYLHEXYL)PHOSPHORIC ACID AND BUFFERED LACTATE SOLUTIONS CONTAINING SELECTED COMPLEXANTS

With the renewed interest in the closure of the nuclear fuel cycle, the TALSPEAK process is being considered for the separation of Am and Cm from the lanthanide fission products in a next generation reprocessing plant. However, an efficient separation requires tight control of the pH which likely will be difficult to achieve on a large scale. To address this issue, we measured the distribution of lanthanide and actinide elements between aqueous and organic phases in the presence of complexants which were potentially less sensitive to pH control than the diethylenetriaminepentaacetic (DTPA) used in the process. To perform the extractions, a rapid and accurate method was developed for measuring distribution coefficients based on the preparation of lanthanide tracers in the Savannah River National Laboratory neutron activation analysis facility. The complexants tested included aceto-, benzo-, and salicylhydroxamic acids, N,N,N',N'-tetrakis(2-pyridylmethyl)ethylenediamine (TPEN), and ammonium thiocyanate (NH{sub 4}SCN). The hydroxamic acids were the least effective of the complexants tested. The separation factors for TPEN and NH{sub 4}SCN were higher, especially for the heaviest lanthanides in the series; however, no conditions were identified which resulted in separations factors which consistently approached those measured for the use of DTPA.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Computational Estimation by Scientific Data Mining with Classical Methods to Automate Learning Strategies of Scientists

Experimental results are often plotted as 2-dimensional graphical plots (aka graphs) in scientific domains depicting dependent versus independent variables to aid visual analysis of processes. Repeatedly performing laboratory experiments consumes significant time and resources, motivating the need for computational estimation. The goals are to estimate the graph obtained in an experiment given its input conditions, and to estimate the conditions that would lead to a desired graph. Existing estimation approaches often do not meet accuracy and efficiency needs of targeted applications. We develop a computational estimation approach called AutoDomainMine that integrates clustering and classification over complex scientific data in a framework so as to automate classical learning methods of scientists. Knowledge discovered thereby from a database of existing experiments serves as the basis for estimation. Challenges include preserving domain semantics in clustering, finding matching strategies in classification, striking a good balance between elaboration and conciseness while displaying estimation results based on needs of targeted users, and deriving objective measures to capture subjective user interests. These and other challenges are addressed in this work. The AutoDomainMine approach is used to build a computational estimation system, rigorously evaluated with real data in Materials Science. Our evaluation confirms that AutoDomainMine provides desired accuracy and efficiency in computational estimation. It is extendable to other science and engineering domains as proved by adaptation of its sub-processes within fields such as Bioinformatics and Nanotechnology.

Computer Science↗

DOE OSTI2013

First-principles calculations of niobium hydride formation in superconducting radio-frequency cavities

Niobium hydride is suspected to be a major contributor to degradation of the quality factor of niobium superconducting radio-frequency (SRF) cavities. In this study, we connect the fundamental properties of hydrogen in niobium to SRF cavity performance and processing. We modeled several of the niobium hydride phases relevant to SRF cavities and present their thermodynamic, electronic, and geometric properties determined from calculations based on density-functional theory. We find that the absorption of hydrogen from the gas phase into niobium is exothermic and hydrogen becomes somewhat anionic. The absorption of hydrogen by niobium lattice vacancies is strongly preferred over absorption into interstitial sites. A single vacancy can accommodate six hydrogen atoms in the symmetrically equivalent lowest-energy sites and additional hydrogen in the nearby interstitial sites affected by the strain field: this indicates that a vacancy can serve as a nucleation center for hydride phase formation. Small hydride precipitates may then occur near lattice vacancies upon cooling. Vacancy clusters and extended defects should also be enriched in hydrogen, potentially resulting in extended hydride phase regions upon cooling. We also assess the phase changes in the niobium-hydrogen system based on charge transfer between niobium and hydrogen, the strain field associated with interstitial hydrogen, and the geometry of the hydride phases. The results of this study stress the importance of not only the hydrogen content in niobium, but also the recovery state of niobium for the performance of SRF cavities.

Ford, Denise C.↗

DOE OSTI2013

Advanced Test Reactor National Scientific User Facility: Addressing advanced nuclear materials research

The Advanced Test Reactor National Scientific User Facility (ATR NSUF), based at the Idaho National Laboratory in the United States, is supporting Department of Energy and industry research efforts to ensure the properties of materials in light water reactors are well understood. The ATR NSUF is providing this support through three main efforts: establishing unique infrastructure necessary to conduct research on highly radioactive materials, conducting research in conjunction with industry partners on life extension relevant topics, and providing training courses to encourage more U.S. researchers to understand and address LWR materials issues. In 2010 and 2011, several advanced instruments with capability focused on resolving nuclear material performance issues through analysis on the micro (10-6 m) to atomic (10-10 m) scales were installed primarily at the Center for Advanced Energy Studies (CAES) in Idaho Falls, Idaho. These instruments included a local electrode atom probe (LEAP), a field-emission gun scanning transmission electron microscope (FEG-STEM), a focused ion beam (FIB) system, a Raman spectrometer, and an nanoindentor/atomic force microscope. Ongoing capability enhancements intended to support industry efforts include completion of two shielded, irradiation assisted stress corrosion cracking (IASCC) test loops, the first of which will come online in early calendar year 2013, a pressurized and controlled chemistry water loop for the ATR center flux trap, and a dedicated facility intended to house post irradiation examination equipment. In addition to capability enhancements at the main site in Idaho, the ATR NSUF also welcomed two new partner facilities in 2011 and two new partner facilities in 2012; the Oak Ridge National Laboratory, High Flux Isotope Reactor (HFIR) and associated hot cells and the University California Berkeley capabilities in irradiated materials analysis were added in 2011. In 2012, Purdue University’s Interaction of Materials with Particles and Components Testing (IMPACT) facility and the Pacific Northwest Nuclear Laboratory (PNNL) Radiochemistry Processing Laboratory (RPL) and PIE facilities were added. The ATR NSUF annually hosts a weeklong event called User’s Week in which students and faculty from universities as well as other interested parties from regulatory agencies or industry convene in Idaho Falls, Idaho to see presentations from ATR NSUF staff as well as select researchers from the materials research field. User’s week provides an overview of current materials research topics of interest and an opportunity for young researchers to understand the process of performing work through ATR NSUF. Additionally, to increase the number of researchers engaged in LWR materials issues, a series of workshops are in progress to introduce research staff to stress corrosion cracking, zirconium alloy degradation, and uranium dioxide degradation during in-reactor use.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Data and scripts associated with “Moisture content modulates DOM thermodynamic regulation of oxygen consumption in drying streambed sediments”

This data package is associated with the publication “Moisture content modulates DOM thermodynamic regulation of oxygen consumption in drying streambed sediments” published in Scientific Reports (Garayburu-Caruso et al., 2026). The package contains processed data products and scripts used to quantify how drying and re-inundation of riverbed sediments influence dissolved organic matter (DOM) thermodynamic properties and their relationship with sediment oxygen (O₂) consumption across 33 stream sites in the contiguous United States. The data package contains DOM thermodynamic metrics (e.g., Gibbs free energy of carbon oxidation and thermodynamic efficiency), and O₂ consumption along with watershed-scale climate and land-cover metrics used as explanatory variables in the analyses. Underlying unprocessed and processed ultrahigh-resolution mass spectrometry data, oxygen consumption rates from laboratory moisture-manipulation experiments, within-sample environmental properties, sediment moisture content and contextual field measurements are archived separately at https://data.ess-dive.lbl.gov/datasets/doi:10.15485/2428003 (Laan et al., 2024) and https://data.ess-dive.lbl.gov/datasets/doi:10.15485/1923689 (Forbes et al.,2023). A preliminary version of this data package was published in February 2026 at the time of manuscript submission. It was updated in June 2026, at the time of manuscript acceptance, to include the finalized data and additional metadata (readme, data dictionary, and file level metadata). For details on how to navigate data packages generated by this project, see https://data.ess-dive.lbl.gov/portals/PNNLRiverCorridorSFA/About. In addition to a readme, this data package also includes a file-level metadata (FLMD) file that describes each file and a data dictionary (DD) that describes all column/row headers and variable definitions. At the top level, the data package is organized into five main folders: (1) Data, (2)Figures, (3) Map, (4) GAM_Reulsts, and (5) src. The Data folder contains analysis-ready tabular files with oxygen consumption rates, DOM thermodynamic properties by site and treatment, site-level environmental variables, watershed-scale metrics, and other derived variables referenced in the manuscript. The Figures folder contains static image files associated with the main text and supplemental figures, while the Map folder includes spatial data and map-layer files used to create the sampling-location map. The GAM results folder contains the results for each of the general additive model (GAM).The src folder contains R scripts used to perform data processing, statistical analyses (including clustering, generalized additive models, and threshold analysis), and figure generation. This data package is associated with a GitHub repository found at https://github.com/WHONDRS-Hub/ECA_DOM_Thermodynamics.

Dissolved organic matter↗

DOE OSTI2016

Effects of process parameters on friction self-piercing riveting of dissimilar materials

In the present work, a recently developed solid state joining technique, Friction self-piercing riveting (F-SPR), has been applied for joining high strength aluminum alloy AA7075-T6 to magnesium alloy AZ31B. The process was performed on a specially designed machine where the spindle can achieve the motion of sudden stop. Effects of rivet rotating rate and punch speed on axial plunge force, torque, joint microstructure and quality have been analyzed systematically. During F-SPR, higher rotating rate and slower punch speed can reduce axial force and torque, which correspondingly results in a slightly smaller interlock between rivet leg and joined materials. Improved local flowability of both aluminum and magnesium alloys under a higher rotating speed results in a thicker aluminum layer surrounding the rivet leg, where formation of Al-Mg intermetallics was observed. Equivalent joint strength obtained in this study are higher than the yield strength of the AZ31 Mg alloy. One of the tensile failure modes is the rivet fracture, which is due to local softening of rivet leg from frictional heat. Lastly, other two failure modes include rivet pullout and shear through of bottom sheet.

36 MATERIALS SCIENCE↗