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DOE OSTI2023

Funneled Depolymerization of Ionic Liquid-Based Biorefinery “Heterogeneous” Lignin into Guaiacols over Reusable Palladium Catalyst

The efficient utilization of lignin, the direct source of renewable aromatics, into value-added renewable chemicals is an important step towards sustainable biorefinery practices. Nevertheless, owing to the random heterogeneous structure and limited solubility, lignin utilization has been primarily limited to burning for energy. The catalytic depolymerization of lignin has been proposed and demonstrated as a viable route to sustainable biorefinery, however, low yields and poor selectivity of products, high char formation, and limited to no recycling of transition-metal-based catalyst involved in lignin depolymerization demands attention to enable practical-scale lignocellulosic biorefineries. In this study, we demonstrate the catalytic depolymerization of ionic liquid-based biorefinery poplar lignin into guaiacols over a reusable zirconium phosphate supported palladium catalyst. The essence of the study lies in the high conversion (>80 %), minimum char formation (7–16 %), high yields of guaiacols (up to 200 mg / g of lignin), and catalyst reusability. In conclusion, both solid residue, liquid stream, and gaseous products were thoroughly characterized using ICP-OES, PXRD, CHN analysis, GC-MS, GPC, and 2D NMR to understand the hydrogenolysis pathway.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Micro‐ and Nanoscale Heterogeneities in Zeolite Beta as Measured by Atom Probe Tomography and Confocal Fluorescence Microscopy

Micro- and nanoscale information on the activating and deactivating coking behaviour of zeolite catalyst materials increases our current understanding of many industrially applied processes, such as the methanol-to-hydrocarbon (MTH) reaction. Atom probe tomography (APT) was used to reveal the link between framework and coke elemental distributions in 3D with sub-nanometre resolution. APT revealed 10–20 nanometre-sized Al-rich regions and short-range ordering (within nanometres) between Al atoms. With confocal fluorescence microscopy, it was found that the morphology of the zeolite crystal as well as the secondary mesoporous structures have a great effect on the microscale coke distribution throughout individual zeolite crystals over time. Additionally, a nanoscale heterogeneous distribution of carbon as residue from the MTH reaction was determined with carbon-rich areas of tens of nanometres within the zeolite crystals. Finally, a short length-scale affinity between C and Al atoms, as revealed by APT, indicates the formation of carbon-containing molecules next to the acidic sites in the zeolite.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Unfolding of the Villin Headpiece Domain: Revealing Structural Heterogeneity with Time‐Resolved X‐Ray Solution Scattering and Markov State Modeling

Understanding protein folding pathways is crucial to deciphering the principles of protein structure and function. Here, the unfolding dynamics of the 35‐residue villin headpiece (HP35) and a norleucine‐substituted variant (2F4K) using a combination of experimental and computational techniques is investigated. Time‐resolved X‐ray solution scattering coupled with equilibrium molecular dynamics simulations and Markov state modeling reveals distinct unfolding mechanisms between the two variants: HP35 and 2F4K. Specifically, HP35 exhibits a two‐state unfolding process, whereas an intermediate state is identified for the 2F4K mutant. A Markov state model constructed from simulations is used to map atomic‐level transitions to experimental observations, providing insights into the role of sequence variations in modulating folding pathways. The findings underscore the importance of integrating experimental and computational approaches to unravel protein unfolding mechanisms between heterogenous structural ensembles.

Nijhawan, Adam K. [Department of Chemistry Northwe↗

DOE OSTI2020

Heterogeneity of soil structure and fertility during desertification of alpine grassland in northwest Sichuan

Abstract The variations of soil structure and soil physical–chemical properties in the process of alpine grassland desertification were revealed, and the indicators of grassland desertification were put forward in order to deepen the understanding of the law of degradation succession and development of alpine grassland. It was used to provide scientific basis for ecological restoration and improvement of ecological service function of alpine grassland. With severe desertification alpine grassland as the core in the Hongyuan County, Tibetan Qiang Autonomous Prefecture of Ngawa, Sichuan Province, China, along both the directions of wetland and arid grassland, the heterogeneity of soil structure and soil fertility in both directions was studied by the analysis of the mean weight diameter (MWD), geometric mean diameter (GMD), >0.25 mm aggregate content ( R 0.25 ), fractal dimension ( D ), soil bulk density, soil moisture content, and soil nutrients. Our results showed that MWD, GMD, and R 0.25 all gradually increased, but the D decreased with the reduction in the degree of desertification in the arid grassland and wetland, resulting in the strong stability of soil structure. The decreasing rate of the D in the direction of arid grassland was faster than that of wetland. Therefore, soil structure stability and erosion resistance in the direction of arid grassland were stronger than that of wetland soil; the D had different response to aggregates with different particle sizes. The aggregate less than 0.25 mm ( r = 0.981, P < 0.01) and 1–2 mm ( r = −0.79, P < 0.01) had the largest responses in the direction of the arid grassland and wetland, respectively; the aggregate more than 1 mm and 1–2 mm can be used as indicators to evaluate desertification of the soil in the direction of the arid grassland and wetland, respectively. The higher the content of the indicating aggregates, the weaker the degree of the desertification.

Ma, Li↗

DOE OSTI2022

Riverscape heterogeneity in estimated Chinook Salmon emergence phenology and implications for size and growth

Abstract Many salmonid‐bearing rivers exhibit thermal and hydrologic heterogeneity at multiple spatial and temporal scales, but how this translates into spatiotemporal patterns of fry emergence is poorly understood. Understanding this variability is important because emergence timing determines the biophysical conditions fish first experience (e.g., temperature, flow, and food supply), thereby influencing growth opportunities and survival during this critical life stage. We predicted spring Chinook Salmon ( Oncorhynchus tshawytscha ) emergence phenology across four northeastern Oregon subbasins over 5–9 years using empirical spawning and temperature data. We then related interannual emergence timing estimates to juvenile salmon size and growth rates at consistent sampling locations. There were clear longitudinal patterns of predicted emergence timing in each subbasin: The shape of these patterns was consistent among years, but not among subbasins. In two subbasins, emergence occurred progressively later with distance upstream, whereas in the other two subbasins emergence was earliest at upstream sites. Within each year, median emergence dates among sites within each subbasin ranged between 44 and 58 days. This spatial variation was comparable to interannual variation, with median emergence dates for a given location in each subbasin ranging between 47 and 74 days among years. Contrary to our expectations, juvenile salmon were not larger in years with earlier emergence, owing to slower estimated spring and summer growth rates compared to years with later emergence. Despite large interannual variation in estimated emergence dates, these results suggest that other factors (e.g., stream flow, temperature, and density‐dependence) were more important than growth duration in determining juvenile salmon growth rates and size among years. We demonstrated considerable spatial and interannual variation in emergence phenology within these subbasins. Understanding how this variation translates to spatiotemporal patterns of juvenile salmon habitat use, growth, and survival has important implications for guiding restoration efforts and understanding how climate change may impact these populations.

Kaylor, Matthew J.↗

DOE OSTI2023

Juvenile life history diversity is associated with lifetime individual heterogeneity in a migratory fish

Abstract Differences in the life history pathways (LHPs) of juvenile animals are often associated with differences in demographic rates in later life stages. For migratory animals, different LHPs often result in animals from the same population occupying distinct habitats subjected to different environmental drivers. Understanding how demographic rates differ among animals expressing different LHPs may reveal fitness trade‐offs that drive the expression of alternative LHPs and enable better prediction of population dynamics in a changing environment. To understand how demographic outcomes and their relationships with environmental variables differ among animals with different LHPs, we analyzed a long‐term (2006–2021) mark–recapture dataset for Chinook salmon ( Oncorhynchus tshawytscha ) from the Wenatchee River, Washington, USA. Distinct LHPs represented in this population include either remaining in the natal stream until emigrating to the ocean as a 1‐year‐old (natal‐reach rearing) or emigrating from the natal stream and rearing in downstream habitats for several months before completing the emigration to the ocean as a 1‐year‐old (downstream rearing). We found that downstream‐rearing fish emigrated to the ocean 19 days earlier on average and returned as adults from the ocean at higher rates. We detected a positive correlation between rate of return from the ocean by downstream‐rearing fish and coastal upwelling in their spring of outmigration, whereas for natal‐reach‐rearing fish we detected a positive correlation with sea surface temperature during their first marine summer. Different responses to environmental variability should lead to asynchrony in adult abundance among juvenile LHPs. A higher proportion of downstream‐rearing fish returned at younger ages compared with natal‐reach‐rearing fish, which contributed to variability in age at reproduction and greater mixing across generations. Our results demonstrate how diversity in juvenile LHPs is associated with heterogeneity in demographic rates during subsequent life stages, which can in turn affect variance in aggregate population abundance and response to environmental change. Our findings underscore the importance of considering life history diversity in demographic analyses and provide insights into the effects of life history diversity on population dynamics and trade‐offs that contribute to the maintenance of life history diversity.

Sorel, Mark H.↗

DOE OSTI2022

On the Counter‐intuitive Heterogeneous Electron Transfer Barrier Properties of Alkanethiolate Monolayers on Gold: Smooth versus Rough Surfaces

Abstract Alkanethiolate monolayers formed on rough gold surfaces can, somewhat surprisingly, act as stronger barriers to heterogeneous electron transfer than those on smooth gold surfaces. This paper presents a possible explanation for this observation by constructing simple geometric models of a “rough” and “smooth” gold surface to examine how microscopic roughness differences can affect the nucleation/growth of the adlayer and size/density of structural defects. Expectedly, the number of defects predicted for adlayers formed on smooth gold is lower than any of those for rough gold. The counter‐intuitive result is that the sizes of a small portion of the defects in the adlayer on the smooth surface are larger than any of those found on the rough surface. The potential implications of these results are discussed.

Chemistry↗

DOE OSTI2025

Hidden Features: How Subsurface and Landscape Heterogeneity Govern Hydrologic Connectivity and Stream Chemistry in a Montane Watershed

ABSTRACT Hydrologic connectivity is defined as the connection among stores of water within a watershed and controls the flux of water and solutes from the subsurface to the stream. Hydrologic connectivity is difficult to quantify because it is goverened by heterogeniety in subsurface storage and permeability and responds to seasonal changes in precipitation inputs and subsurface moisture conditions. How interannual climate variability impacts hydrologic connectivity, and thus stream flow generation and chemistry, remains unclear. Using a rare, four‐year synoptic stream chemistry dataset, we evaluated shifts in stream chemistry and stream flow source of Coal Creek, a montane, headwater tributary of the Upper Colorado River. We leveraged compositional principal component analysis and end‐member mixing to evaluate how seasonal and interannual variation in subsurface moisture conditions impacts stream chemistry. Overall, three main findings emerged from this work. First, three geochemically distinct end members were identified that constrained stream flow chemistry: reach inflows, and quick and slow flow groundwater contributions. Reach inflows were impacted by historic base and precious metal mine inputs. Bedrock fractures facilitated much of the transport of quick flow groundwater and higher‐storage subsurface features (e.g., alluvial fans) facilitated the transport of slow flow groundwater. Second, the contributions of different end members to the stream changed over the summer. In early summer, stream flow was composed of all three end members, while in late summer, it was composed predominantly of reach inflows and slow flow groundwater. Finally, we observed minimal differences in proportional composition in stream chemistry across all four years, indicating seasonal variability in subsurface moisture and spatial heterogeneity in landscape and geologic features had a greater influence than interannual climate fluctuation on hydrologic connectivity and stream water chemistry. These findings indicate that mechanisms controlling solute transport (e.g., hydrologic connectivity and flow path activation) may be resilient (i.e., able to rebound after perturbations) to predicted increases in climate variability. By establishing a framework for assessing compositional stream chemistry across variable hydrologic and subsurface moisture conditions, our study offers a method to evaluate watershed biogeochemical resilience to variations in hydrometeorological conditions.

Johnson, Keira [College of Earth, Ocean, and Atmos↗

DOE OSTI2026

Heterogeneous Multilayer Nanopores via Chemically Tuned Dielectric Breakdown for Single‐Molecule Sensing

Solid-state nanopores are powerful platforms for single-molecule sensing, yet their performance is often constrained by fabrication complexity, noise, and limited control over surface properties. Here we report a direct method to fabricate heterogeneous multilayer nanopores using chemically tuned controlled dielectric breakdown (CT-CDB). We integrate hBN, MoS 2 , or graphene atop a silicon nitride membrane to form five distinct bilayer and tri-layer architectures, with bare SiN x nanopore as a control. CT-CDB achieves pore formation reproducibly through material-stacks with high efficiency, good pore size control, and strong yield, validated by various characterizations. Transferrin protein translocation experiments, supported by simulations, reveal that multilayer configurations modulate protein conformations, ionic current blockade and dwell time distributions, reflecting combined effects of membrane type, interfacial chemistry, and local electric field gradients. A supervised machine learning framework is implemented to assist identifying multilayer structure effects embedded in signal signatures, with over 96% accuracy. This work presents a modular and scalable framework for functional nanopore engineering with complex structural integration, thereby expanding the potential of 2D materials in single-molecule sensing applications.

2D materials↗

DOE OSTI2026

IntraShuffler: A Privacy Preserving Framework for Heterogeneous DP Federated Learning

Heterogeneous Differential Privacy (HDP) in Federated Learning (FL) allows clients to select individual privacy budgets () according to institutional policies and data sensitivity. In practice, many HDP-FL systems employ -aware server aggregation to improve model utility by re-weighting client updates according to their declared privacy budgets. However, gradient updates in FL retain structural patterns induced by non-independent and identically-distributed (non-IID) data, and these additional signals exposed by -aware aggregation create new opportunities for inference by an honest-but-curious server. In this work, we first show that a server equipped with gradient denoising and surrogate modeling can mount a Privacy Inference Attack that infers distributional attributes of clients and links updates from the same client across training rounds, measured via surrogate inference accuracy and linkage success, under realistic knowledge constraints. The Shuffle-Model has been widely studied as a defense against such inference risks by anonymizing update sources, but it is fundamentally incompatible with HDP-FL -aware aggregation. To address this challenge, we propose IntraShuffler, a middleware defense framework designed for HDP-FL systems. IntraShuffler introduces a privacy-aware shuffling mechanism that groups clients into privacy-compatible buckets and performs parameter-level shuffling within each bucket to disrupt persistent gradient structure while preserving -aware aggregation. Experiments across four different datasets show that IntraShuffler reduces gradient recoverability by over 60% and decreases surrogate inference accuracy from 0.78 to 0.33 while maintaining comparable model utility across multiple FL aggregation rules.

Riya, Farhin Farhad [ORNL]↗

DOE OSTI2023

Ecosystem-Level Biomimicry for the Built Environment: Adopting Systems Ecology Principles for the Control of Heterogeneous Energy Systems

This paper presents, to our knowledge, the first system-level engineering study to bio-mimic the cybernetics and flow dynamics of energy resources in natural ecosystems for the control of heterogeneous energy infrastructures in the built environment. To this end, we introduce a novel Biomimetic Pulsing State (BPS) control that functionally mimics mature ecosystems. A preliminary Modelica-based case study features a single-family residential building with electrical and HVAC subsystems. The BPS control objective is to minimize the energy exchange between the building and the grid for the purposes of future self-supporting buildings and grid stability. The building contains PV, a wind turbine, a battery storage system, and a fan coil/heat pump HVAC system served by an ambient district energy network. Evaluating the control performance (BPS vs. constant setpoint) over several renewable energy scenarios (net importer, net zero, net exporter), simulation results show how the building's HVAC system can dynamically adjust its electrical load and temperatures to the electrical system's net energy status in real-time with BPS control. As a net importer, the heat pump consumed 29% less energy and its peak power reduced by 15% with BPS control compared to the constant setpoint case, with the zone air temperature 1 degree C lower on average. As a net exporter, the heat pump effectively consumed the same energy, but the peak power increased by 34% with BPS control, while the zone air temperature was 1 degree C higher when renewable energy was abundant, preheating the home. BPS and constant setpoint control produced comparable results under a net zero scenario. While further evaluation is essential, BPS control may help communities meet their sustainability and resiliency targets as they transition towards fully distributed and renewable energy grids.

biomimicry↗

DOE OSTI2025

Testing CP properties of the Higgs boson coupling to τ leptons with heterogeneous graphs

In this paper we explore the possibility of utilizing Deep Learning in measuring the CP properties of the coupling of Higgs boson to τ leptons at the High Luminosity Large Hadron Collider. We employ three Deep Learning (DL) networks, Multi-Layer Perceptron (MLP), Graph Convolution Network (GCN), and Graph Transformer Network (GTN) to enhance signal-to-background separation. The angle between τ lepton decay planes at the detector level is CP-sensitive observables, and we develop Heterogeneous Graphs that integrate diverse node and edge structures to incorporate the CP-sensitive observable efficiently. Using simplified detector simulations we estimate the reconstruction accuracy of the angle between τ lepton planes at the detector level, considering hadronic τ decay modes and standard model backgrounds. With $\sqrt{s}$ = 14 TeV and $\mathcal{L}$ = 100 fb -1 , MLP excludes CP mixing angles above 20° at 68% confidence level (CL), while GCN and GTN achieve exclusions at 90% CL and 95% CL, respectively. The networks also achieve a 3σ significance in excluding a pure CP-odd state.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2021

Mechanical analysis of heterogeneous materials with higher-order parameters

Abstract Even though heterogeneous porous materials are widely used in a variety of engineering and scientific fields, such as aerospace, energy-storage technology, and bio-engineering, the relationship between effective material properties of porous materials and their underlying morphology is still not fully understood. To contribute to this knowledge gap, this paper adopts a higher-order asymptotic homogenization method to numerically investigate the effect of complex micropore morphology on the effective mechanical properties of a porous system. Specifically, we use the second-order scheme that is an extension of the first-order computational homogenization framework, where a generalized continuum enables us to introduce length scale into the material constitutive law and capture both pore size and pore distribution. Through several numerical case studies with different combinations of porosity, pore shapes, and distributions, we systematically studied the relationship between the underlying morphology and effective mechanical properties. The results highlight the necessity of higher-order homogenization in understanding the mechanical properties and reveal that higher-order parameters are required to capture the role of realistic pore morphologies on effective mechanical properties. Furthermore, for specific pore shapes, higher-order parameters exhibit dominant influence over the first-order continuum.

42 ENGINEERING↗

DOE OSTI2022

The heterogeneous nature of mechanically accelerated grain growth

Abstract While grain growth is traditionally viewed as a purely thermally driven process, nanocrystalline metals can undergo grain growth under mechanical loads, even at room temperature. We performed a detailed atomistic study of the heterogeneous nature of mechanically accelerated grain growth in a polycrystalline Pt nanowire. Using molecular dynamics simulations, we compared the grain-growth behavior of individual grains during tensile and shear cyclic loading, for three different equivalent strain levels, and at two temperatures. Pure thermal grain growth with no mechanical loading provided a baseline reference case. On average, grains that were already susceptible to thermal grain growth were stimulated to grow faster with mechanical loading, as expected. However, when analyzed on a grain-by-grain basis, the results were far more complex: grains that grew fastest under one stimuli were less accelerated under other stimuli. Even when the magnitude of loading changed, the relative growth of individual grains was distorted. We interpret this complexity from the perspective of superimposed growth mechanisms.

Chen, Elton Y.↗

DOE OSTI2024

An innovative heterogeneous transfer learning framework to enhance the scalability of deep reinforcement learning controllers in buildings with integrated energy systems

Deep Reinforcement Learning (DRL)-based control shows enhanced performance in the management of integrated energy systems when compared with Rule-Based Controllers (RBCs), but it still lacks scalability and generalisation due to the necessity of using tailored models for the training process. Transfer Learning (TL) is a potential solution to address this limitation. However, existing TL applications in building control have been mostly tested among buildings with similar features, not addressing the need to scale up advanced control in real-world scenarios with diverse energy systems. This paper assesses the performance of an online heterogeneous TL strategy, comparing it with RBC and offline and online DRL controllers in a simulation setup using EnergyPlus and Python. The study tests the transfer in both transductive and inductive settings of a DRL policy designed to manage a chiller coupled with a Thermal Energy Storage (TES). The control policy is pre-trained on a source building and transferred to various target buildings characterised by an integrated energy system including photovoltaic and battery energy storage systems, different building envelope features, occupancy schedule and boundary conditions (e.g., weather and price signal). The TL approach incorporates model slicing, imitation learning and fine-tuning to handle diverse state spaces and reward functions between source and target buildings. Results show that the proposed methodology leads to a reduction of 10% in electricity cost and between 10% and 40% in the mean value of the daily average temperature violation rate compared to RBC and online DRL controllers. Moreover, online TL maximises self-sufficiency and self-consumption by 9% and 11% with respect to RBC. Conversely, online TL achieves worse performance compared to offline DRL in either transductive or inductive settings. However, offline Deep Reinforcement Learning (DRL) agents should be trained at least for 15 episodes to reach the same level of performance as the online TL. Therefore, the proposed online TL methodology is effective, completely model-free and it can be directly implemented in real buildings with satisfying performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Heterogeneous creep deformation behavior of functionally graded transition joints (GTJs)

Dissimilar metal welds (DMWs) made between ferritic steels and austenitic alloys are used extensively in high-temperature power plant components. These DMWs experience premature creep failure in the ferritic steel’s heat affected zone (HAZ), close to the weld interface. Steep variations in microstructure and chemical composition across the dissimilar weld interface have been the contributing factors for the failure. Graded transition joints (GTJs), developed by functionally grading the chemical composition in layers, have been proposed as potential candidates to replace DMWs. In this research, GTJ coupons were fabricated between 2.25Cr-1Mo steel and Alloy 800H base material using two filler materials: (i) Inconel 82 and (ii) P87. These samples were aged at 600°C for 2000h to accelerate high-temperature microstructural evolution seen in service conditions, before subjecting them to short-term (~1 month) creep tests. Surface strains were measured using digital image correlation (DIC) technique to extract creep strain rates at different locations within GTJs. Both the GTJs exhibited heterogeneous creep strain distribution. Creep strain accumulated in the FGHAZ of 2.25Cr-1Mo steel, similar to type IV failure associated with Cr-Mo steel weldments. Microstructure based creep model framework was developed to describe the discrete creep strain rates observed in various 2.25Cr-1Mo steel regions of GTJs.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Improved irradiation resistance of accident-tolerant high-strength FeCrAl alloys with heterogeneous structures

In this work, post–neutron irradiation examination is performed on advanced accident-tolerant fuel (ATF) cladding iron-chromium-aluminum (FeCrAl) alloys with ~10–13at. % Cr, ~10–12 at. % Al, ~1 at. % Mo, and minor alloying elements including Y irradiated to a damage level of 7 displacements per atom (dpa) at irradiation temperatures of 267–282 °C. A compositional dependency of the Cr and Al content is observed on the ratio of sessile and glissile dislocation loops, where the density of a$\langle$100$\rangle$ type loops is somewhat higher than the a/2$\langle$111$\rangle$ type loops. The α' precipitate number density is inversely correlated to the starting Cr concentration of the alloys of interest. The irradiation to a higher dose of 7 dpa results in a higher density of dislocation loops and α' precipitates for the same alloys at a lower irradiation dose, such as 1.8 dpa. In this work, the effect of α' precipitates on the dislocation loop density is discussed, and the presence of α' appears to inhibit the nucleation of loops. Compared with first-generation FeCrAl alloys, these advanced alloys with heterogeneous structure exhibit a lower Cr concentration in α' precipitation at the same dose level; they act as weaker obstacles deviating from the primary hardening contribution from the mature α'. Hence, the overall irradiation-induced hardening decreases; our alloys show improved radiation resistance because of their stronger sink strengths. The results presented in this paper could provide insights for the design and optimization of ATF cladding materials for future fission and space applications.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Heterogeneous fatigue damage in a nickel-based single-crystal superalloy unraveled using correlative 3D X-ray technology

Nickel-based single-crystal (Ni-SX) superalloys under cyclic stress are susceptible to cracking at stress-concentration sites, eventually leading to low-cycle fatigue (LCF) failure. LCF cracks typically originate from intrinsic defects (e.g., voids and carbides) within solidified dendrites. However, systematic quantitative experimental analyses of defect-mediated local damage remain limited. To thoroughly understand the microscopic origins and evolution of LCF damage, correlated 3D mapping of dendrites across various regions is essential. Here, in this study, macroscale micro-computed tomography (μ-CT) was initially used to capture internal interdendritic secondary cracks within bulk DD413 superalloy after LCF testing at 760 °C. Subsequently, a multimodal methodology combining synchrotron 3D microdiffraction (3D-μXRD), high-resolution μ-CT, and electron microscopy was established. This approach allowed precise localization of internal damage zones near interdendritic secondary cracks and detailed mapping of the 3D correlated distributions of dendrites, defects, and residual stress/strain fields within these zones at submicron spatial resolution. Finally, the same approach was applied to specimens subjected to interrupted loading at approximately 40 % of the fatigue life to uncover the early damage states of dendrites. The dendrite cores (DCs) and interdendritic regions (IDs) exhibit microscale heterogeneous mechanical responses: nearly defect-free DCs accumulate local irreversible slip along specific slip systems to generate slip bands, while the IDs containing various defects accommodate local microplasticity through the activation of multiple slip systems around these defects. The local tensile stress near defects in the IDs exceeds that in the DC slip band regions by more than threefold, leading to the generation of local damage zones within the IDs. Chain-like defect distributions facilitate the interconnection of these local zones into a continuous damage region, further elevating the overall tensile stress in the IDs. Additionally, geometrically necessary dislocations alone are insufficient as indicators of LCF damage; both the internal stress state and its magnitude must be considered. These experimental results provide critical data and insights for the development of multi-physics fatigue models.

Localized deformation↗