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DOE OSTI2025

Evaluating the bond strength and fracture mechanisms of cold-sprayed zinc coating on AZ91 magnesium substrate via a combined experimental and computational approach

Magnesium (Mg) alloys are ideal candidates for automotive applications due to their high strength to weight ratio, castability, recyclability etc., however, they lack corrosion and oxidation resistance. Solid-state deposition techniques, such as cold spray, have been demonstrated to enhance their corrosion resistance as it relies on the severe plastic deformation of powder particles upon impact with the substrate to form a metallurgical bond with the substrate and within the coating. At cold sprayed interfaces, a heterogeneous microstructure is formed that includes some porosity, oxides and intermetallics which can significantly affect coating performance. Thus, establishing a direct correlation between the interface microstructure and its properties can aid in designing optimal cold spray parameters. In this study, we investigated the microstructure and mechanical properties of a zinc (Zn) coating deposited on a high pressure die cast (HPDC) AZ91 Mg substrate via high resolution scanning transmission electron microscopy, in situ micro-tensile testing, and finite element method (FEM) modeling. Micro-tensile pillars fabricated using the plasma focused ion beam (PFIB) successfully isolates the coating-substrate interface within the gauge length. The average bond strength of Zn-Mg interface was determined to be ∼140 MPa with failure occurring partially at the interface and mostly into the coatings. A detailed microstructural characterization revealed evidence of a strong metallurgical bonding at the Zn-Mg interface and formation of the C14 MgZn 2 laves phase interlayer resulting in a mixed mode of fracture during the micro-tensile experiments. FEM modeling reveals the stress distribution along the interfaces and suggests that a MgZn 2 layer thickness between 200–400 nm is optimum to increase the bond strength and minimize the triaxiality. Such a site-specific interfacial analysis with correlative computational modeling provides crucial insight into the overall performance of cold spray interfaces.

Bond strength↗

DOE OSTI2025

Integrated process-structure–property–performance optimization of cold-sprayed zinc coatings on AZ91 magnesium alloy

High-pressure die cast (HPDC) AZ91 magnesium alloy is widely used in automotive components such as transmission housings and brackets for its excellent strength-to-weight ratio. Zinc-based cold spray coatings can be applied selectively to vulnerable areas to enhance corrosion resistance, minimize galvanic coupling with dissimilar metals, and eliminate the need for full-surface oxide coatings, making the process more efficient and targeted. A comprehensive evaluation of 16 combinations of nitrogen carrier gas temperatures and pressures led to the identification of an optimal range of process parameters, yielding Zn coatings with porosity <0.5 % by area, wear rates reduced by a factor of two compared to uncoated AZ91, and adhesion strengths up to 35 MPa. The enhanced mechanical performance of the coating is attributed to the low porosity and the formation of a metallurgical bond at the coating-substrate interface. Corrosion studies using macroscale potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) revealed a significant decrease in corrosion rate and a shift to more noble corrosion potentials (ZCP) for coated substrates. Furthermore, the Zn cold-sprayed samples exhibited significantly lower corrosion-induced evolved hydrogen content compared to the base AZ91 substrate and AZ91 coated with industrial coatings, demonstrating that the Zn layer effectively protects the substrate from the corrosive environment. Overall, cold spray Zn coatings significantly improve the mechanical and corrosion performance of AZ91 Mg alloys, addressing key material challenges and enabling their broader use in automotive applications.

Corrosion performance↗

DOE OSTI2026

Enhancing fatigue life of aluminum alloy castings through cavitation water jet peening: Experiments and simulations

This study presents an investigation into the enhancement of the fatigue life of aluminum castings through the application of cavitation water-jet peening (CWJP). CWJP harnesses the impacts of water cavitation to induce surface compressive residual stress within metallic materials. In this work, CWJP was applied to a high pressure die-cast (HPDC) Al–Si alloy A380 with three different water-jet traverse velocities. The fatigue-life improvement, evaluated in a 4-point bending configuration (stress ratio R = 0.1), was found to vary with applied stress level and ranges from 1.6 to 10 times that of the parent alloy. The data also shows that decreasing the traverse velocity results in greater compressive residual stresses within the surface layer and a concurrent increase in surface roughness. This residual stress layer extends to a depth of 400 μm below the surface, as confirmed by through-thickness residual stress and microhardness measurements. CWJP treatment effectively slows down fatigue crack propagation, as evidenced by microstructural observations of narrower striation spacing. Simulations reveal that compressive residual stresses, in addition to surface hardening during CWJP, are key to improving fatigue life. A 20% increase in surface hardness and 150 MPa compressive residual stress imposed by CWJP process provides an average 5-fold enhancement of fatigue life across different stress levels. This study demonstrates the potential of CWJP as an effective surface treatment to enhance the fatigue life of aluminum castings, such as HPDC components for automotive applications.

Al casting↗

DOE OSTI2025

Persistent urinary metabolic signatures in children with type 1 diabetes

There are an estimated 3.7 million people with undiagnosed type 1 diabetes (T1D), living primarily in poor areas of the globe. Therefore, there is a need for non-invasive, affordable tests to provide accurate diagnosis despite the time post-disease onset and fasting state. Here, we studied persistent urinary T1D biomarkers that can be used to develop such tests. Here, we analyzed the urine metabolomes of three independent cohorts of samples collected within 48 h (from Indiana University), and 1 year (from University of Colorado) and 1–10 years (6 years in average) (from Children’s National Medical Center) post-diagnosis. Samples were submitted to gas chromatography-mass spectrometry and machine learning an0alyses to determine diagnostic metabolite panels. The data were also mapped into a metabolic pathway to understand persistently regulated processes in T1D. Seven metabolites showed consistent increases in all three cohorts: d-glucose, d-mannose, myo-inositol, 3-hydroxyisobutyric acid, gluconolactone, d-gluconic acid, and d-glucuronic acid. A combination of machine learning analysis and metabolite ratios as biomarker candidates diagnosed T1D with high sensitivity and specificity across different cohorts and times. Mapping the regulated metabolites into a pathway showed impairment in glycolysis and overflow of glucose towards other pathways in subjects with T1D that was persistent over time. We identified and cross-validated highly specific and sensitive urinary biomarkers. This opens opportunities to develop affordable, robust, and non-invasive tests. The results also show that most of the biomarkers were signatures of dysregulated glucose metabolism.

Type 1 diabetes↗

DOE OSTI2025

Measurements of a LYSO crystal array from threshold to 100 MeV

We report measurements of ten custom-made high-homogeneity LYSO crystals. The investigation is motivated by the need for a compact, high-resolution, and fast electromagnetic calorimeter for a new rare pion decay experiment. Each 2.5 x 2.5 x 18 cm 3 crystal was first characterized for general light yield properties and then its longitudinal response uniformity and energy resolution were measured using low-energy gamma sources. The ten crystals were assembled as an array and subjected to a 30–100 MeV positron beam with excellent momentum definition. The energy and timing resolutions were measured as a function of energy, and the spatial resolution was determined at 70 MeV. An additional measurement using monoenergetic 17.6 MeV gammas produced through a p-Li resonance was later made after the photosensors used in positron testing were improved. Here, as an example of the results, the energy resolution at 70 MeV of (1.52 ± 0.03) % is more than two times better than reported results using previous generation LYSO crystals.

Electromagnetic calorimeter↗

DOE OSTI2026

Power performance and loads characterization of laboratory-scale cross-flow rotors fabricated using additive manufacturing

Tidal energy conversion is a relatively new application for additive manufacturing (AM), where the focus has been on fabricating axial-flow turbine blades. AM techniques add material precisely where it is needed, creating more complex shapes with less waste. Cross-flow rotor geometry presents an opportunity for AM to improve rotor performance by fabricating features that cannot be created economically via conventional manufacturing. The challenges associated with using AM in cross-flow design include water resistance and degradation over time while retaining a level of quality equivalent to conventionally machined parts. In this work, AM materials were tested by environmentally conditioning samples in a seawater tank for 5 months, followed by performance and phase-resolved load testing of laboratory-scale rotors in a hydraulic flume. We found that while metals like titanium and Inconel have excellent performance in marine environments, achieving the desired geometry and performance is difficult. Thermoplastics degraded in seawater but were easier to form into desired geometries and could exceed the performance of an aluminum control rotor. Warping and surface finish were significant detractors from AM rotor performance. These results suggest that the primary benefits of using AM for cross-flow rotors is to quickly fabricate and test unconventional rotor geometries.

16 TIDAL AND WAVE POWER↗

DOE OSTI2025

Rapid analysis of 237 Np and Pu isotopes in unseparated sample matrices using ICP-MS/MS

Inductively coupled plasma tandem mass spectrometry (ICP-MS/MS) is an emerging technique for measuring actinide isotopes when assessing pre- and post- detonation nuclear material. In this study, ICP-MS/MS was investigated for direct Np and Pu quantitation in unseparated, dissolved bulk soil matrices. To achieve this, purified nitric oxide (NO) was investigated for the reactivity of Th, Np, U, Pu, Am, and Cm. Purifying NO prior to the collision reaction cell (CRC) results in increased sensitivity and allows for higher gas flows to be utilized for the removal of interferences. Here, the interference from uranium hydrides was mitigated to less than 3.85 x 10 -11 . This method was demonstrated on standard reference materials which were measured for 237 Np and 238,239,240 Pu in dilute sample digestions. The 238 Pu measurement was validated by spiking into a standard reference material and was accurately measured with an excess of 85000 of 238 U.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

Carbon-conserving bioproduction of malate in an E. coli -based cell-free system

Formate, a biologically accessible form of CO 2 , has attracted interest as a renewable feedstock for bioproduction. However, approaches are needed to investigate efficient routes for biological formate assimilation due to its toxicity and limited utilization by microorganisms. Cell-free systems hold promise due to their potential for efficient use of carbon and energy sources and compatibility with diverse feedstocks. However, bioproduction using purified cell-free systems is limited by costly enzyme purification, whereas lysate-based systems must overcome loss of flux to background reactions in the cell extract. Here, we engineer an E. coli-based system for an eight-enzyme pathway from DNA and incorporate strategies to regenerate cofactors and minimize loss of flux through background reactions. We produce the industrial di-acid malate from glycine, bicarbonate, and formate by engineering the carbon-conserving reductive TCA and formate assimilation pathways. We show that in situ regeneration of NADH drives metabolic flux towards malate, improving titer by 15-fold. Background reactions can also be reduced 6-fold by diluting the lysate following expression and introducing chemical inhibitors of competing reactions. Together, these results establish a carbon-conserving, lysate-based cell-free platform for malate production, producing 64 μM malate after 8 h. This system conserves 43 % of carbon otherwise lost as CO 2 through the TCA cycle and incorporates 0.13 mol CO 2 equivalents/mol glycine fed. Finally, techno-economic analysis of cell-free malate production from formate revealed that the high cost of lysate is a key challenge to the economic feasibility of the process, even assuming efficient cofactor recycling. This work demonstrates the capabilities of cell-free expression systems for both the prototyping of carbon-conserving pathways and the sustainable bioproduction of platform chemicals.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2025

nmRanalysis: An Open-Source Web Application for Semi-automated NMR Metabolite Profiling

Though data acquisition and initial signal pre-processing of nuclear magnetic resonance (NMR) spectra have achieved high degrees of automation, downstream processing - specifically the profiling of spectra - has bottlenecked the overall NMR analysis workflow. Several efforts have been made to mitigate this bottleneck, but these solutions often trade an increase in automation for limitations elsewhere. Here, in this technical note, we introduce nmRanalysis, a user-friendly web-application that integrates the strengths of existing profiling tools for a more automated profiling workflow. nmRa-nalysis additionally incorporates novel features, including a machine-learning-driven recommender system for me-tabolite identification, further increasing the utility of nmRanalysis over the individual tools that it incorporates.

Flores, Javier E. [Pacific Northwest National Labo↗

DOE OSTI2025

Rapid Screening of Single-Atom Catalyst Synthesis Conditions Using ToF-SIMS and Facet-Dependent Single-Crystal Substrates

Single-atom catalysts (SACs) offer superior catalytic performance compared to traditional nanoparticle catalysts but are challenging to develop because of the need for extensive optimization and specialized characterization techniques. Here, this study presents a rapid and versatile method for detecting synthesis conditions and elucidating deposition mechanisms of SACs on various substrates. By depositing active elements (Au, Cu, Ni and Rh) on facet-specific single-crystalline substrates (CeO 2 , TiO 2 , MgO and Al 2 O 3 ) and employing time-of-flight secondary ion mass spectroscopy (ToF-SIMS), we assessed facet-dependent deposition behaviors and identified optimal conditions for solution-based SAC synthesis. On CeO 2 and TiO 2 , we confirmed facet-dependent deposition, primarily influenced by oxygen vacancy density and photocatalytic activity, respectively. MgO exhibited the formation of metal oxide/hydroxide clusters for all active elements, and the degree of clustering for Cu and Ni was correlated with the facet hydrolysis susceptibility. Notably, Au and Rh deposition on MgO was facet-independent, attributed to the formation of hydroxide species in solution. Al 2 O 3 , due to its chemical stability and lack of surface defects, did not show active element deposition. This study not only provides a time and cost-efficient method for prescreening SAC synthesis conditions, but it also provides valuable insights into the various deposition mechanisms governing SAC formation on different substrates, paving the way for the rational design of tailored SACs for various catalytic applications.

ToF-SIMS↗

DOE OSTI2025

Assessing the Impact of Measurement Precision on Metabolite Identification Probability in Multidimensional Mass Spectrometry-Based, Reference-Free Metabolomics

Identification of compounds with minimal ambiguity remains a central challenge in mass spectrometry-based metabolomics. Conventional compound identification relies on comparing analytical signatures (e.g., mass-to-charge ratio, collision cross section, tandem mass spectra) against reference data obtained from measurements of authentic chemical standards. The breadth of annotatable compounds using this approach is necessarily limited by availability of authentic standards, analytical throughput, and resolving power of the separations that underly the measurements. The maturation of computational methods, both theory-driven and artificial intelligence/machine learning-based, for prediction of various molecular properties relevant to multidimensional mass spectrometry measurements has opened the door to a new “reference-free” paradigm of compound annotation. Through augmenting existing reference data for molecular properties with computational predictions, the universe of identifiable chemical species can be expanded significantly beyond its current limits. An unexplored aspect of this novel approach is understanding how to gauge confidence in resulting annotations, especially as the compound search space is expanded. Intuitively, the confidence of a compound annotation is related to the inherent discriminatory power of the molecular properties used for identification, as well as the precision with which the properties are measured or predicted. In this work, we characterize this relationship between measurement precision and identification probability in a systematic and quantitative fashion for a defined region of chemical space that includes organic small molecule metabolites. Importantly, this work establishes a framework for conducting metabolite identification probability analysis that enables others to quantify this relationship for their own compounds and properties of interest.

Metabolite Identification↗

DOE OSTI2025

Bench-Scale Apparatus for Rapid, Simultaneous, Comprehensive Vapor–Liquid Equilibrium and Kinetic Property Measurements to Advance CO 2 Capture Solvent Technology

We present here, the design, fabrication, and testing of a new "pressure, volume, temperature (PVT)" apparatus that enables rapid standardized testing for viscosity, vapor–liquid equilibria, and kinetics for water-lean carbon capture solvents. This unit is the first of its kind where equilibrium data are collected during operation as a PTx (pressure–temperature–composition) cell while kinetic data are collected simultaneously with an internal mini wetted-wall contactor (WWC) using controlled adjustments of CO 2 injections to allow for measurements of gas flux (in and out of the liquid). Additionally, in situ measurements of viscosity data are also continuously collected while a solvent is in circulation during gas absorption. This cell empowers comprehensive testing of critical CO 2 capture solvent properties in a single measurement, ensuring all data are collected at the same temperature, pressure, and CO 2 loading. This apparatus also expedites screening of materials since less than 50 mL of sample is needed as compared to 2–3 L needed to get similar data from a conventional WWC. In conclusion, we describe here the methodology of data collected on this new PVT cell, nicknamed “Gary” in honor of Professor Gary Rochelle, for multiple water-lean amine solvents, which we compare to data collected from conventional instrumentation for amine testing.

Zheng, Richard [STARS Technology Corporation, Rich↗

DOE OSTI2025

Solvation Structure of 237 Np 4+ in a Noncomplexing Environment

Here, the solvation structure of an Np 4+ ion in an aqueous, noncomplexing and nonoxidizing environment of trifluoromethanesulfonic (triflic) acid was investigated with X-ray absorption spectroscopy (XAS) combined with ab initio molecular dynamics (AIMD) and time-dependent density functional theory (TDDFT) calculations. Np L III -edge X-ray absorption near-edge structure (XANES) and extended X-ray absorption fine structure (EXAFS) data were collected for Np 4+ in 1, 3, and 7 M triflic acid using a laboratory-scale spectrometer and separately at a synchrotron facility, producing data sets in excellent agreement. TDDFT calculations revealed a weak pre-edge feature not previously reported for Np L III -edge XANES. AIMD modeling results showed differences in the hydration shell of the Np 4+ ion at different concentrations of triflic acid; these results are supported by the experiment. EXAFS fit models to the experiment resulted in similar coordination of Np 4+ in noncomplexing aqueous media as reported in the literature for 1 M perchloric acid but, together with calculations, revealed more than one distance between Np and O atoms in 7 M triflic acid. These results imply monodentate coordination with sulfonate groups in 7 M triflic acid and suggest the possibility of proto-neptunyl species in relatively low-concentration Np 4+ acid solutions.

Boglaienko, Daria V. [Pacific Northwest National L↗

DOE OSTI2026

A Multiplexed Quantitative Analysis of Germline Single Amino Acid Variants by Targeted Proteomics in Nondepleted Human Plasma

Single amino acid variants (SAAVs) in protein sequences are often a direct result of single-nucleotide polymorphisms (SNPs). Certain germline SAAVs have shown biological relevance in different disease conditions but lack precise quantification in circulation, which could hinder functional investigations and progress in biomarker development. Here, we have developed a multiplexed liquid chromatography-selected reaction monitoring (LC-SRM) assay that monitors 5 wild-type and variant peptide pairs (Complement Factor B: CFB-R32Q/R32W, Clusterin: CLU-N317H, Fetuin B: FETUB-K360R, and Kininogen: KNG1-L212P) in nondepleted human plasma. The assay was optimized for imprecision, linearity, stability, and calibration assessments with CVs of under 20%. The wild-type and variant peptide pairs were characterized in a set of healthy individual plasma samples. These target identifications were also validated by SNP genotyping with more than 99% accuracy. For all protein targets, we observed significantly lower concentrations of WT species in the presence variant peptides. In CFB, the concentration of R32Q was significantly lower than its counterpart R32W variant and WT species. Furthermore, our results distinguished phenotypes of homozygosity and heterozygosity of the SAAV presence through direct concentration level characterization. These findings provide some insights into how SAAVs affect quantitative assessments of target peptides. The assay demonstrates a platform for proteogenomic analyses with potential applications in both research and clinical settings.

genetics↗

DOE OSTI2024

Surface-Treated Composite Polymer as a Stable Artificial Solid Electrolyte Interphase Layer for Lithium Metal Anodes

Lithium (Li) metal batteries (LMBs) are one of the most promising high energy density batteries to meet the demands of electric transportation. However, the practical applications of LMBs are hindered by short cycle life and safety concern, mainly associated with side reactions between Li metal anode and liquid electrolyte and the growth of Li dendrites during cycling. In this study, we develop a stable artificial solid electrolyte interphase (aSEI), which consists of a surface-treated (S T ) PEO–Li 6.4 Ga 0.2 La 3 Zr 2 O 12 composite polymer coating layer (CPL) on Li metal anode. The developed aSEI is stable against selected electrolyte and enables a uniform electrodeposition of Li. Therefore, S T CPL@Li||LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811) cells exhibit improved cycling stability compared with bare Li||NMC811 cells at moderate to high current densities. Notably, using a 50 µm thick Li and a practical NMC811 cathode (~4.8 mAh cm -2 ), a capacity retention of 85% is obtained for S T CPL@Li||NMC811 cells at a current density of 2.4 mAcm -2 after 300 cycles compared with 24% for bare Li||NMC811 cells. Furthermore, S T CPL@Li||NMC811 cells demonstrate higher capacities at charge current densities of 2.4, 4.8 and 7.2 mAcm -2 compared with bare Li||NMC811 cells. Further, these findings suggest that S T CPL is promising for high current density practical LMBs.

25 ENERGY STORAGE↗

DOE OSTI2025

Tailoring the Physicochemical Properties of Nb Thin Films via Surface Engineering Methods

The modification of surface oxide layers formed on niobium (Nb) thin films via chemical mechanical planarization (CMP) and accelerated neutral atom beam (ANAB) processing provides a promising route toward tailoring their emergent properties and performance when used as superconducting qubits. Here, in this study, we show that CMP- and ANAB-formed Nb oxides are significantly thinner and smoother than the native oxide, as revealed by transmission electron microscopy (TEM) and atomic force microscopy. Scanning TEM and energy-dispersive X-ray spectroscopy along with X-ray photoelectron spectroscopy identified an oxidation gradient within the native and surface-engineered oxides. The topside layer is dominated by Nb 5+ (Nb 2 O 5 ), with various Nb suboxides present closer to the oxide/metal interface. Time-of-flight secondary ion mass spectrometry (ToF-SIMS) depth profiling confirmed the presence of an oxygen content gradient and demonstrated the enhanced resistance of the CMP- and ANAB-formed oxides to oxygen surface exchange and subsequent diffusion via 18 O 2 isotopic labeling experiments. ToF-SIMS also identified an interfacial layer containing trapped hydrogen (H)-containing species at the Nb oxide/metal interface. In situ ToF-SIMS and TEM revealed migration of the H/OH interfacial layer coinciding with decomposition of the surface oxide. Furthermore, our density functional theory calculations indicated that both H from moisture present in ambient air and bulk H in Nb films tend to segregate at the interface. These findings underscore the importance of understanding surface oxidation mechanisms, hydrogen incorporation, and their impact on the designed functionalities of Nb-based devices.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Cu-, Co-, and Zn-Based Metal–Organic Framework-Derived Nanoporous Ion Emitters for Picogram Level Analysis of Actinides

Thermal ionization mass spectrometry (TIMS) is often regarded as the preferred technique for trace-level isotopic analysis of actinides owing to its high sensitivity and absence of carry-over effects. However, actinide sample utilization efficiency (SUE) is typically low (<0.05%) without the use of activators or specialized loading approaches which can yield SUEs of >5%. To this effect, we investigate a series of metal–organic framework (MOF)-based nanoporous ion emitters (nano-PIEs) that show enhanced ionization of actinides when used in TIMS loading. We study the impact of physical and chemical properties of MOFs on TIMS SUEs using two families of MOFs that can be synthesized under similar reaction conditions. The structural and chemical properties of these MOFs can be systematically modified one at a time while keeping other features the same. This allows us to strategically investigate their impact on SUEs. The first family of MOFs considered in this study is Zeolitic Imidazole Frameworks (ZIFs) which are made using 2 methyl-imidazole as an organic linker with zinc (ZIF-8) and cobalt (ZIF-67) as metal centers. Additionally, the effect of morphology was also studied using Zn-based ZIF-L with a 2-dimensional structure. The second family of MOFs was synthesized using benzene-1,3,5-tricarboxylate (BTC) with copper (Cu-BTC) and zinc (Zn-BTC) as the metal center. Among the MOFs tested, Cu-BTC showed the highest SUE with an average SUE of 0.27 ± 0.15%, followed closely by Zn-BTC (0.24 ± 0.10%), ZIF-8 (0.17 ± 0.10%), and trailed by the other MOFs. When the MOFs were pyrolyzed in N 2 before loading, an apparent increase in the SUE was observed with ZIF-8 and Cu-BTC showing average SUEs of 0.25 ± 0.08% and 0.34 ± 0.13%, respectively, with the highest measured SUE of 0.53% for pyrolyzed Cu-BTC. In conclusion, this observed increase in SUE by up to an order of magnitude compared to bare filaments demonstrates the efficacy and potential of MOF-derived nano-PIEs for TIMS application.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Conversion of Waste PET Plastic to Aramid Fiber

A three-step synthesis was used to convert waste polyethylene terephthalate (PET) into the high value polymer, poly-para-phenylene terephthalamide (PPTA), used in the production of high strength aramid fiber, such as Kevlar. Improvements to the polymerization reaction by addition of calcium chloride to the solvent, N-methyl-2-pyrrolidone (NMP), and rigorous anhydrous conditions enabled the production of a PET-derived PPTA with a 4.15 dL/g inherent viscosity in sulfuric acid that is amenable to fiber spinning. PPTA fibers were spun using a wet spinning apparatus under varied process parameters to assess their impact on fiber surface morphology, diameter, and the mechanical properties of the fibers. Select fibers were subjected to a post-spinning heat treatment at 150 °C , which improved the tensile strength and modulus by 100% and 30%, respectively, relative to the as-spun fibers. Techno-economic and life cycle analyses were conducted to evaluate the economic feasibility and the life-cycle greenhouse gases (GHG) emissions of the approach. In conclusion, the results suggest the potential for up to a 30% cost reduction, and comparable GHG emissions against conventional petroleum-based processes.

Lifecycle Analysis↗