Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “36 MATERIALS SCIENCE”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Adaptive immersed isogeometric level-set topology optimization

Here, this paper presents for the first time an adaptive immersed approach for level-set topology optimization using higher-order truncated hierarchical B-spline discretizations for design and state variable fields. Boundaries and interfaces are represented implicitly by the iso-contour of one or multiple level-set functions. An immersed finite element method, the eXtended IsoGeometric Analysis, is used to predict the physical response. The proposed optimization framework affords different adaptively refined higher-order B-spline discretizations for individual design and state variable fields. The increased continuity of higher-order B-spline discretizations together with local refinement enables direct control over the accuracy of the representation of each field while simultaneously reducing computational cost compared to uniformly refined discretizations. A flexible mesh adaptation strategy enables local refinement based on geometric measures or physics-based error indicators. These adaptive discretization and analysis approaches are integrated into gradient-based optimization schemes, evaluating the design sensitivities using the adjoint method. Numerical studies illustrate the features of the proposed framework with static, linear elastic, multi-material, two- and three-dimensional problems. The examples provide insight into the effect of refining the design variable field on the optimization result and the convergence rate of the optimization process. Using coarse higher-order B-spline discretizations for level-set fields promotes the development of smooth designs and suppresses the emergence of small features. Moreover, adaptive mesh refinement for state variable fields results in a reduction of overall computational cost. Higher-order B-spline discretizations are especially interesting when evaluating gradients of state variable fields due to their higher inter-element continuity.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A comparative analysis of residual stresses from friction stir processing of aluminum cast 380 and wrought 7075 alloy sheets: experimental characterization and modeling

Residual stresses are often overlooked in friction stir processing (FSP), but their significant impact on fatigue performance necessitates their consideration in optimizing processing parameters. The first step in this effort is understanding how process conditions influence residual stress distributions, especially across different alloys. This study focuses on determining and explaining the through-thickness residual stress variations and the effect of process temperature on the residual stress magnitude in wrought AA7075 and cast AA380.0 alloys. Additionally, for AA380.0, the impact of a second FSP pass was investigated. To achieve this, hole-drilling electronic speckle pattern interferometry (ESPI) and the thermal pseudo-mechanical (TPM) model within finite element analysis were employed to study the 3D distributions of in-plane residual stresses in processed samples under various conditions. A key finding was the varying impact of process temperatures on residual stress magnitudes. Higher process temperatures reduced stresses in AA380.0 but increased them in AA7075. Additionally, the through-thickness stress distributions differed between the two alloys. Further analysis revealed that yield stresses are crucial in explaining these phenomena and the effects of additional FSP passes. Further, this fundamental understanding will be vital in guiding the efforts to mitigate residual stresses and assess their impact on the performance of FSP aluminum alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Autonomous direct freeform fabrication strategy for multi-axis additive manufacturing

Multi-axis additive manufacturing (M-AM) enables precise material deposition along both planar and curved layers, eliminating the need for support structures through a continuous material deposition approach. In contrast to conventional 2-dimensional planar layers constrained to a fixed building orientation, the deposition on freeform layers demands the specification of guided curves to determine material deposition directions which are no longer to be fixed to a build direction. There are challenges that arise when fabricating components with multiple “build” directions, necessitating the decomposition of geometries and the specification of guided curves for the resulting volumes. Furthermore, multi-axis systems introduce heightened challenges due to an increased degree of freedom in motion. Consequently, the potential risks of collision between the deposited geometry and the motion platform become a notable concern. This research proposes a freeform layering algorithm to address the challenge of seamless transitions between planar and curved layers in the process planning of M-AM. The algorithm computes 3D “printable” layers by leveraging topological information derived from the geometry to be built and integrates collision-free manufacturability considerations into the computational process. These accumulated volumes serve as a “substrate” and support volumes for subsequent deposition, allowing later layers to be built without the need for additional support material. In conclusion, the proposed method successfully devises a freeform layering approach suitable for intricate models that demand substantial support, thus enabling the fabrication of diverse geometries in a manner previously unachievable.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Fatigue behavior of low-cost, non-spherical Ti-6Al-4V powder processed via laser powder bed fusion

Hydride-dehydride Ti-6Al-4V powder with particle size distribution of 75–175 μm were used to manufacture fatigue samples. Optimized processing parameters were used to maintain a relative density of >99.5% in the samples. Fatigue tests were carried out in R = σ min /σ max = -1 condition under stresses ranging from 150 to 500 MPa and the results were compared to samples that were additively manufactured using spherical powders. The fatigue lives were similar between the two types of powder; i.e., powder morphology has no effect on fatigue performance. However, the high surface roughness and martensitic microstructure resulting from the laser powder bed fusion process result in poor performance compared to samples machined from conventionally produced materials. In conclusion, crack initiation occurred consistently from surface defects because of high surface roughness of the additively manufactured parts.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Fundamentals on dependence of volume on pressure and temperature

The common wisdom that volume decreases with pressure and increases with temperature is analyzed in terms of Hillert nonequilibrium thermodynamics in the present work. It is shown that the derivative of volume to pressure in a stable system is always negative, i.e., volume decreases with the increase of pressure, when all other natural variables of the system are kept constant. This originates from the stability requirement that the conjugate variables, such as volume and negative pressure, must change in the same direction in a stable system. Consequently, since volume and temperature are not conjugate variables, they do not have to change in the same direction and thus do change in opposite directions in both natural and man-made systems. It is shown that the decrease of volume with the increase of temperature, commonly referred as negative thermal expansion (NTE) in the literature, originates from the statistical competitions of configurations in the system when the volumes of metastable configurations are smaller than that of the ground-state configuration. As a result, it is demonstrated that the zentropy theory can concisely explain and accurately predict NTE based on the density functional theory without fitting parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Synchrotron-based diffraction-enhanced imaging and diffraction-enhanced imaging combined with CT X-ray imaging systems to image seeds at 30 keV

Utilized the upgraded Synchrotron-based non-destructive Diffraction-enhanced imaging and Diffraction-enhanced imaging coupled with CT X-ray imaging systems to image the chickpea seeds, to enhance the contrast in plant root architecture, visibility of fine structures of root architecture growth and some aspects of physiology at acceptable level. DEI-CT images were acquired with 30 keV synchrotron X-rays. A series of DEI-CT slices were assembled together, to form a 3D data set. DEI-CT images explored more structural information and morphology. Noticed detailed anatomical, physiological observations, and contrast mechanisms. Furthermore, with these systems, some of the complex plant traits, root morphology, growth of laterals and subsequent laterals can be visualized directly.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Ohmic contact formation at the Au/Sr 3 Ir 2 O 7 interface

Here, using X-ray photoelectron spectroscopy (XPS), we show that Au forms an Ohmic contact with the surface of the narrow-bandgap Mott insulator Sr 3 Ir 2 O 7 thin films. XPS reveals no significant binding energy shift with increasing Au overlayer thickness on epitaxial Sr 3 Ir 2 O 7 (001) thin films, consistent with the linear current-voltage (I-V) behavior and indicative of negligible band bending. The absence of Schottky barrier formation at the Au/Sr 3 Ir 2 O 7 interface corroborates the metallic surface character of the Sr 3 Ir 2 O 7 thin film, as observed in angle-resolved photoemission spectroscopy (ARPES) studies, suggesting that the interface behaves effectively as a metal-on-metal contact. Furthermore, XPS points to the presence of distinct surface/interface and bulk electronic states for Sr 3 Ir 2 O 7 . This study provides critical material information for designing iridate-based electronic devices.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Kinetic control of phase evolution and defect-mediated recombination in AACVD-grown copper antimony sulphide thin films

Copper antimony sulphide (CAS) is a multinary chalcogenide semiconductor in which small deviations from stoichiometry can drive phase competition and strong defect-mediated modulation of optoelectronic properties. However, the systematic roles of copper precursor fraction and deposition time in governing phase evolution, off-stoichiometry, and recombination dynamics in aerosol-assisted chemical vapour deposition (AACVD)-grown undoped CAS thin films remain insufficiently understood. In this work, undoped CAS thin films were deposited by AACVD using Cu(dedtc)2 and Sb(dedtc)3 single-source precursors at 550 °C and a carrier gas flow rate of 150 sccm, while the Cu(dedtc)2 mole fraction (x = 0.15 – 0.55) and deposition time (1 – 2 hours) were systematically varied to probe how growth kinetics influence phase composition, microstructure, and defect-mediated optical properties without post-deposition annealing or extrinsic doping. Increasing copper precursor content drives phase evolution toward tetrahedrite-dominant CAS films at intermediate Cu(dedtc)2 mole fractions, with the film deposited at x = 0.35 exhibiting the strongest tetrahedrite character within the parameter space examined. The films are also copper-rich, antimony-poor, and sulphur-deficient, consistent with off-stoichiometric growth and intrinsic defect formation, plausibly including copper interstitials, Cu-on-Sb antisites, and sulphur vacancies. These growth-dependent compositional deviations are accompanied by tunable indirect optical bandgaps of approximately 1.60 – 2.18 eV and weak visible photoluminescence governed by defect-mediated recombination. Time-resolved photoluminescence reveals bi-exponential decay behaviour with lifetimes of approximately 0.1 – 3.6 ns, with emission dominated by slower donor–acceptor pair recombination and a smaller contribution from faster trap-assisted pathways. Collectively, these results establish an explicit kinetic process–structure–defect–property relationship for AACVD-grown CAS thin films and provide a growth–structure–property framework relevant to future optimization of CAS-based optoelectronic and energy materials.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Attention-based 3D – convolutional neural network model for mechanical property predictions using visible light images in metal additive manufacturing

Additive manufacturing (AM), while commonly used for rapid prototyping and creating components with complex geometries, has not been widely adopted for critical applications across the aerospace, automotive, defense, energy, and medical industries. This is, in part, due to the challenges of controlling flaws and uncertainty in the mechanical behavior of additively manufactured components. In recent years, there has been an increase in research aimed at predicting the final mechanical properties of additively manufactured components during the printing process. To address these issues, a 3D-CNN model was trained using low-cost in situ visible-light camera data, anomaly classifications, and the chosen process parameters to predict the ultimate tensile strength (UTS), yield strength (YS), total elongation (TE), and uniform elongation (UE). The 3D-CNN layers of the model employed attention mechanisms to prioritize features in the data, thereby improving prediction accuracy. Furthermore, the effect of each process parameter and anomaly class is investigated using attention-based dynamic sigmoid weighted gates to interpret the influence each class has on the final prediction. Different combinations of the in situ data were fed into the 3D-CNN, with varying amounts of image layers, to determine the ideal combination for predicting mechanical properties in situ. Here, the 3D-CNN model achieved mean absolute percentage errors (MAPE) below 5% for both UTS and YS while using only a single camera input and under half of the available image layers.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Ferroelectric Al 1− x B x N sputtered thin films on n -type Si bottom electrodes

Ferroelectric Al 1−x B x N thin films are grown on highly doped and plasma treated (100) n-type Si. We demonstrate ferroelectricity for x = < 0.01, 0.02, 0.06, 0.08, 0.13, and 0.17 where the n-type Si is both the substrate and bottom electrode. Polarization hysteresis reveals remanent polarization values between 130 and 140 μC/cm 2 and coercive field values as low as 4 MV/cm at 1 Hz with low leakage. The highest resistivity and most saturating hysteresis occurs with B contents between x = 0.06 and 0.13. We also demonstrate the impact of substrate plasma treatment time on Al 1−x B x N crystallinity and switching. Cross-sectional transmission electron microscopy and electron energy loss spectra reveal an amorphous 3.5 nm SiN x layer at the Al 1−x B x N interface post-plasma treatment and deposition. The first ~ 5 nm of Al 1−x B x N is crystallographically defective. Using the n-type Si substrate, we demonstrate Al 1−x B x N thickness scaling to 25 nm via low-frequency hysteresis and CV. Serving as the bottom electrode and substrate, the n-type Si enables a streamlined growth process for Al 1−x B x N for a wide range of Al 1−x B x N compositions and layer thicknesses.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Electron beam irradiation effects on bulk metals: a comparative study of polycrystalline versus single-crystalline structures

This study investigates the effects of electron beam (e-beam) irradiation on the mechanical and structural properties of eight bulk metallic samples, comprising both polycrystalline (PC) and single-crystalline (SC) forms of Ni, Cr, V, and Ti. These metals were evaluated as potential candidates for beam exit windows in high-power (MW-class) particle accelerators. The primary objective is to identify metals capable of withstanding the conditions of high-power/MW-class e-beam accelerators and serve effectively as exit windows. Selection criteria were based on each metal’s intrinsic properties, power dissipation capability, and irradiation-induced changes in mechanical behavior, including hardness, elastic modulus, and defect density. Comprehensive characterization was conducted using field-emission scanning electron microscopy (FESEM), atomic force microscopy (AFM), scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM–EDS), X-ray diffraction (XRD), high-resolution transmission electron microscopy (HRTEM), selected area electron diffraction (SAED), and nanoindentation, performed both before and after exposure to a ~¿66 kGy dose from a 10 MeV e-beam accelerator. Results revealed that e-beam irradiation induced hardening in PC Ni, whereas PC Ti, commonly used in beam exit windows, exhibited softening. The observed softening in PC Ti is attributed to grain coarsening, elongation, and the formation of twins and twin boundaries, in contrast to the smaller, compressed grains in the pristine (Pr) PC Ti samples, consistent with the Hall–Petch relationship. The stresses due to twinning are small and insignificant in influencing the overall hardening of the PC Ti irradiated sample when compared to the stresses due to the dislocation density. Conversely, SC Ti samples exhibited irradiation-induced hardening. The SC Ti irradiated samples developed additional irradiation-induced modifications in crystallographic texture of (100), (101), (110), (200), (112), (004), and (211) as evidenced from the XRD results, which could probably explain the hardening effect that is caused by irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Graphene reinforced UHMWPE fibers

Thermoplastic polymers are increasingly used in electric vehicles, hydrogen fuel cell vehicles, and other decarbonization applications due to their lightweight and formability. Higher-strength polymers are needed to supplant metals in the vehicle structure, thereby reducing mass and improving efficiency. Ultra-high molecular weight polyethylene (UHMWPE) fibers possess one of the highest strength-to-weight ratios of technical polymers, and further improvement via reinforcement by nanofillers, such as graphene, will expand their performance envelope. Here, in this work, UHMWPE/graphene nanocomposite fibers were gel spun and characterized for their morphological, microstructural, thermal, and mechanical properties. The addition of a low fraction of graphene improved the tensile strength of the fibers by 25% and tensile modulus by 32%. Differential scanning calorimetry showed an increase in melting temperature and degree of crystallinity, which indicates improved coordination of the molecular chains induced by the addition of graphene. The reinforcement also affected the cross-sectional shape of the fibers; the aspect ratio of the fibers’ elliptical shape declined with increasing graphene content showing the skeletal effect of the graphene nanofillers in the polymer matrix. The reinforcing effect of graphene declined above a threshold concentration, and theoretical modeling was applied to demonstrate that increased agglomerates led to reduced properties. This work demonstrates a simple, effective method to produce graphene-reinforced UHMWPE fibers and lays a foundation for understanding the potential for leveraging graphene to form ultra-high-performance nanocomposite fibers for myriad engineering applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Actinium purification from elemental components of stainless steel and aluminum

Radioisotopes of actinium are valuable because of their potential use in the medical industry. Actinium-225 shows promise for treating disease—like cancer—via targeted alpha therapy (TAT), and the longer-lived actinium-227 is the parent of two radionuclides with potential application in TAT radiopharmaceuticals, thorium-227 and radium-223. Continuing progress in the development of these medical applications requires robust and diverse methods for extracting and purifying actinium from a wide range of matrices. Further, to define the strengths and limitations of separation methods commonly employed in actinium processing, we characterized the performance of ion exchange and extraction chromatographic steps for removing contaminants found in stainless steel (chromium, iron, nickel, and silicon) and aluminum from actinium-227. While AG-MP1 anion exchange resin with HCl (aq) successfully removed iron, cation exchanger AG 50W-X8 removed most other contaminants. The most persistent contaminant was aluminum, which was removed using a DGA Normal extraction resin. These results are presented within the context of applying that methodology toward actinium purification strategies.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Quantification of uranium metal and total uranium in U-UO 2 mixtures using H 3 PO 4 -HCl

Here, the selective dissolution of uranium metal from its mixtures with UO 2 was studied to establish a simple and rapid quantitative method. Uranium metal was found to selectively dissolve as U(IV) into a solution of phosphoric and hydrochloric acids, with quantitative dissolution occurring within 1 h. Total dissolution of uranium as U(VI) could then be obtained by nitric acid addition and heating for 0.5–1 h. Analysis of the resulting U(IV) and U(VI) solutions by ICP-OES or UV–Vis spectroscopy yielded uranium metal-to-UO 2 ratios with an accuracy of ± 10% or better. Accuracy of the ICP-OES method was slightly better than UV–Vis, but the simplicity of the latter makes it an attractive option for some applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Single particle trace element analysis of uranium oxide standards with laser-induced breakdown spectroscopy

Femtosecond Laser-Induced Breakdown Spectroscopy (LIBS) was used to analyze over 1000 individual particles of uranium oxide trace element standard CRM124. Intra-granular analysis showed elemental concentrations were consistent across different surface locations on each uranium grain. However, inter-granular comparison revealed large heterogeneity between different grains of the same sample. By comparing the distribution of elemental concentrations across the particle populations, we were able to correctly identify a manufacturing process involving wet chemistry, rather than a dry mixing of two powders to give an overall chemical average. In conclusion, this demonstrates the utility of LIBS as a large-scale single particle analysis tool for nuclear forensics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Measurement of partial vapor pressures of salt mixtures via combined horizontal transpiration and thermogravimetric analysis

A method combining thermogravimetric analysis (TGA) and horizontal transpiration with elemental analysis via inductively coupled plasma mass spectrometry or ion chromatography enabled calculation of partial pressures of individual salts in molten mixtures. TGA quantified total mass loss, while transpiration identified vapor-phase composition. Furthermore, two chloride (NaCl-MgCl 2 , NaCl-MgCl 2 + UCl 3 ) salts and one mixed halide (LiCl-LiF + Li 2 O) salt were analyzed at 750 °C and 550 °C, respectively. NaCl and MgCl 2 vapor pressures were 2.19–2.61 × 10 -4 atm and 2.47–2.48 × 10 -5 atm (dependent upon the identity of the invesitgated mixture); UCl 3 was 1.42 × 10 -7 atm. LiCl and LiF vapor pressures at 550 °C were 1.53 × 10 -6 and 6.32 × 10 -6 atm, respectively. Additionally, the TGA method was validated against values from the literature for unary LiCl and LiF.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Structural Characterization of Disulfide-Linked p53-Derived Peptide Dimers

Disulfide bonds provide a convenient method for chemoselective alteration of peptide and protein structure and function. We previously reported that mild oxidation of a p53-derived bisthiol peptide (CTFANLWRLLAQNC) under dilute non-denaturing conditions led to unexpected disulfide-linked dimers as the exclusive product. The dimers were antiparallel, significantly α-helical, resistant to protease degradation, and easily reduced back to the original bisthiol peptide. Here, in this work, we examine the intrinsic factors influencing peptide dimerization using a combination of amino acid substitution, circular dichroism (CD) spectroscopy, and X-ray crystallography. CD analysis of peptide variants suggests critical roles for Leu6 and Leu10 in the formation of stable disulfide-linked dimers. The 1.0 Å resolution crystal structure of the peptide dimer supports these data, revealing a leucine-rich LxxLL dimer interface with canonical knobs-into-holes packing. Two levels of higher-order oligomerization are also observed in the crystal: an antiparallel “dimer of dimers” mediated by Phe3 and Trp7 residues in the asymmetric unit and a tetramer of dimers mediated by Trp7 and Leu10. In CD spectra of Trp-containing peptide variants, minima at 227 nm provide evidence for the dimer of dimers in dilute aqueous solution. Importantly, and in contrast to the original dimer model, the canonical leucine-rich core and robust dimerization of most peptide variants suggests a tunable molecular architecture to target various proteins and evaluate how folding and oligomerization impact various properties, such as cell permeability.

36 MATERIALS SCIENCE↗
DOE OSTI2024

High-Temperature Oxidation Study in a Multi-Oxidant Environment Using 18 O Tracer

The goal of this study was to use 18 O-enriched water to better understand the role of H 2 O in high-temperature oxidation. Seven model and three commercial M-Cr and M-Cr-Al alloys were studied in air with 10% of H 2 O at 800 °C for 5 h. Oxygen from water vapor was more reactive than oxygen from the air and 18 O enriched at the outermost layers of the formed Cr- and Al-rich oxides. Alloys with Al and/or Ti additions showed signs of internal oxidation but 18 O was not enriched inside the alloy in locations with internal oxidation. In conclusion, depending on the alloy Al content, the oxide went from Al oxidation beneath a chromia scale to external alumina scale formation.

18O-enriched water↗