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DOE OSTI2025

Extrusion‐Spheronization of Mock Energetic Materials

The primary method for producing plastic bonded explosive (PBX) granules, or “prills”, has remained relatively unchanged for 70 years despite the complex nature of the process. In this work, we demonstrate the feasibility of using an extrusion‐spheronization technique to produce prills for PBX applications. We begin by detailing an inert formulation with similar properties of PBXs and then demonstrate the extrusion‐spheronization processing of these materials. A study is then performed where the spheronization process time of the extruded materials is varied and the resultant prills are morphologically characterized. Further, these prills are then pressed into high‐density articles and subject to compression testing to elucidate trends in process, properties, and performance. It was found that, for our formulation (95 wt.% melamine/5 wt.% polymer binder) and process, a spheronization time of 60 s yielded relatively uniform particles that exhibited improved poured, tapped, and pressed densities. Mechanical strength did not have a strong trend with process time as all spheronized materials had similar peak compression stress at failure. After further optimization, extrusion‐spheronization may be a promising path for future PBX formulation.

extrusion spheronization↗

DOE OSTI2023

Warming of the lower Columbia River , 1853 to 2018

Abstract Water temperature is a critical ecological indicator; however, few studies have statistically modeled century‐scale trends in riverine or estuarine water temperature, or their cause. Here, we recover, digitize, and analyze archival temperature measurements from the 1850s onward to investigate how and why water temperatures in the lower Columbia River are changing. To infill data gaps and explore changes, we develop regression models of daily historical Columbia River water temperature using time‐lagged river flow and air temperature as the independent variables. Models were developed for three time periods (mid‐19th, mid‐20th, and early 21st century), using archival and modern measurements (1854–1876; 1938–present). Daily and monthly averaged root‐mean‐square errors overall are 0.89°C and 0.77°C, respectively for the 1938–2018 period. Results suggest that annual averaged water temperature increased by 2.2°C ± 0.2°C since the 1850s, a rate of 1.3°C ± 0.1°C/century. Increased water temperatures are seasonally dependent. An increase of approximately 2.0°C ± 0.2°C/century occurs in the July–Dec time‐frame, while springtime trends are statistically insignificant. Rising temperatures change the probability of exceeding ecologically important thresholds; since the 1850s, the number of days with water temperatures over 20°C increased from ~5 to 60 per year, while the number below 2°C decreased from ~10 to 0 days/per year. Overall, the modern system is warmer, but exhibits less temperature variability. The reservoir system reduces sensitivity to short‐term atmospheric forcing. Statistical experiments within our modeling framework suggest that increased water temperature is driven by warming air temperatures (~29%), altered river flow (~14%), and water resources management (~57%).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

What can surface wind observations tell us about interannual variation in wind energy output?

The past decade of wind power growth was supported by capacity factor improvements and associated cost reductions. But are higher capacity factors a technology success story or, as suggested by recent research, has the influence of technology been overstated by ignoring positive surface wind speed trends? The answer could influence estimates of wind energy's cost and even future deployment rates. We find that US surface wind speed observations imply a 2.6% improvement in capacity factors from 2010 to 2019. Yet newer vintages of wind plants have recorded capacity factors that are ~25% larger than plants built close to 2010. It follows that technological factors and improved site quality, not higher wind speeds, drove most of the improvement in capacity factors. Additionally, we match hundreds of meteorological stations to nearby (< 25 km) wind plants and compare annual estimated generation, based on a function of surface wind speed observations, to annual recorded generation. Researchers rely on this publicly available surface data because measurements co-located with wind plants are generally considered proprietary. Our analysis addresses a research gap: interannual variation in observed surface wind speeds is rarely compared to observed data at wind plant locations and turbine heights. We find that despite its common use for this purpose, generation estimates based on publicly available surface observational data provide a poor proxy for interannual variability in recorded wind generation. These findings suggest that caution is generally needed when researchers use surface wind speed measurements to investigate long-term wind energy trends.

17 WIND ENERGY↗

DOE OSTI2024

Multiplicity-dependent production of Σ(1385) ± and Ξ(1530) 0 in pp collisions at $\sqrt{s}$ = 13 TeV

The production yields of the Σ(1385) ± and Ξ(1530) 0 resonances are measured in pp collisions at $\sqrt{s}$ = 13 TeV with ALICE. The measurements are performed as a function of the charged-particle multiplicity $\langle$dN ch /dη$\rangle$, which is related to the energy density produced in the collision. The results include transverse momentum (p T ) distributions, p T - integrated yields, mean transverse momenta of Σ(1385) ± and Ξ(1530) 0 , as well as ratios of the p T - integrated resonance yields relative to yields of other hadron species. The Σ(1385) ± /π ± and Ξ(1530) 0 /π ± yield ratios are consistent with the trend of the enhancement of strangeness production from low to high multiplicity pp collisions, which was previously observed for strange and multi-strange baryons. The yield ratio between the measured resonances and the long-lived baryons with the same strangeness content exhibits a hint of a mild increasing trend at low multiplicity, despite too large uncertainties to exclude the flat behaviour. The results are compared with predictions from models such as EPOS-LHC and PYTHIA 8 with Rope shoving. The latter provides the best description of the multiplicity dependence of the Σ(1385) ± and Ξ(1530) 0 production in pp collisions at $\sqrt{s}$ = 13 TeV.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

A framework for detection and attribution of regional precipitation change: Application to the United States historical record

Abstract Despite the emerging influence of anthropogenic climate change on the global water cycle, at regional scales the combination of observational uncertainty, large internal variability, and modeling uncertainty undermine robust statements regarding the human influence on precipitation. Here, we use output from global climate models in a perfect-data sense to develop a framework for conducting regional detection and attribution (D&A) for precipitation, starting with the contiguous United States (CONUS) where observational uncertainty is lower than in other regions. Our unified approach can simultaneously detect systematic trends in mean and extreme precipitation, attribute trends to anthropogenic forcings, compute the effects of forcings as a function of time, and map the effects of individual forcings. Model output is used to conduct a set of tests that yield a parsimonious representation for characterizing seasonal precipitation over the CONUS for the historical record (1900 to present day), which ensures our D&A is insensitive to structural uncertainty. Our framework is developed using synthetic data in a Pearl-causal perspective wherein causality can be identified using intervention-based simulations. While the hypothesis-based framework and accompanying generalized D&A formula we develop should be widely applicable, we include a strong caution that the hypothesis-guided simplification of the formula for the historical climatic record of CONUS as described in this paper will likely fail to hold in other geographic regions and under future warming.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Detecting impacts of surface development near weather stations since 1895 in the San Joaquin Valley of California

Abstract Temperature readings observed at surface weather stations have been used for detecting changes in climate due to their long period of observations. The most common temperature metrics recorded are the daily maximum (TMax) and minimum (TMin) extremes. Unfortunately, influences besides background climate variations impact these measurements such as changes in (1) instruments, (2) location, (3) time of observation, and (4) the surrounding artifacts of human civilization (buildings, farms, streets, etc.) Quantifying (4) is difficult because the surrounding infrastructure, unique to each site, often changes slowly and variably and is thus resistant to general algorithms for adjustment. We explore a direct method of detecting this impact by comparing a single station that experienced significant development from 1895 to 2019, and especially since 1970, relative to several other stations with lesser degrees of such development (after adjustments for the (1) to (3) are applied). The target station is Fresno, California (metro population ~ 15,000 in 1900 and ~ 1 million in 2019) situated on the eastern side of the broad, flat San Joaquin Valley in which several other stations reside. A unique component of this study is the use of pentad (5-day averages) as the test metric. Results indicate that Fresno experienced + 0.4 °C decade −1 more nighttime warming (TMin) since 1970 than its neighbors—a time when population grew almost 300%. There was little difference seen in TMax trends between Fresno and non-Fresno stations since 1895 with TMax trends being near zero. A case is made for the use of TMax as the preferred climate metric relative to TMin for a variety of physical reasons. Additionally, temperatures measured at systematic times of the day (i.e., hourly) show promise as climate indicators as compared with TMax and especially TMin (and thus TAvg) due to several complicating factors involved with daily high and low measurements.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Multi-Scale Temporal Patterns in Stream Biogeochemistry Indicate Linked Permafrost and Ecological Dynamics of Boreal Catchments

Temporal patterns in stream chemistry provide integrated signals describing the hydrological and ecological state of whole catchments. However, stream chemistry integrates multi-scale signals of processes occurring in both the catchment and stream. Deconvoluting these signals could identify mechanisms of solute transport and transformation and provide a basis for monitoring ecosystem change. Here, we applied trend analysis, wavelet decomposition, multivariate autoregressive state-space modeling, and analysis of concentration-discharge relationships to assess temporal patterns in high-frequency (15 min) stream chemistry from permafrost-influenced boreal catchments in Interior Alaska at diel, storm, and seasonal time scales. We compared catchments that varied in spatial extent of permafrost to identify characteristic biogeochemical signals. Catchments with higher spatial extents of permafrost were characterized by increasing nitrate concentration through the thaw season, an abrupt increase in nitrate and fluorescent dissolved organic matter (fDOM) and declining conductivity in late summer, and flushing of nitrate and fDOM during summer rainstorms. In contrast, these patterns were absent, of lower magnitude, or reversed in catchments with lower permafrost extent. Solute dynamics revealed a positive influence of permafrost on fDOM export and the role of shallow, seasonally dynamic flowpaths in delivering solutes from high-permafrost catchments to streams. Lower spatial extent of permafrost resulted in static delivery of nitrate and limited transport of fDOM to streams. Shifts in concentration-discharge relationships and seasonal trends in stream chemistry toward less temporally dynamic patterns might therefore indicate reorganized catchment hydrology and biogeochemistry due to permafrost thaw.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Analysis of the Ion Conversion Mechanisms in the Effluent of Atmospheric Pressure Plasma Jets in Ar with Admixtures of O 2 , H 2 O and Air

Ionic species in atmospheric pressure plasma jets (APPJs) play an important role in plasmasurface and plasma-liquid interactions, nonetheless, they have not received the same attention as their neutral reactive species counterparts. In this work, a molecular beam mass spectrometer (MBMS) was used to characterize the ion compositions in the effluent of an APPJ operating in ambient air for different feed gases including Ar + O 2 , Ar + air and Ar + H 2 O mixtures inspired by gas compositions used for biomedical applications. Changes in compositions of positive and negative ions as a function of nozzle-to-substrate distance along the plasma plume were analyzed and compared with a pseudo-1D plug flow model. Positive and negative ions were detected up to distances of 12 mm from the visible plasma plume tip. The measurements enable to follow the ion conversion pathways in the effluent of the APPJs as a function of distance from the nozzle. The trends in ion yield obtained from a pseudo-1D plug flow model showed generally a good agreement with the experimentally observed trends after addition of ionic reactions to the previously reported reaction set but also some distinctive differences were observed. The dominant positive ions in the far effluent are water ion clusters, the most stable ion for all gas mixtures investigated, while a large variety of negative ions was found for different gas mixtures.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

A Comprehensive Scientific Survey of Excipients Used in Currently Marketed, Therapeutic Biological Drug Products

The steady development of biotechnology-derived therapeutic biologics over the last few decades has generated drugs that are now standard medical treatments for a range of indications. While the development of protein products has surged in recent years, the formulation and delivery of these complex molecules have relied on drug-specific studies and, in some instances, data from non-proteinaceous drug products. The commonalities, trends, and gaps in excipient technologies used to support the development of therapeutic proteins largely remain unexplored due to the drug-specific nature of many formulations. Using a comprehensive and relational database approach, we aimed to provide a scientific survey of all approved or licensed biotechnology-derived drug products with the goal of providing evidence-based information on common attributes and trending features in protein product excipients. We examined 665 formulations, and 395 unique formulations based on having unique excipients within them, that supported 211 therapeutic proteins as of June 2020. We report the prevalence of each excipient class and excipient chemical used in eight different drug types including monoclonal antibodies, antibody conjugates, cytokines and growth factors, enzymes, polypeptide hormones, pulmonary surfactants, recombinant fusion proteins, and toxins. We also report the prevalence by excipient type among all therapeutic proteins, in the context of each drug’s recommended pH range, concentration ranges for excipients, and route of administration. The results of our analyses indicate certain excipients common to monoclonal antibodies, cytokines, and polypeptide hormones. We also report on excipients unique to protein drug products, such as amino acids, solubilizers, and lyoprotectants. Overall, our report summarizes the current landscape of excipients used in marketed biotechnology-derived therapeutic biologic products.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2024

Validation of Hole-Drilling Residual Stress Measurements in Workpieces of Various Thickness

A recent revision to the ASTM E837 standard for near-surface residual stress measurement by the hole-drilling method describes a new thickness-dependent stress calculation procedure applicable to “thin” and “intermediate” workpieces for which strain versus depth response depends on workpiece thickness. This new calculation procedure differs from that of the prior standard, which applies only to thick workpieces with strain versus depth response independent of thickness. Herein we assess the new calculation procedures by performing hole-drilling residual stress measurements in samples with a range of thickness. Near-surface residual stress is measured in a thick aluminum plate containing near-surface residual stress from a uniform shot peening treatment, and in samples of different thickness removed from the plate at the peened surface. A finite element (FE) model is used to assess consistency between measured residual stress across the range of sample thickness. Measured residual stress varies with sample thickness, with thinner samples exhibiting smaller near-surface compressive stress and a larger gradient of subsurface stress. These trends are consistent with both observed bending (curvature) of the removed samples and the trend in FE-calculated expected residual stress. The measured and expected residual stresses are in good agreement for samples of intermediate thickness, but the agreement decreases with sample thickness. Measured residual stress is invariant with gage circle diameter. The new thickness-dependent stress calculation procedure for hole-drilling provides meaningful improvement compared to thick-workpiece calculations.

42 ENGINEERING↗

DOE OSTI2021

Method for Rapid Modeling of Distortion in Laser Powder Bed Fusion Metal Additive Manufacturing Parts

The simulation and modeling of part-level distortion and residual stress in diverse metal additive manufacturing (AM) geometries has great potential to enable the rapid adoption of this technology in engineering design. Moreover, the use of additive manufacturing component libraries (CLs) offer a computationally efficient means of quantifying these part-level defects resultant from AM processing. We report on how the individual simulations of simple shapes, potential entries in a CL, can be superimposed to provide an indication of distortion and residual stresses in complex geometries. Laser powder bed fusion AM was used to construct test geometries of varied shapes and their combinations in the form of CLs in an effort to characterize location-dependent and feature-dependent distortion distributions. Blue light scanning was used to experimentally measure 3D distortions in order to investigate the interaction between the component shapes and local boundary conditions. Overall, part-level distortions were highly dependent on test component geometry, local boundary conditions, and shape combination. Commercial finite element software was used to verify experimental trends and to make predictions of distortion. The use of CLs resulted in over 20 times savings in computational cost while reproducing overall trends in distortion for test geometry assemblies. Therefore, it is anticipated that the use of CLs for L-PBF AM geometries has demonstrated potential to facilitate efficient simulations of full component AM assemblies, thereby reducing the need for costly trial-and-error-type experimental analysis.

36 MATERIALS SCIENCE↗

DOE OSTI2021

High-Throughput Statistical Interrogation of Mechanical Properties with Build Plate Location and Powder Reuse in AlSi10Mg

Abstract Additive manufacturing (AM) allows agile, rapid manufacturing of geometrically complex components that would otherwise be impossible through traditional manufacturing methods. With this maturing manufacturing technology comes the need to adopt testing methods that are commensurate with the speed of additive manufacturing and take advantage of its geometric flexibility. High-throughput tensile testing (HTT) is a technique that allows a large number of tensile bars to be tested in a short amount of time. In the present study, HTT is used to evaluate AM AlSi10Mg produced using powder bed fusion with a Renishaw AM250 machine. Three parameters were varied in this study: (1) powder reuse history, (2) location on the build plate, and (3) size of the tensile specimen. For all parameter combinations, at least 22 specimens were tested; in several cases, over 40 were tested. This large dataset, consisting of over 500 tensile tests, permits Weibull statistical analysis and provides sufficient fidelity to isolate subtle trends that would have likely been missed in smaller, traditional datasets. The observed trends are rationalized in terms of the role of porosity and surface crust on mechanical response.

Carroll, Jay D. (ORCID:0000000258184709)↗

DOE OSTI2025

Corrosion Response of Ni-19Cr-5Fe in Molten NaCl-MgCl 2 Salt

Ni-based alloys are strong candidates for use in high-temperature molten salt reactors due to their superior corrosion resistance and mechanical stability compared to stainless steels. In this study, the static corrosion behavior of a Ni-19Cr-5Fe model alloy was systematically evaluated in a purified molten NaCl-MgCl 2 salt at 700°C for 30, 240, and 500 h. Post-exposure analyses were conducted to assess microstructural evolution, corrosion depth, and elemental depletion profiles. Corrosion rates, quantified by chromium depletion depth, followed an inverse power-law trend with increasing exposure time, indicating diffusion-limited kinetics. This trend is attributed to limitations in mass transport in the static salt and to the progressive local depletion of reactive chromium species. Coupled electron backscatter diffraction and energy dispersive X-ray spectroscopy analysis further revealed that the grain boundary character significantly influences corrosion susceptibility: high-angle grain boundaries exhibited pronounced Cr depletion and pitting, while low-angle and Σ3 boundaries remained comparatively resistant. These results offer valuable insight into the role of microstructure in corrosion processes and reinforce the importance of time-dependent material evaluation in molten salt environments relevant to advanced reactor designs.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Assessing the Effectiveness of Large-Scale Environmental Restoration: Challenges and Opportunities

A recent National Academies consensus report addresses monitoring and assessment of cumulative effects of large-scale and multiple restoration projects within the context of long-term environmental change. Fines and penalties from the Deepwater Horizon oil spill in the Gulf of Mexico (GoM) have supported hundreds of restoration projects at spatial scales not often possible in the past. Here, in this paper, the report committee members and staff provide personal reflections from our time working on the study. We found that gaps in data collection, issues with data accessibility, and a lack of synthesis and analysis are hindering the ability to answer a basic question: What are the impacts of these many restoration efforts on improving ecosystem health and productivity in the GoM at the regional and Gulf wide scale? Restoration efforts are occurring in environments where many trends are changing and exhibiting higher variability than in the past, suggesting that previously successful restoration practices may no longer be adequate to compensate for the effects of environmental changes and variability. Our proposed approach to these challenges includes employing emerging monitoring technologies; using conceptual models; devising an adaptive management framework; rethinking restoration outcome goals; assessing cumulative effects; and undertaking rigorous synthesis and analysis of existing information on long-term environmental trends and restoration efforts. Restoration scientists and practitioners working in the GoM have an unprecedented opportunity to demonstrate large-scale environmental recovery if advances in monitoring, synthesis, assessment, and action are taken quickly. We are cautiously optimistic that, with mid-course adjustments, continued progress toward large-scale environmental recovery is possible.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Shortened Duration of Global Warming Slowdowns with Elevated Greenhouse Gas Emissions

Continuous emissions of anthropogenic greenhouse gases (GHGs) and aerosols in the last 160 years have resulted in an increasing trend of global mean surface temperatures (GMSTs). Due to interactions with natural variability, rates of the combined anthropogenically and naturally induced warming trends are characterized by significant slowdowns and speedups on decadal timescales. In this work, by analyzing observed and model-simulated data, we investigate how the duration of these episodes will change with different strengths of GHG and aerosol forcing. We found that the duration of warming slowdowns can be more than 30 yr with a slower rate of anthropogenic emissions but would shorten to about 5 yr with a higher one. This duration reduction depends on both the magnitude of the climate response to anthropogenic forcing and the strength of the internal variability. Moreover, the warming slowdowns can still occur even towards the end of this century under high emissions scenarios but with significantly shortened duration.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Changing Degree of Convective Organization as a Mechanism for Dynamic Changes in Extreme Precipitation

Purpose of Review: What does recent work say about how changes in convective organization could lead to changes in extreme precipitation? Recent Findings: Changing convective organization is one mechanism that could explain variation in extreme precipitation increase through dynamics. In models, the effects of convective self-aggregation on extreme precipitation are sensitive to parameterization, among other factors. In both models and observations, whether or not convective organization influences extreme precipitation is sensitive to the time and space scales analyzed, affecting extreme precipitation on some scales but not others. While trends in observations in convective organization associated with mean precipitation have been identified, it has not yet been established whether these trends are robust or relevant for events associated with extreme precipitation. Summary: Recent work has documented a somewhat view of how changes in convective organization could affect extreme precipitation with warming, and it remains unclear whether or not they do.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Change of Electrical and Transport Properties of Nickel Oxide by Carrier Concentration and Temperature through First-Principle Calculations

Abstract Nickel is typically used as one of the main components in electrical contact devices or connectors. Nickel oxide (NiO) is usually formed on the surfaces of electrodes and can negatively impact system performance by introducing electrical contact resistance. The thermal, electrical, and transport properties of NiO, as a Mott insulator or a p-type semiconductor, can be altered by operating and environmental conditions such as temperature and stress/strain by contact. In this study, we investigate the fundamental material properties of NiO through the first-principle calculations. First, we obtain and compare the lattice parameter, magnetic moment, and electronic structure for NiO via the WIEN2K simulations with four different potentials (i.e., GGA, GGA + U, LSDA, and LSDA + U). Then, using the WIEN2K simulation results with LSDA + U potential that produces a highly accurate bandgap for NiO, we calculate the electrical conductivity and electrical part of the thermal conductivity of nickel and NiO as a function of temperature and carrier concentration through the BoltzTraP simulations. Systematic simulation results revealed that the electrical conductivity relative to the relaxation time for NiO increases with the carrier concentration, while it shows a slightly decreasing trend with temperature under a fixed carrier concentration. By contrast, the electrical part of the thermal conductivity shows an increasing trend considering carrier concentration and temperature.

Shah, Nayem Md. Reza↗

DOE OSTI2025

3D printing of packaging inserts from biomass-fungi composites: Environmental sustainability analysis

In this study, a comprehensive Life cycle assessment (LCA) is conducted on molded packaging inserts from expanded polystyrene (EPS) foam, molded packaging inserts from biomass-fungi composite, and 3D-printed packaging inserts from biomass-fungi composite under the low mix / high volume (LMHV) scenario and molded and machined packaging inserts from EPS foam, molded and machined packaging inserts from biomass-fungi composite, and 3D-printed packaging inserts from biomass-fungi composite under the high mix / low volume (HMLV) scenario. Six environmental impact categories—climate change, acidification, eutrophication, fossil resource scarcity, land use, and water consumption—are analyzed to evaluate the environmental trade-offs associated with each type of packaging inserts. Under the LMHV scenario, molded packaging inserts from biomass-fungi composite emerge as the best option due to their lower impact on climate change, acidification and water consumption compared to other types of packaging inserts. Conversely, molded packaging inserts from biomass-fungi composite face challenges in land use and eutrophication, primarily due to raw material production. LCA also reveals that 3D-printed packaging inserts from biomass-fungi composite are the most environmentally favorable option under the HMLV scenario, due to significantly lower contributions to climate change, eutrophication, and water consumption compared to other types of packaging inserts. Conversely, 3D-printed packaging inserts from biomass-fungi composite face challenges in acidification and land use, primarily due to raw material production. As part of the LCA, sensitivity analyses show that sourcing energy from 100% renewable sources substantially lowers climate change impacts across all packaging types, while varying transportation distances results in only minor changes, indicating the dominant role of upstream material and manufacturing processes. Additional sensitivity analysis is conducted under the HMLV scenario to assess the impact of material removal during machining on the environment. The amount of material removal is varied from 10 to 70% for the sensitivity analysis and it highlights that the amount of material removed during machining has no significant impact on climate change for packaging inserts from EPS foam. However, molded and machined packaging inserts from biomass-fungi composite show an increasing trend in climate change with higher amount of material removal, while 3D-printed packaging inserts from biomass-fungi composite exhibit a decreasing trend, driven by reduced raw material usage and energy consumption.

09 BIOMASS FUELS↗