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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.

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At least 919 records · Page 51
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers

High-density bonded rare-earth magnets are manufactured using pellet-fed additive manufacturing (AM)/material extrusion and an integrated additive manufacturing-compression molding (AM-CM) process. Neodymium iron boron – samarium iron nitride in polyamide 12 (NdFeB-SmFeN/PA12) of 93 % weight fraction (65 % volume fraction) are used for the study. The mechanical properties (tensile strength and modulus), magnetic properties (maximum energy density, coercivity, remanence) are reported. Manufacturing parameters such as layer height, barrel temperatures, screw speed and gantry feed rate are optimized to obtain the highest possible density of the magnets using a small-scale desktop material extrusion printer. Large scale integrated additive manufacturing-compression molding (AM-CM) is then utilized to increase the density of the magnets by reducing porosity defects common in the material extrusion process. The density of as-printed magnets was 5.2 g/cm 3 with a BH max value of 124.14 kJ/m 3 , tensile strength of 20 MPa and a modulus of 2 GPa. AM-CM increased the density of the compound by 5.5 % (5.49 g/cm 3 ). The reduction in porosity was confirmed using X-ray tomography (XCT). Improvement in mechanical strength of the material was also observed, with an increase in tensile strength of 25 % (25.09 MPa) and increase in tensile modulus of 275 % (5.49 GPa). Scanning electron microscopy showed increased particle-matrix adhesion with the integrated AM-CM process.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fabrication of highly dense isotropic Nd-Fe-B nylon bonded magnets via extrusion-based additive manufacturing [Fabrication of highly dense isotropic Nd-Fe-B bonded magnets via extrusion-based additive manufacturing]

Magnetically isotropic bonded magnets with a high loading fraction of 70 vol.% Nd-Fe-B are fabricated via an extrusion-based additive manufacturing, or 3D printing system that enables rapid production of large parts. The density of the printed magnet is ~5.2 g/cm 3 . The room temperature magnetic properties are: intrinsic coercivity H ci = 8.9 kOe (708.2 kA/m), remanence B r = 5.8 kG (0.58 T), and energy product (BH)max = 7.3 MGOe (58.1 kJ/m 3 ). The as-printed magnets are then coated with two types of polymers, both of which improve the thermal stability as revealed by flux aging loss measurements. Tensile tests performed at 25 °C and 100 °C show that the ultimate tensile stress (UTS) increases with increasing loading fraction of the magnet powder, and decreases with increasing temperature. AC magnetic susceptibility and resistivity measurements show that the 3D printed Nd-Fe-B bonded magnets exhibit extremely low eddy current loss and high resistivity. Lastly, we demonstrate the performance of the 3D printed magnets in a DC motor configuration via back electromotive force measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Bacterial communities protect the alga Microchloropsis salina from grazing by the rotifer Brachionus plicatilis

Open algal ponds are likely to succumb to unpredictable, devastating crashes by one or several deleterious species. Developing methodology to mitigate or prevent pond crashes will increase algal biomass production, drive down costs for algae farmers, and reduce the risk involved with algae cultivation, making it more favorable for investment by entrepreneurs and biotechnology companies. In this work, we postulate that specific algal-bacterial co-cultures grown with the green alga Microchloropsis salina prevented grazing by the marine rotifer, Brachionus plicatilis. We obtained seven algal-bacterial co-cultures from crashed rotifer cultures, maintained them in co-culture with Microchloropsis salina , and used a microalgal survival assay to determine that algae present in each co-culture were protected from rotifer grazing and culture crash. After months of routinely diluting and maintaining these seven algal-bacterial co-cultures, we repeated the assay and found the opposite result: none of the seven bacterial communities protected the microalgae from rotifer grazing. We performed 16S rRNA gene amplicon sequencing on the protective and nonprotective co-culture samples and identified substantial differences in the makeup of the bacterial communities. Protective bacterial communities consisted primarily of Alphaproteobacteria (Rhodobacteraceae) and Gammaproteobacteria ( Marinobacter , Pseudomonas, Methylophaga ) while nonprotective bacterial communities were less diverse and missing many putatively crucial members. We compared the seven protective communities with the seven nonprotective communities and we correlated specific bacterial amplicon sequence variants with algal protection. With these data, our future research will aim to define and develop an engineered-microbiome that can stabilize industrial Microchloropsis salina cultures by protecting against grazer-induced pond crashes.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Persistence of bacterial-mediated anti-rotifer protection in preliminary outdoor cultivation trial for Microchloropsis salina

Outdoor algal cultivation systems are susceptible to a wide variety of deleterious species. In previously published studies, we observed protection using microbial consortia at laboratory scale cultures; Microchloropsis salina in the presence of microbial consortia were protected from grazing from the marine rotifer, Brachionus plicatilis. Our objective for the present work was to determine if this protection conferred by microbial consortia in controlled laboratory experiments would persist in an open, outdoor multi-liter cultivation system. We found that algal protection did persist as evidenced by the presence of fewer motile rotifers and decreased rotifer-associated egg counts for the consortia-treated outdoor cultures. Due to the low temperature and light conditions that reduced growth of the algae outdoors, we performed an indoor laboratory assay which also confirmed the persistence of algal protection. Lastly, the lower numbers of motile rotifers and fewer rotifer-associated eggs in the consortia-treated algal cultures suggests a possible protective mechanism by the consortia through interfering with the rotifer lifecycle or reproduction. Finally, these initial results support the possibility that low cost, prophylactic treatments with microbial consortia can protect algae from deleterious species in outdoor cultivation systems.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2026

Functionalized benzylamines from commercial kraft lignin

Benzylamines are key intermediates in pharmaceuticals, agrochemicals, and polymers, but their conventional production relies on benzyl chloride - a petroleum-derived compound with high toxicity and energy demands. Lignin, accounting for up to 30% of plant biomass, is the largest renewable source of aromatic carbon on Earth. However, its highly complex and recalcitrant structure poses a major barrier to efficient conversion into high-value chemicals. Here, in this study, we developed a catalytic approach to convert commercial kraft lignin into phenolic benzylamines through selective depolymerization and subsequent functionalization. We systematically evaluated the effects of three alcohol solvents, formic acid (FA), and a ruthenium-on‑carbon (Ru/C) catalyst on monophenol yield and selectivity. Up to 6.5 wt% monophenol yield was achieved using methanol (MeOH), FA, and Ru/C at 300 °C for 2 h. Quantum thermodynamic simulations based on the COSMO-RS model confirmed the superior solvation and reactivity of the MeOH + FA system, rationalizing observed product yield. The purified monophenolic products, primarily guaiacol and alkyl guaiacols, were then converted into functionalized benzylamines with >90% yield via a multicomponent Mannich reaction under mild conditions. Techno economic analysis (TEA) and life cycle assessment (LCA) underscore the importance of improving lignin depolymerization yields and expanding biorefinery scale. Solvent-only configurations outperform other options in both cost and emissions, with the methanol-only case performing the best ($\$$105 /kg and 26 kg CO 2e /kg) at a large-scale facility. This study establishes a scalable, bio-based pathway for producing benzylamines from commercial kraft lignin, advancing lignin valorization and offering a sustainable alternative to produce petrochemical-based benzylamines.

Catalytic reduction↗
DOE OSTI2025

Component Identification of Solid Biomass Fuels Using Reflected Light Microscopy: Interlaboratory Study 2

As nations transition toward sustainable energy systems, biomass has become a vital component of global energy portfolios. Derived from organic materials such as wood, agricultural residues, forestry byproducts, and organic waste, biomass is a renewable energy source with significant environmental and economic benefits. Responsible biomass energy production can improve waste management, reduce emissions of greenhouse gases, and mitigate environmental pollution. However, as the diversity of biomass-derived fuels increases, robust quality assessment methods are essential to ensure their efficiency, safety, and minimal environmental impact. Reflected light microscopy (RLM) is one such technique with the potential to complement conventional physico-chemical analyses by enabling a rapid identification of material constituents and impurities. To refine this methodology and evaluate the reproducibility of solid biomass component identification using RLM, an interlaboratory study (ILS) was conducted. The study involved the recognition of 58 components across 45 photomicrographs, with the participation of 65 scientists and students from 25 countries. The participants faced high difficulty identifying some of the marked components, and as a result, the percentage of correct answers ranged from 19.0 % to 98.3 %, with an average correct identification rate of 62.7 %. The most challenging aspects of the identification process included distinguishing between woody and non-woody (agro) biomass, accurately identifying petroleum-derived materials, and differentiating agro biomass from inorganic matter. The results suggest that while RLM is an important tool for characterizing solid biomass, further development of methodology guidelines and training are necessary to enhance its effectiveness. Future research should prioritize preparing detailed, image-rich, microscopic morphological descriptions of biomass fuel components, which could improve the accuracy and reliability of using RLM in biomass fuel characterization.

09 BIOMASS FUELS↗
DOE OSTI2016

Subcritical ethylic biodiesel production from wet animal fat and vegetable oils: A net energy ratio analysis

Ethylic transesterification process for biodiesel production without any chemical or biochemical catalysts at different subcritical thermodynamic conditions was performed using wet animal fat, soybean and palm oils as feedstock. The results indicate that 2 h of reaction at 240 °C with pressures varying from 20 to 45 bar was sufficient to transform almost all lipid fraction of the samples to biodiesel, depending on the reactor dead volume and proportions between reactants. Conversions of 100%, 84% and 98.5% were obtained for animal fat, soybean oil and palm oil, respectively, in the presence of water, with a net energy ration values of 2.6, 2.1 and 2.5 respectively. Finally, these results indicate that the process is energetically favorable, and thus represents a cleaner technology with environmental advantages when compared to traditional esterification or transesterification processes.

09 BIOMASS FUELS↗
DOE OSTI2014

Projecting changes in annual hydropower generation using regional runoff data: An assessment of the United States federal hydropower plants

Federal hydropower plants account for approximately half of installed US conventional hydropower capacity, and are an important part of the national renewable energy portfolio. Utilizing the strong linear relationship between the US Geological Survey WaterWatch runoff and annual hydropower generation, a runoff-based assessment approach is introduced in this study to project changes in annual and regional hydropower generation in multiple power marketing areas. Future climate scenarios are developed with a series of global and regional climate models, and the model output is bias-corrected to be consistent with observed data for the recent past. Using this approach, the median decrease in annual generation at federal projects is projected to be less than –2 TWh, with an estimated ensemble uncertainty of ±9 TWh. Although these estimates are similar to the recently observed variability in annual hydropower generation, and may therefore appear to be manageable, significantly seasonal runoff changes are projected and it may pose significant challenges in water systems with higher limits on reservoir storage and operational flexibility. Lastly, future assessments will be improved by incorporating next-generation climate models, by closer examination of extreme events and longer-term change, and by addressing the interactions among hydropower and other water uses.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Understanding the impacts of inorganic species in woody biomass for preprocessing and pyrolysis–A review

Woody biomass represents an abundant resource for sustainable biofuels, biochemicals, and bioproducts. Technologies for converting woody biomass have been established for decades, and research consistently highlights the critical role of inorganic species and ash plays in feedstock handling and conversion processes, including equipment plugging, corrosion, and catalyst deactivation. A thorough understanding of the variability, transport behavior, and downstream impact of inorganic species in woody biomass is essential for defining feedstock quality specifications and developing effective management strategies for conversion processes. This review compiles critical information in five main sections: 1) inorganic species concentration in woody biomass, based on anatomical fractions and their sources of variability; 2) technique features for quantifying inorganic elemental chemical analysis; 3) impacts of inorganic species on biomass preprocessing; 4) impacts of inorganic species on pyrolysis, and 5) mitigation strategies. Additionally, this review explores future challenges and opportunities in addressing the impacts of inorganic species on biomass quality. These insights aim to support the sustainable development of the biomass-to-bioenergy pipeline and ensure high-quality lignocellulosic feedstocks for efficient downstream conversions. The findings offer valuable guidance to policy makers, industry stakeholders, and researchers in developing effective strategies for managing inorganic species in woody biomass and fostering the sustainable processes for lignocellulosic biorefineries.

09 BIOMASS FUELS↗
DOE OSTI2023

Impacts of divalent cations (Mg 2+ and Ca 2+ ) on PFAS bioaccumulation in freshwater macroinvertebrates representing different foraging modes

Per- and polyfluoroalkyl substances (PFAS) have extensively contaminated freshwater aquatic ecosystems where they can be transported in water and partition to sediment and biota. In this paper, three freshwater benthic macroinvertebrates with different foraging modes were exposed to environmentally relevant concentrations of eight perfluoroalkyl carboxylates (PFCA), three perfluoroalkyl sulfonates (PFSA), and three fluorotelomer sulfonates (FTS) at varying divalent cation concentrations of magnesium (Mg 2+ ) and calcium (Ca 2+ ). Divalent cations can impact PFAS partitioning to solids, especially to sediments, at higher concentrations. Sediment dwelling worms (Lumbriculus variegatus), epibenthic grazing snails (Physella acuta), and sediment-dwelling filter-feeding bivalves (Elliptio complanata) were selected due to their unique foraging modes. Microcosms were composed of synthetic sediment, culture water, macroinvertebrates, and PFAS and consisted of a 28-day exposure period. L. variegatus had significantly higher PFAS bioaccumulation than P. acuta and E. complanata, likely due to higher levels of interactions with and ingestion of the contaminated sediment. “High Mg 2+ ” (7.5 mM Mg 2+ ) and “High Ca 2+ ” (7.5 mM Ca 2+ ) conditions generally had statistically higher bioaccumulation factors (BAF) than the “Reference Condition” (0.2 mM Ca 2+ and 0.2 mM Mg 2+ ) for PFAS with perfluorinated chain lengths greater than eight carbons. Long-chain PFAS dominated the PFAS profiles of the macroinvertebrates for all groups of compounds studied (PFCA, PFSA, and FTS). Furthermore, these results indicate that the study organism has the greatest impact on bioaccumulation, although divalent cation concentration had observable impacts between organisms depending on the environmental conditions. Elevated cation concentrations in the microcosms led to significantly greater bioaccumulation in the test organisms compared to the experimental reference conditions for long-chain PFAS.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Effects of dissolved cations, dissolved organic carbon, and exposure concentrations on per- and polyfluoroalkyl substances bioaccumulation in freshwater algae

Per- and polyfluoroalkyl substances (PFAS) have attracted global attention because of their persistence, toxicity, bioaccumulation potential, and associated adverse effects. As important primary producers, freshwater algae constitute the base of the food web in freshwater aquatic ecosystems. However, the effects of key environmental factors on PFAS uptake and bioaccumulation in freshwater algae have not been thoroughly studied. In this study, three bioaccumulation experiments were conducted to evaluate the influence of dissolved cations, dissolved organic carbon, and exposure concentrations on PFAS bioaccumulation in algae. Among the 14 studied PFAS, seven long-chain PFAS tended to bioaccumulate in algae. Elevated divalent cations (Ca 2+ and Mg 2+ ) and dissolved organic carbon did not significantly change the algal bioconcentration factors (BCFs) of PFAS, suggesting complexity of the interactions among PFAS, environmental factors, and biotic activities. Additionally, increasing exposure concentrations (0.5, 1, 5, and 10 μg/L of each PFAS) increased PFAS concentrations in algae but decreased the BCF values. This indicated that attention should be paid to the application of BCFs in future studies, including ecological risk assessment. Moreover, fluorotelomer sulfonic acids (FTSs) were incompletely recovered, suggesting that biotransformation occurred. Further studies should be conducted to evaluate whether algae play a role in FTSs biotransformation and to determine the mechanisms. In conclusion, studying the impacts of key environmental factors on PFAS bioaccumulation in algae is crucial for understanding the bioaccumulation processes that occur at the lowest trophic level and that eventually affect the dynamics of entire aquatic ecosystems.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗
DOE OSTI2016

Evolution of structural and magnetic properties in La x Ce 2-x Co 16 Ti for $0 \leq x \leq 2$

Here we examine the intrinsic magnetic and structural properties of the title alloys, permanent magnet materials based on the abundant rare-earth elements lanthanum and cerium, since these properties (T C , M s H a (K 1 , K 2 )) will set the upper limits on the quality of permanent magnet that can be fabricated from said alloys. Ce 2 Co 16 Ti has a high magnetic anisotropy (H a = 65 kOe) but a relatively low saturation magnetization (M s = 7.3 kG), and La 2 Co 16 Ti has a high Ms(9.5 kG) but Ha too low for most applications (16 kOe). Though these two end-members have previously well-known properties, changing economic conditions have made re-examination of systems containing cerium and lanthanum necessary as the economic viability of rare earth mining becomes dependent on extraction of products beyond what is currently considered useful and profitable within the rare earth elements. We find that replacing some lanthanum with cerium in La 2 Co 16 Ti increases H a by a factor of more than two, while decreasing M s by less than 5%. The measured Ms indicate maximum possible energy products in excess of 20 MG·Oe in these materials, which have Curie temperatures near 600 °C. Real energy products are expected to be greatest near x = 1. In conclusion, these findings identify La x Ce 2-x Co 16 Ti as a promising system for development of so-called gap magnets that fill the energy product gap between expensive rare-earth magnets and current non-rare earth alternatives.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Phase relationships in the CeFe 8 Co 3 Ti 1 - y Si y system

We investigated the phase formation behavior of the nominal CeFe 8 Co 3 Ti 1-y Si y system for 0 ≤ y ≤ 0.6 by powder x-ray diffraction and scanning electron microscopy with energy dispersive x-ray spectroscopy for ingots formed by arc-melting then annealing at 1000 °C and quenching to room temperature. The ingots are seen to nearly single phase for y ≤ 0.4 and are multi-phase for y ≥ 0.5 though a compound of the ThMn 12 type does indeed form for all values of y. We also measured the saturation magnetizations (M s ), Curie temperatures (T C ), and magnetic anisotropy fields (H a ) for the y ≤ 0.4 samples and the values of Ms and Ha appear to be nearly identical for all y 0.4. TC, but, is seen to increase about 20 °C in this range for increasing y.

36 MATERIALS SCIENCE↗