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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

Coupled geomechanical investigation of depletion-induced fault reactivation

Fault reactivation during subsurface fluid production pose significant challenges to safe and sustainable resource extraction. Here, this study presents a three-dimensional coupled geomechanical framework to investigate the processes driving fault reactivation, capturing the interactions between reservoir dynamics and geomechanical responses. Verification against theoretical estimations based on linear poroelasticity confirms the model's capacity in representing reservoir background stress responses. However, the study reveals that relying solely on background stress states can underestimate or overestimate fault reactivation potential, emphasizing the importance of including localized stress perturbations such as differential compaction and stress redistribution. Applied to a fault (M1) inspired by the geological characteristics of the Groningen field, the model shows slip initiation at 2965 m depth with 16.0 MPa depletion, aligning with field observations where seismicity occurred at approximately 3 km depth after 15.8 MPa depletion. Parametric studies reveal: (1) inelastic reservoir compaction delays fault reactivation and mitigates fault slip by reducing stress concentration, (2) higher intermediate in-situ stress magnitudes decrease the Coulomb Failure Stress (CFS) increase rate and reduce fault slip, (3) larger fault offsets amplify shear stress near the offset zone, promoting earlier reactivation and longer rupture propagation, and (4) fault permeability significantly influences pressure diffusion, with low-permeability faults leading to sharper stress changes and earlier fault destabilization. These insights highlight the critical role of geological and mechanical parameters in fault reactivation and provide a predictive framework for mitigating induced seismicity risks.

Coupled geomechanical modeling↗
DOE OSTI2021

Experiment and non-local crystal plasticity finite element study of nanoindentation on Al-8Ce-10Mg alloy

Cerium and magnesium strengthened aluminum alloys, or Al-Ce-Mg, is a recently developed alloy family that exhibits good mechanical properties at elevated temperatures (~300 °C). To examine the single-crystal properties of Al-Ce-Mg alloys, nanoindentation experiments are conducted in this study. A crystal plasticity finite element model (CPFEM) with the evolution of geometrically necessary dislocations (GNDs) is applied to simulate the indentation in individual grains. A parametric study is carried out to investigate the sensitivity of each crystal plasticity model parameter to the indentation behavior. The highly sensitive parameters are calibrated by matching the indentation load-depth curves, while the rest parameters are obtained from bulk polycrystal uniaxial tension tests. Overall, satisfactory matching between experiment and simulation is obtained for each individual grain. The calculated hardness, as determined from the experiment, shows the dependence on indent depth, which is captured by the GND model. Furthermore, the effect of grain orientation and neighboring grains to nanoindentation behavior have been discussed with the comparison between the simulation and experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Analytical simulation of meander morphology from equilibrium to long-term evolution: Impacts of channel geometry and vegetation-induced coarsening

This study introduces an innovative approach to modeling meandering river morphology, integrating and investigating the effects of geometric characteristics and vegetation-induced channel coarsening. The developed comprehensive framework combines several advanced techniques: Genetic Programming for refining the scour factor of transverse bed slope, a Leaf Area Index (LAI)-enhanced analytical model for quantifying vegetative flow resistance, and an upstream-weighted moving average method for efficient approximation of the convolution integral in meander migration calculations. The model is validated against both an idealized Kinoshita meander and a natural bend of the Tumen River (China) in equilibrium, demonstrating its robustness across diverse scales and conditions. The model's ability to simulate the long-term evolution, including cutoff events, provides valuable insight for river management strategies. The current findings demonstrate that channel geometry, particularly width-to-depth ratio, plays a dominant role in meander evolution, with wider channels prone to more complex and rapid morphological changes. Vegetation effects are most pronounced in channels with moderate width-to-depth ratios, where they can significantly influence migration rates and bed topography. A combination of channel widening and deepening, coupled with strategic vegetation management, can effectively enhance navigability while maintaining channel stability in the studied Tumen River reach. Sensitivity analyses highlight the complex interplay between hydraulic conditions, sediment characteristics, and vegetation in shaping river morphology. This research advances understanding of the multifaceted nature of meandering river systems and offers practical tools for informed decision-making in river engineering and environmental management, particularly in the context of climate change and increasing anthropogenic pressures on fluvial ecosystems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Stratigraphic Identification with Airborne Electromagnetic Methods at the Hanford Site, Washington

Stratigraphic units can influence the fate and transport of subsurface contaminants within groundwater. Units having coarse-grained sediments act as preferential flow pathways, and therefore can accelerate the transport of contaminants to reach human and ecological receptors. At legacy waste sites, detailed knowledge of subsurface stratigraphy can be used for effective monitoring and remediation planning to help minimize risk to human health and the environment. Airborne electromagnetic (AEM) methods can non-invasively provide information on kilometer-scale or larger subsurface stratigraphic features and fill informational gaps in directly sampled data from sparsely located boreholes. In this paper, we present inversion results of a 412 line-km frequency-domain AEM survey to delineate subsurface stratigraphic features at the Hanford Site, located in southeastern Washington State. The inversion was performed using a massively parallel 3D electromagnetic modeling and inversion code, where the modeling is based on solving frequency-domain Maxwell’s equations using an unstructured-mesh finite-element method and the inversion employs a Gauss-Newton optimization scheme. The results are compared to an underlying geologic framework model (GFM), built by interpolating contact depths of stratigraphic units interpreted from site borehole datasets. In areas with good borehole coverage, the inversion results show a good match with the GFM to a depth of about 60 m. Outside of these areas, the inversion results exhibit inconsistencies from the assumptions made to create the GFM, demonstrating that the AEM survey results can be used to improve the understanding of the geological conceptual model.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Deep learning inversion of gravity data for detection of CO 2 plumes in overlying aquifers

In this work, we developed an effective U-Net based deep learning (DL) model for inversion of surface gravity data on a rectangular grid to predict 2-D high-resolution subsurface CO 2 distribution along a vertical cross-section due to CO 2 leakage through a wellbore within a deep CO 2 storage reservoir. We used synthetic data to model two types of CO 2 leakage scenarios: one CO 2 plume in a shallow aquifer (single plume case), and two plumes present at different depths (double plume case). The 3-D synthetic plume samples were created by sampling among predetermined CO 2 plume depths, saturations, and volumes. The corresponding surface gravity data on a rectangular grid were generated by a 3-D forward model. The U-Net model detected 72% of single-plume samples, and one or both plumes in 75% of double-plume samples. Most of the undetected single plumes have small gravity field strengths below the typical noise level of 5 μGal. This model generated reproducible, reliable predictions with acceptable errors and demonstrated improved spatial resolution over the conventional least-squares inversion. In contrast to the conventional least-squares inversion, which often overestimates the size of its target and underestimates its density, this U-Net model accurately delineated the boundary of a target. Furthermore, this DL inversion detected deep, small, or low saturation CO 2 plumes that are often more difficult to resolve with conventional gravity inversion methods. We note the limitations of this feasibility study, including the use of synthetic data with regular CO 2 plume shapes, and the prediction of a 2-D plume cross-section rather than the full 3-D plume, as well, we recognize the lower detection fraction for double-plume scenarios. Nevertheless, this study demonstrates that DL gravity inversion is a promising and potentially superior method to conventional least-squares inversion. Our U-Net based deep learning inversion approach may be adapted for inversion of other types of geophysical data. DL inversion can facilitate near real-time monitoring of geologic carbon sequestration to provide site operators with prompt information about subsurface CO 2 distribution for risk management and mitigation.

58 GEOSCIENCES↗
DOE OSTI2020

Global methane emissions from coal mining to continue growing even with declining coal production

This paper presents projections of global methane emissions from coal mining under different coal extraction scenarios and with increasing mining depth through 2100. The paper proposes an updated methodology for calculating fugitive emissions from coal mining, which accounts for coal extraction method, coal rank, and mining depth and uses evidence-based emissions factors. A detailed assessment shows that coal mining-related methane emissions in 2010 were higher than previous studies show. This study also uses a novel methodology for calculating methane emissions from abandoned coal mines and represents the first estimate of future global methane emissions from those mines. The results show that emissions from abandoned mines increase faster than those from active ones. Using coal production data from six integrated assessment models, this study shows that by 2100 methane emissions from active underground mines increase by a factor of 4, while emissions from abandoned mines increase by a factor of 8. Abandoned mine methane emissions continue through the century even with aggressive mitigation actions.

coal mine methane, abandoned coal mine methane, em↗
DOE OSTI2025

Establishing a silica gel zone in well annulus and evaluating its performance in blocking vertical water flow

Wells are often constructed for monitoring purposes with relatively long screen lengths (e.g., >10 m). Vertical water flows can occur within the artificial or natural filterpack annulus that surrounds the screened interval, bypassing packer assemblies installed inside the wellbore. Attempts to isolate discrete vertical zones during groundwater sampling are unsuccessful when annular flow occurs and lead to remedy decisions based on biased or incorrect interpretations. Blocking vertical annular water flow and contaminant transport will help obtain more accurate concentrations of contaminants from sampling in targeted depth intervals. The application of silica gels formed from the injected colloidal silica CS suspensions is a novel approach to minimize or prevent movement of vertical movement of groundwater in the surrounding filterpack annulus. In this work, we tested the feasibility of injecting CS suspensions to target locations and developed a modified CS formulation that is injectable and prevents gravity sinking. We studied the distribution and penetration of silica gel at laboratory scale in mock well annulus with surrounding formations. We evaluated the performance of the silica gel in blocking vertical water flow in the annulus and in minimizing chemical transport through the gel zone. CS suspension formulations have been defined that are ready for injection, stay in target locations, and form gel within desired time frames. Injection of CS suspensions achieved uniform distribution in a well annulus filter pack, fully occupied the annulus pore space, and penetrated the formation surrounding the filter packer with a sufficient distance to create a hydraulic annular seal when the injection was applied at a sufficient rate. The depth of penetration into the formation was dependent on the permeability contrast between the filter pack and the surrounding formation. Silica gel that formed in the annulus blocked vertical water flow and stopped the chemical transport through the gel zone. In conclusion, this research reveals that using CS suspension injection and sequential gelation (CS-GEL) is a promising technology for blocking vertical water flow and chemical transport through the filter pack in targeted zones within the annulus of long-screened well systems.

Colloidal silica suspension↗
DOE OSTI2020

Comparison of four learning-based methods for predicting groundwater redox status

Knowing the location where groundwater denitrification occurs, or by proxy the groundwater redox status (oxic, mixed, and anoxic), is valuable information for assessing and managing potential agricultural land-use impacts on freshwater quality. We compare the efficacy of supervised (Linear Discriminant Analysis LDA; Boosted Regression Trees, BRT; and Random Forest, RF) and unsupervised (Modified Self-Organizing Map, MSOM) learning-based methods to predict groundwater redox status in the agriculturally dominated Tasman, Waikato, and Wellington regions of New Zealand. Thresholds applied to regional groundwater-quality samples provide redox status variables and learn heuristics constrained by these variables and applied to spatial factors (climate, elevation, geologic, hydrology soils, and well depth) identify optimal sets of regional predictor variables. A split-sample approach is used to train and test the learning methods ability to predict redox status using the optimal predictor variables. Overall, the supervised methods demonstrate a prediction bias toward oxic conditions and inability to perform statistically well when using independent regional data; for example, consider kappa statistics for BRT (Tasman: 0.42, Waikato: 0.38, Wellington: 0.17), RF (Tasman: 0.42, Waikato: 0.47, Wellington: 0.17 and LDA (Tasman: 0.46, Waikato: 0.32, Wellington: 0.17). By contrast, the unsupervised method performs statistically well when predicting oxic, mixed, and anoxic conditions and corresponding depths when using independent regional data; for example, consider MSOM kappa statistics for Tasman: 0.78, Waikato: 0.80, Wellington: 0.76. The unsupervised learning method provides the added benefits of being (1) able to combine predictions into 3D regional anoxic probability plots for interpreting the spatial influence of paleosols and groundwater flowpaths on redox status, and (2) readily extended to map 3D redox status across New Zealand and other countries despite data bias and sparsity.

machine learning algorithms, Random Forest, booste↗
DOE OSTI2020

A new soil mixing layer model for simulating conservative solute loss from initially saturated soil to surface runoff

Surface water pollution due to solute loss from soil to surface runoff is a serious threat to the environment, and it is of great significance to predict the solute loss. While soil mixing layer theory has been widely used to predict the solute loss, it has been observed that the conventional soil mixing layer models with constant mixing layer depth underestimate solute concentration in surface runoff, and thus underestimate the solute loss after surface runoff starts. This study introduced a new soil mixing layer model with a new concept that the mixing layer depth increases downward with time after surface runoff occurs. This new concept was implemented by adding a mixing front between the soil mixing layer and its underlying soil layer, which is conceptually similar to the wetting front of soil infiltration given by the Green-Ampt equation. This is equivalent to treating the soil mixing layer as a deforming control volume. A mechanistic explanation for the new model was presented. This study also developed a closed form solution of the new model. The new model was evaluated by simulating five laboratory experiments conducted by two groups of researchers. The first two experiments have ponding water, and consider different drainage and runoff conditions at both early and late runoff times. The other three experiments do not have ponding water, and consider different infiltration conditions at the bottom of soil boxes. Simulation results of the five experiments show that the new model resolves the underestimation problem of conventional soil mixing layer models. The new model is subject to a total of six limits such as that the new model only considers conservative solute. Three limits are related to the assumptions used to derive the closed form solution, and they may be alleviated in a future research as briefly discussed at the end of the paper.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Impacts of climate change on future hurricane induced rainfall and flooding in a coastal watershed: A case study on Hurricane Harvey

The warming climate is likely to increase hurricane-associated extreme rainfall and lead to sea-level rise (SLR). Thus, how the floods induced by intense hurricanes respond to these potential changes is of great concern. This study investigates the future warmer climate impacts on hurricane-induced extreme rainfall, and—more importantly—the subsequent compound flooding at the watershed scale (from an event-based analysis perspective). To this goal, a modeling framework is designed based on the Distributed Hydrology Soil Vegetation Model (DHSVM), the Two-Dimensional fvand the Regional Community Earth System Model (R-CESM). The framework was applied to Hurricane Harvey (2017) at the Clear Creek watershed (a coastal watershed in the southern Houston) as a case study. The results show that the projected maximum rainfall totals over the watershed would be exacerbated by 17.7 % and 49.7 % in the 2050s and 2090s (respectively) under Representative Concentration Pathway 8.5 (RCP 8.5). This means a 16.1 % increase in Harvey rainfall over the watershed per degree Celsius increase in Mean Surface Temperature over the Gulf of Mexico region (18°~31° N, 77°~98° W). Meanwhile, the increases in maximum inundation extent would be 11.0 % (2050s) and 19.5 % (2090s). Furthermore, considerable increases in maximum inundation depth and duration in regions along the middle and downstream of Clear Creek (and also those around Clear Lake) are expected. The projected SLR will have little effect on the maximum inundation depth and extent if storm surge changes are not taken into account; meanwhile, it will influence the inundation duration at downstream locations. In conclusion, this modeling framework can be also applied at other coastal watersheds to evaluate the projected climate change impacts on the compound flooding induced by extreme climate events.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Effect of powder layer thickness on the microstructural development of additively manufactured SS316

By Increasing the powder layer thickness we could increase material deposition rates and reduce build times during laser powder bed fusion (LPBF). However, increasing the powder layer thickness could also negatively affect the local melting and subsequent microstructure of the printed material. This study systematically investigated, for the first time, the defect evolution and microstructural changes of LPBF stainless steel 316 (SS316) processed by using various powder layer thicknesses of 40, 80, and 120 μm while also varying the laser dwell time for the pulsed laser. Through image analysis, the pore density was found to increase with increasing powder layer thickness, particularly when the dwell time was too high or too low. The maximum achievable density (>99%) was found over a wide processing window when using the smallest powder layer thickness of 40 μm between dwell times of 60 and 100 μs. Increasing the powder layer thicknesses to 80 and 120 μm resulted in maximum densities of 98.7 and 96.8%, respectively, but the window for acceptable laser dwell times that could achieve these densities narrowed considerably. A microstructural analysis of the melt pools was performed to measure the melt pool depths and widths, both of which increased with increasing dwell time. However, increasing the powder layer thickness did not affect the melt pool depth and only minorly affected the width. A sub-grain cellular structure distinguished the melt pool boundaries. The cell size increased with increasing dwell time and decreasing powder layer thickness. Moreover, the cell size was used to calculate a cooling rate that had a magnitude of 10 7 K/s and increased with increasing powder layer thickness.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Decoupling indentation size and strain rate effects during nanoindentation: A case study in tungsten

Materials indented at small scales may simultaneously exhibit indentation size and strain rate effects which complicate the identification of the mechanisms that control deformation and strength. Here, in this work, we explore the possibility that indentation size and rate effects in some materials can be decoupled in a simple way. Nanoindentation tests with various load-time histories were carried out to measure the hardness of a tungsten single crystal over a wide range of indentation depths (~500–3600 nm) and indentation strain rates (~5 ×10 –5 –2 ×10 –1 s –1 ). Under these conditions, this material exhibits significant indentation size and rate effects, but the size effect is, to a good approximation, independent of strain rate. It is shown that this behavior can be understood by the Nix-Gao model for the indentation size effect modified to include the effects of a strain rate dependent friction stress. As a consequence, the size and rate dependencies of the hardness can be expressed as the sum of two independent terms: H($\dot{ε}$ i , h c )=H f ($\dot{ε}$ i ) + (H 0 – H f ) $\sqrt{1+ \frac{h^*}{h_c}}$, where H($\dot{ε}$ i , h c ) is the hardness at given indentation strain rate ($\dot{ε}$ i ) and contact depth (h c ), H f ($\dot{ε}$ i ) is the hardness contributed by the rate dependent friction stress, and (H 0 – H f ) and h* are size and rate independent constants that follow from the Nix-Gao analysis. This formula, together with an expression for the rate dependence of H f , was successfully applied to decouple the indentation size and rate effects observed in tungsten. In addition, the physics underlying the rate independence of indentation size effect is discussed, which provides guidance for application of the proposed approach to other materials.

42 ENGINEERING↗
DOE OSTI2021

Evolution of Microstructure and Surface Characteristics of FeCrAl alloys when Subjected to Flow Boiling Testing

FeCrAl alloys are candidate materials for manufacturing accident-tolerant fuel (ATF) cladding intended for light water reactors to increase fuel reliability and safety during design-basis and beyond-design-basis accident scenarios. The evolution of the materials' surface characteristics, microstructure, and mechanical properties when exposed to the Critical Heat Flux (CHF) in flow boiling testing is crucial for safety analysis while providing insights into their thermal-hydraulic performance in nuclear reactors. After CHF, the surface chemistry of two FeCrAl alloys, APMT and C26M, was studied to understand their evolution at the early stage of high-temperature excursions in short time periods. The results indicated a thin layer composed of oxides and hydroxides of Al, Cr, and Fe with varying proportions at different depths in the layer, as indicated by X-ray photoelectron spectroscopy (XPS) and depth profiling. The cross-sections prepared by focused ion beam (FIB) revealed the growth of an oxide layer, in the range of 90-180 nm thick, on the alloys' surfaces. The evolution of the materials' surface chemistry also led to a noticeable post CHF excursion increase in their wettability, with a slight increase in roughness. Further, the investigation of the materials' mechanical properties indicated a modest increase in hardness by 10-15% as well as an increase in their yield strength, as evidenced by the microindentation and ring compression tests conducted before and after CHF testing. Scanning electron Microscopy (SEM) and X-ray diffraction (XRD) were used to investigate microstructural features of the materials and their changes after CHF treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Layer dissolution in accumulative roll bonded bulk Zr/Nb multilayers under heavy-ion irradiation

In this work, the heavy-ion irradiation behavior of bulk zirconium-niobium multilayered composites was investigated up to large doses. Multilayers with an average individual layer thicknesses ranging between 15 and 80 nm were synthesized by accumulative roll bonding technique. The irradiation was performed with a defocused 7 MeV Zr 2+ ion beam at 500 °C. The maximum dose achieved was ~145 dpa at the depth of ~1.5 μm from the irradiated surface. Sub-surface microstructural damage and the chemical redistribution were characterized by transmission electron microscopy and energy dispersive spectroscopy, respectively. Irrespective of the layer thicknesses, the irradiation condition caused layer instability and the extent of damage varied with the dose levels. Doses lesser than ~60 dpa caused layer fragmentation and greater than ~60 dpa resulted in layer dissolution. The chemical mixing of layers occur to a depth of ~1 μm, consuming multiple bi-layer periods. Despite the elevated irradiation temperature (500 °C) and a slightly positive heat of mixing (+6 kJ/mol), no phase separation was observed and single-phase was retained in the mixed region. The results demonstrate that chemical mixing was facilitated by the liquid phase miscibility of Zr and Nb, which propelled the interdiffusion within the thermal spikes towards mixing.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Transmission electron microscopy characterization of the fuel-cladding chemical interactions in HT9 cladded U-10Zr fuel

Fuel cladding chemical interaction (FCCI) is a key phenomenon needs to be better understood to establish the design basis for U-10Zr metallic fuel performance. Characterizing the microstructure and chemical composition of FCCI at micron and sub-micron scale is critically important toward a more mechanistic understanding of FCCI phenomenon and its potential effects on cladding integrity and metallic fuel performance. This paper, by using transmission electron microscopy, investigated the FCCI region in HT9 cladded U-10Zr fuel irradiated to 5.7% FIMA burnup at a peak inner cladding temperature of 615 °C in Fast Flux Test Facility (FFTF). Four distinct layers are identified in the FCCI region. The migration of Fe into the fuel side leads to the formation of several U-Zr-Fe ternary phases, including ?-Fe0.5Zr0.32U0.18, e-Fe0.3Zr0.4U0.3, and ?-Fe0.06Zr0.23U0.71, mingled with UFe2, U6Fe, and U phase at various Fe penetration depth up to ~ 150 µm. On the cladding side, grain coarsening and significant lanthanides infiltration along grain boundaries are observed. Laves phase, (Fe,Cr)2(Mo,W), which typically does not exist in fresh HT9, is identified in a wide radial range in the cladding. The typical HT9 martensitic lath structure and pre-existing M23C6 precipitates disappear, partially or completely, depending on the radial distance from the fuel-cladding interface. Those microstructural and compositional changes could cause mechanical degradation in the HT9 cladding. The present characterization results will improve the understanding of FCCI phenomenon and facilitate the development of microstructure-informed FCCI modeling for metallic fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

XPS post-mortem analysis of plasma-facing units extracted from WEST after the C3 (2018) and C4 (2019) campaigns

Four monoblocks coming from one ITER-like plasma-facing unit from the Q3B sector of the lower divertor, named as monoblock (MB)3, MB9, MB20, and MB30, were exposed to the deuterium and helium plasma mixture during the C3 (2018) and C4 (2019) campaigns of the Tungsten Environment in Steady-state Tokamak (WEST), followed by a detailed ex-situ X-ray photoelectron spectroscopy investigation. The surface and in-depth chemistry of the tungsten monoblocks indicated the formation of a re-deposited mixture in the deposition-dominated area of the divertor, thicker than 218 and 172 nm for MB3 and MB9, respectively. The redeposition layer was dominated by a mixture of boron carbides accompanied by tungsten carbides in MB3, while in MB9, the redeposition layer was dominated by tungsten borides. The remaining two monoblocks, MB20 and MB30, were collected from the erosion region and showed similar chemical behavior with a blended mixture of oxidized and metallic tungsten followed by boron carbides within a 50 nm depth range. Boron fixation in the layers is an expected consequence of the boronizations used during the operation, but the chemical status of redeposited elements was characterized for the first time in this work.

Marin, Alexandru [Pennsylvania State University]↗
DOE OSTI2025

Deformation band corrosion as a result of applied stress and cold-work in 304 stainless steel in simulated pressurized water reactor primary water conditions

Stainless steels like 304SS are commonly used in pressurized water reactor primary water environments due to their excellent resistance to stress corrosion cracking (SCC). However, SCC susceptibility has been observed in cold-worked 304SS. Cold-rolling introduces a high density of defects, such as deformation bands or dislocations, into the microstructure; applied stress, even if macroscopically below the yield stress, can result in regions with high localized stresses. Cold-worked and non-cold-worked samples were exposed to 360 °C simulated PWR primary water for 1500 h with and without active loading. Corrosion susceptibility of dislocations and deformation bands induced by cold-rolling and/or applied stress was studied using high-resolution (analytical) transmission electron microscopy. Deformation bands were generated in all specimens examined in the study. Penetrative oxidation was observed in some deformation bands in each specimen. The depth of penetrative deformation band oxidation frequently exceeded the depth of grain boundary oxidation in all specimens. However, deformation band oxides generally were narrowly confined to the deformation band plane. Highly Ni-rich regions were observed beyond all oxidation fronts. Surface oxides were thicker in the specimens exposed under active loading. In conclusion, the implications of these findings at surfaces for deformation bands intersecting stress corrosion crack paths are discussed.

EFTEM↗
DOE OSTI2026

Developing cathode infiltration processes for all-solid-state bilayer LLZO cells

To realize the bilayer architecture of lithium lanthanum zirconate (LLZO) for application in solid-state batteries (SSBs), the scaffold structure must be optimized, and effective cathode infiltration strategies must be established. In this study, we fabricate a modified bilayer LLZO using a sacrificial layer to enhance surface porosity, and systematically investigate various cathode infiltration techniques to fill the scaffold with oxide cathode active materials (CAM). Structural characterizations showed that the sacrificial layer significantly increased open surface porosity, enabling the surface of the scaffold to be filled with CAM. To further increase infiltration depth, applying vacuum or vibration was compared, with the full-depth infiltration achieved using a sonicator-based vibration. Full cells prepared using the modified bilayer LLZO and vibration-assisted technique demonstrated successful operation. This work demonstrates a practical and scalable approach for engineering bilayer LLZO structures and integrating oxide cathodes into porous scaffolds, offering a promising pathway toward high-performance solid-state batteries.

Bilayer↗