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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Chemical and Structural Changes in Corn Stover After Ensiling: Influence on Bioconversion

Production of biofuels, bioproducts, and bioenergy requires a well-characterized, stable, and reasonably uniform biomass supply and well-established supply chains for shipping biomass from farm fields to biorefineries, while achieving year-round production targets. Preserving and stabilizing biomass feedstock during storage is a necessity for cost-effective and sustainable biofuel production. Ensiling is a common storage method used to preserve and even improve forage quality; however, the impact of ensiling on biomass physical and chemical properties that influence bioconversion processes has been variable. Our objective in this work was to determine the effects of ensiling on lignocellulosic feedstock physicochemical properties and how that influences bioconversion requirements. We observed statistically significant decreases (p < 0.05) in the content of two major structural carbohydrates (glucan and xylan) of 5 and 8%, respectively, between the ensiled and non-ensiled materials. We were unable to detect differences in sugar yields from structural carbohydrates after pretreatment and enzymatic hydrolysis of the ensiled materials compared to non-ensiled controls. Based on this work, we conclude that ensiling the corn stover did not change the bioconversion requirements compared to the control samples and incurred losses of structural carbohydrates. At the light microscopy level, ensiled corn stover exhibited little structural change or relocation of cell wall components as detected by immunocytochemistry. However, more subtle structural changes were revealed by electron microscopy, as ensiled cell walls exhibit ultrastructural characteristics such as wall delimitation intermediate between non-ensiled and dilute-acid-pretreated cell walls. These findings suggest that alternative methods of conversion, such as deacetylation and mechanical refining, could take advantage of lamellar defects and may be more effective than dilute acid or hot water pretreatment for biomass conversion of ensiled materials.

09 BIOMASS FUELS↗
DOE OSTI2022

The development and use of decision support framework for informing selection of select agent toxins with modelling studies to inform permissible toxin amounts

Many countries have worked diligently to establish and implement policies and processes to regulate high consequence pathogens and toxins that could have a significant public health impact if misused. In the United States, the Antiterrorism and Effective Death Penalty Act of 1996 (Public Law 104-132, 1996), as amended by the Bioterrorism Preparedness and Response Act of 2002 (Public Law 107-188, 2002) requires that the Department of Health and Human Services (HHS) [through the Centers for Disease Control and Prevention (CDC)] establish a list of bacteria, viruses, and toxins that have the potential to pose a severe threat to public health and safety. Currently, this list is reviewed and updated on a biennial basis using input from subject matter experts (SMEs). We have developed decision support framework (DSF) approaches to facilitate selection of select toxins and, where toxicity data are known, conducted modelling studies to inform selection of toxin amounts that should be excluded from select agent regulations. Exclusion limits allow laboratories to possess toxins under an established limit to support their research or teaching activities without the requirement to register with the Federal Select Agent Program. Fact sheets capturing data from a previously vetted SME workshop convened by CDC, literature review and SME input were developed to assist in evaluating toxins using the DSF approach. The output of the DSF analysis agrees with the current select toxin designations, and no other toxins evaluated in this study were recommended for inclusion on the select agent and toxin list. To inform the selection of exclusion limits, attack scenarios were developed to estimate the amount of toxin needed to impact public health. Scenarios consisted of simulated aerosol releases of a toxin in high-population-density public facilities and the introduction of a toxin into a daily consumable product supply chain. Using published inhalation and ingestion median toxic dose (TD 50 ) and median lethal dose (LD 50 ) values, where available, a range of toxin amounts was examined to estimate the number of people exposed to these amounts in these scenarios. Based on data generated by these models, we proposed toxin exclusion values corresponding to levels below those that would trigger a significant public health response (i.e., amounts estimated to expose up to ten people by inhalation or one hundred people by ingestion to LD 50 or TD 50 levels of toxin in the modeled scenarios).

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

From Farm to Flight: CoverCress as a Low Carbon Intensity Cash Cover Crop for Sustainable Aviation Fuel Production. A Review of Progress Towards Commercialization

Thlaspi arvense L. (Field Pennycress; pennycress) is being converted into a winter-annual oilseed crop that confers cover crop benefits when grown throughout the 12 million-hectares U.S. Midwest. To ensure a fit with downstream market demand, conversion involves not only improvements in yield and maturity through traditional breeding, but also improvements in the composition of the oil and protein through gene editing tools. The conversion process is similar to the path taken to convert rapeseed into Canola. In the case of field pennycress, the converted product that is suitable as a rotational crop is called CoverCress™ as marketed by CoverCress Inc. or golden pennycress if marketed by others. Off-season integration of a CoverCress crop into existing corn and soybean hectares would extend the growing season on established croplands and avoid displacement of food crops or ecosystems while yielding up to 1 billion liters of seed oil annually by 2030, with the potential to grow to 8 billion liters from production in the U.S. Midwest alone. The aviation sector is committed to carbon-neutral growth and reducing emissions of its global market, which in 2019 approached 122 billion liters of consumption in the U.S. and 454 billion liters globally. The oil derived from a CoverCress crop is ideally suited as a new bioenergy feedstock for the production of drop-in Sustainable Aviation Fuel (SAF), renewable diesel, biodiesel and other value-added coproducts. Through a combination of breeding and genomics-enabled mutagenesis approaches, considerable progress has been made in genetically improving yield and other agronomic traits. With USDA-NIFA funding and continued public and private investments, improvements to CoverCress germplasm and agronomic practices suggest that field-scale production can surpass 1,680 kg ha -1 (1,500 lb ac -1 ) in the near term. At current commodity prices, economic modeling predicts this level of production can be profitable across the entire supply chain. Two-thirds of the grain value is in oil converted to fuels and chemicals, and the other one-third is in the meal used as an animal feed, industrial applications, and potential plant-based protein products. In addition to strengthening rural communities by providing income to producers and agribusinesses, cultivating a CoverCress crop potentially offers a myriad of ecosystem services. The most notable service is water quality protection through reduced nutrient leaching and reduced soil erosion. Biodiversity enhancement by supporting pollinators’ health is also a benefit. While the efforts described herein are focused on the U.S., cultivation of a CoverCress crop will likely have a broader application to regions around the world with similar agronomic and environmental conditions.

09 BIOMASS FUELS↗
DOE OSTI2026

Measuring labor productivity dynamics in U.S. industrial and electric power sectors: a case study (2014–2023)

This study proposes a subsystem methodology for measuring labor productivity in the U.S. industrial and electric power sectors by leveraging public data available between 2014 and 2023. Building on Pasinetti’s framework and subsequent developments, the approach employs Vertically Integrated Sectors (VIS) to account for both direct and indirect productivity effects. The novelty of this work is twofold. First, it enables the estimation of productivity trends over time, providing a robust foundation for empirical analysis. Second, it applies the methodology to a case study of the electric generation sector, highlighting its practical relevance. Using data from the Bureau of Economic Analysis, the Bureau of Labor Statistics, and the Impact Analysis for Planning (IMPLAN) tool, the study reveals significant discrepancies between conventional productivity measures and those derived from the VIS approach. Furthermore, the proposed method aligns with the principles of Integrated Energy Systems by capturing the interrelations among generation, distribution, storage, and consumption. This alignment underscores its utility and applications for energy-related policy and planning. Overall, the findings contribute to more precise labor productivity assessments, supporting informed decision-making and future research. Additionally, the method highlights the importance of considering the whole supply chain, providing interrelated metrics for labor productivity which includes both, direct and indirect effects on the final labor productivity metric. By incorporating intersectoral dependencies, this method offers a more comprehensive and accurate measure of labor productivity compared to traditional metrics.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Cradle to grave: the importance of the fuel cycle to molten salt reactor sustainability

Advanced reactor technologies are being considered for the next-generation of nuclear power plants. These plants are designed to have a smaller footprint, run more efficiently at higher temperatures, have the flexibility to meet specific power or heating needs, and have lower construction costs. This paper offers a perspective on molten salt reactors, promoted as having a flexible fuel cycle and close-to-ambient pressure operation. A complexity introduced by reducing the reactor footprint is that it may require low-enriched fuel for efficient operation, available from enrichment of the feed salt or by reusing actinides from existing used nuclear fuel (UNF). Recycling UNF has the potential to reduce high-level waste, if done correctly. Release limits from UNF processing are stringent, and processes for waste reduction, fission gas trapping, and stable waste-form generation are not yet ready for commercial deployment. These complex processes are expensive to develop and troubleshoot because the feed is highly radioactive. Thus, fuel production and supply chain development must keep abreast of reactor technology development. Another aspect of reactor sustainability is the non-fuel waste streams that will be generated during operation and decommissioning. Some molten salt reactor designs are projected to have much shorter operational lifetimes than light-water reactors: less than a decade. A goal of the reactor sustainability effort is to divert these materials from a high-level waste repository. However, processing of reactor components should only be undertaken if it reduces waste. Economic and environmental aspects of sustainability are also important, but are not included in this perspective.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Circular Bioeconomy Concepts—A Perspective

Circular economy concepts—including a circular bioeconomy—aim to transition the current, essentially linear, economic system to a more sustainable one. However, organizations and researchers currently define the circular economy concept differently, resulting in inconsistencies and difficulty in effectively implementing the framework. In this paper, we provide our perspective on the conceptual definitions of the circular economy, bioeconomy, and circular bioeconomy, outlining potential overlaps and differences and proposing a harmonized interpretation that stresses the importance of the carbon cycle. We conclude that the key goal of a circular economy is to slow, narrow, and close material resource loops, built on the foundation of renewable energy and non-toxic materials. Further, a sustainable bioeconomy goes beyond simply switching fossil resources with renewable, biological resources. It requires low-carbon energy inputs, sustainable supply chains, and promising disruptive conversion technologies for the sustainable transformation of renewable bioresources to high-value bio-based products, materials, and fuels. The bio-based circular carbon economy, in particular, stresses capturing atmospheric carbon via photosynthesis and exploiting this unique feature to the fullest extent possible. It sits at the intersection between the circular economy and the bioeconomy concept, resulting in a framework that focuses on closing the carbon cycle and stressing the opportunity to create an additional carbon sink capability in the technosphere by utilizing biogenic carbon for products and materials that are circulated in same or improved use cycles. Lastly, a sustainable circular bioeconomy transition will necessitate a set of consistent metrics that fit all products and industries.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2026

Unlocking the Future of Aircraft Manufacturing: The Environmental Benefits of Laser Patterning for Surface Enhancement of Aircraft-Certified Alloys

Surface protection and functional modification of aircraft-certified aluminum alloys are essential for corrosion resistance, durability, and long-term airworthiness. At the same time, increasingly restrictive environmental regulations motivate the development of alternatives to legacy wet-chemical surface treatments. This study presents an integrated assessment of ultrafast femtosecond laser surface texturing as a surface functionalization approach for Aluminum 6061 alloys within an aerospace manufacturing and sustainability context. Ultrashort-pulse laser processing enables controlled micro- and nano-scale surface topographical modification with limited thermal impact, allowing adjustment of wettability and surface functionality while preserving bulk material integrity. As a dry and contactless process, femtosecond laser treatment eliminates the use of hazardous chemicals, reduces consumable inputs, and generates minimal secondary waste. A streamlined cradle-to-gate life cycle assessment conducted in accordance with ISO 14040/14044 indicates a lower global-warming potential per functional unit compared with conventional surface treatments, including anodization, plasma-assisted coatings, and organic coating systems. Complementary qualitative analyses addressing environmental health and safety, supply-chain risk, and ESG alignment indicate potential advantages related to occupational safety, regulatory compliance, waste management, and end-of-life recyclability. The investigation is performed on planar Aluminum 6061 reference surfaces with a treated area of 25 mm 2 , providing a controlled laboratory-scale basis for analyzing process behavior, functional surface modification, and associated environmental metrics. Within this defined scope, the results support further evaluation of femtosecond laser surface texturing as a surface engineering option for future aerospace manufacturing.

corrosion resistance↗
DOE OSTI2025

Rare Earth Element Detection and Quantification in Coal and Rock Mineral Matrices

As global demand for rare earth elements (REEs) increases, maintaining the production and supply chain is critical. Technologies capable of being used in the field and in situ in the subsurface for rapid REE detection and quantification facilitates the efficient mining of known resources and exploration of new and unconventional resources. Laser-induced breakdown spectroscopy (LIBS) is a promising technique for rapid elemental analysis both in the laboratory and in the field. Multiple articles have been published evaluating LIBS for detection and quantification of REEs; however, REEs in their natural deposits have not been adequately studied. In this work, detection and quantification of two REEs, La and Nd, have been studied in both synthetic and natural mineral matrices at concentrations relevant to REE extraction. Measurements were performed on REE-containing rock and coal samples (natural and synthetic) utilizing different LIBS instruments and techniques, specifically a commercial benchtop instrument, a custom benchtop instrument (single- and double-pulse modes), and a custom LIBS probe currently being developed for in situ, subsurface, borehole wall detection and quantification of REEs. Plasma expansion, emission intensity, detection limits, and double-pulse signal enhancement were studied. The limits of detection (LOD) were found to be 10/14 ppm for La and 15/25 ppm for Nd in simulated coal/rock matrices in single-pulse mode. Signal enhancement of 3.5 to 6-fold was obtained with double-pulse mode as compared to single-pulse operation.

La detection↗
DOE OSTI2023

Elevating the Practical Application of Sodium-Ion Batteries through Advanced Characterization Studies on Cathodes

Sodium-ion batteries (SIBs) have emerged as promising alternatives to their lithium-ion counterparts due to the abundance of sodium resources and their potential for cost-effective energy storage solutions. The chemistry for SIBs has been investigated since the 1980s, but it went through a slow research and development process. Recently, there has been an acceleration in technology maturation due to a supply chain crisis originating from unequal resource distribution and sustainability and safety concerns regarding lithium-ion batteries. However, the practical application of SIBs has been hindered primarily by challenges related to cathode materials, specifically, surface and structural stabilities in different conditions. Through the integration of advanced techniques such as in situ spectroscopy, operando diffraction, and high-resolution microscopy, a comprehensive understanding of the cathode’s dynamic behavior and degradation mechanisms can be achieved. The identified structural modifications, phase transitions, and degradation pathways offer critical insights into the design of robust cathode materials with prolonged cycling stability, fast charging capability, high energy density, great low-temperature performance, and safety. This review underscores the pivotal role of cutting-edge characterization techniques in guiding the development of high-performance sodium-ion batteries, thereby fostering the realization of sustainable and efficient energy storage solutions for diverse technological applications.

25 ENERGY STORAGE↗
DOE OSTI2024

Challenges in the Use of AI-Driven Non-Destructive Spectroscopic Tools for Rapid Food Analysis

Routine, remote, and process analysis for foodstuffs is gaining attention and can provide more confidence for the food supply chain. A new generation of rapid methods is emerging both in the literature and in industry based on spectroscopy coupled with AI-driven modelling methods. Current published studies using these advanced methods are plagued by weaknesses, including sample size, abuse of advanced modelling techniques, and the process of validation for both the acquisition method and modelling. This paper aims to give a comprehensive overview of the analytical challenges faced in research and industrial settings where screening analysis is performed while providing practical solutions in the form of guidelines for a range of scenarios. After extended literature analysis, we conclude that there is no easy way to enhance the accuracy of the methods by using state-of-the-art modelling methods and the key remains that capturing good quality raw data from authentic samples in sufficient volume is very important along with robust validation. A comprehensive methodology involving suitable analytical techniques and interpretive modelling methods needs to be considered under a tailored experimental design whenever conducting rapid food analysis.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Mechanical Response and Processability of Wet-Laid Recycled Carbon Fiber PE, PA66 and PET Thermoplastic Composites

The interest in recycled carbon fiber (rCF) is growing rapidly and the supply chain for these materials is gradually being established. However, the processing routes, material intermediates and properties of rCF composites are less understood for designers to adopt them into practice. This paper provides a practical pathway for rCFs in conjunction with low cost and, for the most part, commodity thermoplastic resins, namely polyethylene (PE), polyamide 66 (PA66) and polyethylene terephthalate (PET). Industrially relevant wet-laid (WL) process routes have been adopted to produce mats using two variants of WL mats, namely (a) high speed wet-laid inclined wire to produce broad good ‘roll’ forms and (b) 3DEPTM process patented by Materials Innovation Technologies (MIT)-recycled carbon fiber (RCF), now Carbon Conversions, which involves mixing fibers and water and depositing the fibers on a water-immersed mold. These are referred to as ‘sheet’ forms. The produced mats were evaluated for their processing into composites as ‘fully consolidated mats’ and ‘non-consolidated’ as-produced mats. Comprehensive mechanical data in terms of tensile strength, tensile modulus and impact toughness for rCF C/PE, C/PA66 and C/PET are presented. The work is of high value to sustainable composite designers and modelers.

compression molding↗
DOE OSTI2024

Atomic Diffusivities of Yttrium, Titanium and Oxygen Calculated by Ab Initio Molecular Dynamics in Molten 316L Oxide-Dispersion-Strengthened Steel Fabricated via Additive Manufacturing

Oxide-dispersion-strengthened (ODS) steels have long been viewed as a prime solution for harsh environments. However, conventional manufacturing of ODS steels limits the final product geometry, is difficult to scale up to large components, and is expensive due to multiple highly involved, solid-state processing steps required. Additive manufacturing (AM) can directly incorporate dispersion elements (e.g., Y, Ti and O) during component fabrication, thus bypassing the need for an ODS steel supply chain, the scale-up challenges of powder processing routes, the buoyancy challenges associated with casting ODS steels, and the joining issues for net-shape component fabrication. In the AM process, the diffusion of the dispersion elements in the molten steel plays a key role in the precipitation of the oxide particles, thereby influencing the microstructure, thermal stability and high-temperature mechanical properties of the resulting ODS steels. In this work, the atomic diffusivities of Y, Ti, and O in molten 316L stainless steel (SS) as functions of temperature are determined by ab initio molecular dynamics simulations. The latest Vienna Ab initio Simulation Package (VASP) package that incorporates an on-the-fly machine learning force field for accelerated computation is used. At a constant temperature, the time-dependent coordinates of the target atoms in the molten 316L SS were analyzed in the form of mean square displacement in order to obtain diffusivity. The values of the diffusivity at multiple temperatures are then fitted to the Arrhenius form to determine the activation energy and the pre-exponential factor. Given the challenges in experimental measurement of atomic diffusivity at such high temperatures and correspondingly the lack of experimental data, this study provides important physical parameters for future modeling of the oxide precipitation kinetics during AM process.

Chemistry↗
DOE OSTI2020

Separation of Radionuclides from a Rare Earth-Containing Solution by Zeolite Adsorption

The increasing industrial demand for rare earths requires new or alternative sources to be found. Within this context, there have been studies validating the technical feasibility of coal and coal byproducts as alternative sources for rare earth elements. Nonetheless, radioactive materials, such as thorium and uranium, are frequently seen in the rare earths’ mineralization, and causes environmental and health concerns. Consequently, there exists an urgent need to remove these radionuclides in order to produce high purity rare earths to diversify the supply chain, as well as maintain an environmentally-favorable extraction process for the surroundings. In this study, an experimental design was generated to examine the effect of zeolite particle size, feed solution pH, zeolite amount, and contact time of solid and aqueous phases on the removal of thorium and uranium from the solution. The best separation performance was achieved using 2.50 g of 12-µm zeolite sample at a pH value of 3 with a contact time of 2 h. Under these conditions, the adsorption recovery of rare earths, thorium, and uranium into the solid phase was found to be 20.43 wt%, 99.20 wt%, and 89.60 wt%, respectively. The Freundlich adsorption isotherm was determined to be the best-fit model, and the adsorption mechanism of rare earths and thorium was identified as multilayer physisorption. Further, the separation efficiency was assessed using the response surface methodology based on the development of a statistically significant model.

58 GEOSCIENCES↗
DOE OSTI2021

A Fundamental Economic Assessment of Recovering Rare Earth Elements and Critical Minerals from Acid Mine Drainage Using a Network Sourcing Strategy

In recent years, acid mine drainage (AMD) has emerged as a promising unconventional source of rare earth elements (REEs) and other critical minerals (CMs) such as cobalt and manganese. In this regard, AMD provides a natural heap leaching effect that extracts and concentrates REE/CM from the host strata creating a partially enriched feedstock suitable for downstream extraction, separation, and recovery. While several prior studies have described processes and approaches for the valorization of AMD, very few have described the supply chain and infrastructure requirements as well as the associated economic assessment. To that end, this paper provides a fundamental economic assessment of REE/CM recovery from AMD using a network sourcing strategy in addition to a robust, flexible feedstock separations and refining facility. The methodology of this paper follows that of a typical techno-economic analysis with capital and operating costs estimated using AACE Class IV (FEL-2) guidelines. To demonstrate the range of possible outcomes, four pricing scenarios were modeled including contemporary prices (September, 2021) as well as the minimum and maximum prices over the last decade. In addition, five production scenarios were considered reflecting variations in the product suite, ranging from full elemental separation to magnet REE and CM production only (i.e., Pr, Nd, Tb, Dy, Y, Sc, Co, and Mn). The results of this analysis show that, with the exception of the minimum price scenario, all operational configurations have positive economic indicators with rates of return varying from 25% to 32% for the contemporary price scenario. The optimal configuration was determined to be production of Co, Mn, and all REEs except for mischmetal, which is not recovered. Sensitivity analysis and Monte Carlo simulation show that capital cost and HCl consumption are the two major factors influencing rate of return, thus indicating opportunities for future technology development and cost optimization. Implications of the study and a cooperative profit-sharing model for sourcing are also described.

42 ENGINEERING↗
DOE OSTI2024

Methane Quantification Performance of the Quantitative Optical Gas Imaging (QOGI) System Using Single-Blind Controlled Release Assessment

Quantitative optical gas imaging (QOGI) system can rapidly quantify leaks detected by optical gas imaging (OGI) cameras across the oil and gas supply chain. A comprehensive evaluation of the QOGI system’s quantification capability is needed for the successful adoption of the technology. This study conducted single-blind experiments to examine the quantification performance of the FLIR QL320 QOGI system under near-field conditions at a pseudo-realistic, outdoor, controlled testing facility that mimics upstream and midstream natural gas operations. The study completed 357 individual measurements across 26 controlled releases and 71 camera positions for release rates between 0.1 kg Ch 4 /h and 2.9 kg Ch 4 /h of compressed natural gas (which accounts for more than 90% of typical component-level leaks in several production facilities). The majority (75%) of measurements were within a quantification factor of 3 (quantification error of –67% to 200%) with individual errors between –90% and 831%, which reduced to –79% to +297% when the mean of estimates of the same controlled release from multiple camera positions was considered. Performance improved with increasing release rate, using clear sky as plume background, and at wind speeds ≤1 mph relative to other measurement conditions.

42 ENGINEERING↗
DOE OSTI2024

The Isotopic Limit of Recycling

Despite advances in recycling technologies and practices, the world still mostly operates on a once-through materials use cycle. The once-through approach to the materials supply chain cannot work into perpetuity. The vast majority of current recycling efforts focus on mechanical or chemical separation-based techniques and are often subsequently limited on the number of times a component can be recycled or upcycled. By looking at things from a particle physics and nuclear history perspective, we propose a thought experiment to determine the physical limit of recycling and propose subsequent limits and standards to evaluate all recycling efforts. This uncommon approach to analysis demonstrates that the current limits to recycling are not physical in nature but engineering.

Lang, Eric↗
DOE OSTI2023

A Comprehensive Assessment Tool for Low-TRL Current Energy Converters

Along with a market-competitive levelized cost of energy, a current energy converter technology strongly benefits from an extensive consideration of socioeconomic, environmental, and regulatory factors early in the design process. As part of a technology performance level assessment, a series of assessment questions and guidance are developed and presented to evaluate an early-stage current energy technology on holistic criteria considering the entire device lifecycle. The assessment represents an accumulation of industry and research experience to date and relies on regular updates to ensure alignment with industry best-practices, regulatory requirements, and up-to-date technical understanding. A cradle-to-grave (materials, manufacturing, installation and deployment, operations and maintenance, and end-of-life) assessment of capabilities and functional requirements (i.e., high, medium, and low) performance criteria for current energy converters deployed in tidal, ocean current, and/or river applications. Key considerations related to manufacturing and installation include supply chain robustness, manufacturability and related job creation in the end-user and/or adjacent communities, and the time-to-repayment of the embodied energy debt. During deployment and maintenance operations, the safety of the device and subsystems during disconnect or grid failure, the difficulty and frequency of offshore heavy-lift activities, the avoidance or mitigation of area-use conflicts, the sea-states and weather conditions that permit maintenance access, and the availability of contingency plans (should conditions change unexpectedly) are a portion of the considered assessment criteria. Results include the potential impact of early-stage design decisions on the socioeconomic, environmental, and regulatory performance of a technology that allows developers to increase the product value and probability of success, and minimize costly late-stage design iterations through early and broad consideration of factors affecting overall performance and acceptability.

life cycle analysis↗
DOE OSTI2024

Mechanical and thermal behavior of additively manufactured Invar 36 using a laser hot wire hybrid DED process

Invar 36 alloy is a material of high interest in the composite tooling sector due to its low coefficient of thermal expansion. Current production of Invar 36 tooling using traditional manufacturing such as casting and forging is associated with long lead times due to a multitude of factors such as labor and component shortages, high material costs, foreign competition, and supply chain issues. An attractive alternate process is the use of an integrated 5-axis CNC hybrid Laser Hot Wire Deposition System (LHWD) for manufacturing invar molds. Here, the hybrid process provides a combination of the additive and subtractive technologies resulting in a synergistic platform for producing and repairing structures and molds. The main novelty and goal of this work is to study the properties of Invar deposited by a LHWD and to provide guidelines for the manufacture of parts using this process. In this study, the thermal expansion behavior of the manufactured specimens has been analyzed and related to its printing parameters and direction. Multiple specimens were extracted for mechanical, dilatometry and metallographic testing. A thermal IR recording of the printing process was also carried out to observe the thermal history of the produced parts to establish thermal influence on performance-property-processing relationship. The results of these tests show the advantage of LHWD technology for the manufacture of Invar alloy parts, as it presents similar thermal expansion behavior as those commercially available with minimal presence of precipitates and no macrostructural failures such as pores, cracks and lacks of fusion.

36 MATERIALS SCIENCE↗