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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 973 records · Page 54
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Self-Consistent Simulation of the Excitation of Compressional Alfvén Eigenmodes and Runaway Electron Diffusion in Tokamak Disruptions

Alfvénic modes in the current quench (CQ) stage of the tokamak disruption have been observed in experiments. In DIII-D the excitation of these modes is associated with the presence of high-energy runaway electrons (REs), and a strong mode excitation is often associated with the failure of RE plateau formation. In this work we present results of self-consistent kinetic-MHD simulations of RE-driven compressional Alfvén eigenmodes (CAEs) in DIII-D disruption scenarios, providing an explanation of the CQ modes. Simulation results reveal that high energy trapped REs can have resonance with the Alfvén mode through their toroidal precession motion, and the resonance frequency is proportional to the energy of REs. The mode frequencies and their relationship with the RE energy are consistent with experimental observations. Further, the perturbed magnetic fields from the modes can lead to spatial diffusion of REs including the nonresonant passing ones, thus providing the theoretical basis for a potential approach for RE mitigation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Epitaxial growth, magnetoresistance, and electronic band structure of GdSb magnetic semimetal films

Motivated by observations of extreme magnetoresistance (XMR) in bulk crystals of rare-earth monopnictide (RE-V) compounds and emerging applications in novel spintronic and plasmonic devices based on thin-film semimetals, we have investigated the electronic band structure and transport behavior of epitaxial GdSb thin films grown on III-V semiconductor surfaces. The Gd 3 + ion in GdSb has a high spin S=7/2 and no orbital angular momentum, serving as a model system for studying the effects of antiferromagnetic order and strong exchange coupling on the resulting Fermi surface and magnetotransport properties of RE-Vs. Here, we present a surface and structural characterization study mapping the optimal synthesis window of thin epitaxial GdSb films grown on III-V lattice-matched buffer layers via molecular-beam epitaxy. To determine the factors limiting XMR in RE-V thin films and provide a benchmark for band-structure predictions of topological phases of RE-Vs, the electronic band structure of GdSb thin films is studied, comparing carrier densities extracted from magnetotransport, angle-resolved photoemission spectroscopy (ARPES), and density-functional theory (DFT) calculations. ARPES shows a hole-carrier rich, topologically trivial, semimetallic band structure close to complete electron-hole compensation, with quantum confinement effects in the thin films observed through the presence of quantum-well states. DFT-predicted Fermi wave vectors are in excellent agreement with values obtained from quantum oscillations observed in magnetic field-dependent resistivity measurements. An electron-rich Hall coefficient is measured despite the higher hole-carrier density, attributed to the higher electron Hall mobility. The carrier mobilities are limited by surface and interface scattering, resulting in lower magnetoresistance than that measured for bulk crystals.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Incremental Threshold Scheme Enabled IoT Group Key Management

Cyber landscape evolves rapidly. Internet of Things (IoT) and Edge Computing (EC) have rapidly become an integral part of the modern computing infrastructure. It is expected that there will be more than 50 billion active and connected IoT devices by 2025 [1]. Pervasive IoT/EC creates unprecedented opportunities bridging the gap between previously segregated cyber and physical spaces. However, this progress also brings along new security challenges. IoT devices typically have limited computation, communication, and storage resources. This leads to security architecture designs such as using symmetric keys for group communication. While secure and efficient in stable network settings, symmetric key solutions are ill-adapted for IoT's highly dynamic device mobility behavior and frequent group membership turnover. Whenever IoT members leave a group, the known symmetric keys cannot be made forgotten, posing a serious vulnerability. This leads to frequent re-groupings that require expensive re-authentication, key regeneration, and key redistribution in order to maintain IoT/EC security. We present a novel symmetric key management framework that integrate an Incremental Threshold Scheme (ITS) cryptographical function into communication protocol's key rotation mechanism to allow for secure and efficient symmetric key communication group member node revocation. This ITS-enabled key management framework alleviates the need of frequent and expensive re-grouping and re-keying needed by today's large and dynamic IoT/EC operations. We further applied this ITS-enabled key management framework to a distributed IoT/EC-integrated publish and subscribe framework for applicability validation.

Li, Mingyan↗
DOE OSTI2020

General Correlations for Laminar Flow Friction Loss and Heat Transfer in Plain Rectangular Plate-Fin Cores

In this paper, new generalized correlations for predicting the average fanning friction factor f and average Nusselt number Nu for laminar flow in plain plate-fin compact cores of rectangular cross section are presented. These are based on extended experimental data, as well as three-dimensional computational simulations, obtained for a broad range of fin density and geometrical attributes. The results indicate that while the fully developed forced convection scales only with the interfin channel cross-sectional ratio α (fin spacing by fin height), the entrance region hydrodynamic and thermal performance is additionally a function of the fin-core length L, flow Reynolds number Re, and fluid Prandtl number Pr. The developing flow and convection is further shown to scale as: (fRe)~(L/d h Re) 1/2 , and Nu ~(L/d h Re) 1/2 Pr 1/3 Φ(α), where f, Re, and Nu are all based on the hydraulic diameter dh of the interfin flow channel. Generalized correlations for both (fRe) and Nu are developed by the corresponding scaling of the forced convection behavior and asymptotic matching of the entrance or developing flow (short fin-core flow length) and the fully developed flow (large fin-core flow length) region performance. Finally, the predictions from these correlations are found to be within ±15% of all available experimental data for air, water, and glycol (0.71 ≤ Pr ≤ 10), and fin cores with 0 < α ≤ 1.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Sampling Low-Dimensional Markovian Dynamics for Preasymptotically Recovering Reduced Models from Data with Operator Inference

This work introduces a method for learning low-dimensional models from data of high-dimensional black-box dynamical systems. The novelty is that the learned models are exactly the reduced models that are traditionally constructed with classical projection-based model reduction techniques. Thus, the proposed approach learns models that are guaranteed to have the well-studied properties of reduced models known from model reduction, without requiring full knowledge of the governing equations and without requiring the operators of the high-dimensional systems. The key ingredient is a new data sampling scheme to obtain re-projected trajectories of high-dimensional systems that correspond to Markovian dynamics in low-dimensional subspaces. The exact recovery of reduced models from these re-projected trajectories is guaranteed pre-asymptotically under certain conditions for finite amounts of data and for a large class of systems with polynomial nonlinear terms. Numerical results demonstrate that the low-dimensional models learned with the proposed approach match reduced models from traditional model reduction up to numerical errors in practice. In conclusion, the numerical results further indicate that low-dimensional models fitted to re-projected trajectories are predictive even in situations where models fitted to trajectories without re-projection are inaccurate and unstable.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Methods—A Practical Approach to the Reversible Hydrogen Electrode Scale

Accurately quantifying applied potential is important to ensuring the comparability, accuracy, and precision of electrochemical studies. Reference electrodes (REs) enable knowledge/determination of the applied potential at electrodes in electrochemical systems. Ultimately, the choice of RE will depend on the particular requirements of a given electrochemical system, however, we note it is imperative to ensure the accuracy of the RE potential and its proper translation to a standardized scale. In this work, we highlight that while there are many commercially available REs, these must be experimentally calibrated to a reliable and practical standard potential scale, for instance the reversible hydrogen electrode (RHE) scale for aqueous systems. With representative data, we provide streamlined instructions on how to calibrate any RE to the RHE scale. We also provide guidance to mitigate and/or avoid possible electrolyte contamination issues arising from REs. Moreover, we offer a step-by-step guide on how to build a practical RHE RE, which may be a suitable and desirable option in certain applications. Our work emphasizes the need for the continuous adoption of standardized reference potential scales and demonstrates the versatility of the RHE scale, particularly in aqueous electrochemistry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Two-stage formation-energy correction (NbZr, TaZr, VZr)

This bundle contains the scripts, the raw and corrected per-structure data, and the manuscript plots for the NbZr / TaZr / VZr BCC binary formation energies and the associated RMSDs. Why a two-stage correction is necessary: The "raw" formation energy of every relaxed VASP configuration is computed in the usual way, FE_raw(c) = E_alloy(c) - sum_i x_i * E_pure_i , where E_pure_i are the per-atom total energies of the pure-element reference structures (Nb, Ta, V, Zr in the same BCC supercell, with identical INCAR / KPOINTS / PAW choices). With perfectly consistent reference runs the raw FE should vanish at the two pure-element endpoints (x = 0 and x = 1) by construction. In practice this does not hold for two reasons that are present in our dataset: 1. Reference-energy inconsistency (composition-dependent bias). Even with identical input parameters, the pure-element runs (stored in `corrected_DFT_pure_element_runs/`) differ slightly from the values that would be implied by the alloy runs at near-pure compositions (a few meV/atom). This bias is approximately linear in concentration, because the residual error in E_pure_Nb (or E_pure_Ta / E_pure_V) propagates into FE_raw(c) as (1 - x) * dE_pure_1, and the corresponding error in E_pure_Zr propagates as x * dE_pure_2. Left uncorrected, this produces a non-physical "tilt" of FE_raw(x) and shifts the entire FE-vs-x cloud away from zero at the endpoints. 2. Endpoint anchoring against the audited true endpoints. The strict endpoint values (FE_x0_meVatom, FE_x1_meVatom in `corrected_fe_strict_endpoints_20260518/strict_endpoint_check_20260518.csv`) were re-derived from an independent cross-check of the pure-element runs. After stage 1 removes the linear bias, the near-pure compositions in the alloy dataset still extrapolate to values that differ slightly from these audited endpoints — because stage 1 is fit from a few near-end alloy bins, not from the audited pure-element references themselves. The README.txt file discusses how these issues are addressed by the two-stage correction, and describes folder layout, pipeline summary, and how to re-run.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Controlled Pyrolysis: A Robust Scalable Composite Recycling Technology

The reinforced composites industry is facing significant challenges in handling the scrap composite material from automobile manufacturing, the wind turbine industry, and others. The fibers in the material, whether they be carbon, glass, or other materials have commercial value if they can be recovered successfully. Successfully means the fibers are clean with no sizing or other binders and have adequate strength and physical properties that would allow them to be economically reprocessed into valuable product. The composites recycling project was an industry-collaborative effort to develop a composite recycling technology using controlled pyrolysis. Through the recycling of scrap and end-of-life (EOL) cured composite materials, this pilot study was intended to create a business case by realizing a cost-effective means for recycling EOL and production scrap composite materials, ultimately reducing the volume of composite materials destined for landfill. The project was led by the Institute for Advanced Composites Manufacturing Innovation (IACMI), the American Composites Manufacturers Association (ACMA), Oak Ridge National Laboratory (ORNL), Continental Structural Plastics (CSP) a Teijin Group Company, CHZ Technologies, and A. Schulman with support from Owens Corning, John Deere, General Electric (GE), Ashland LLC, and Plastics Europe (CEFIC). The team studied and tested CHZ Technologies’ controlled pyrolysis system, known as the Thermolyzer TM , which operates on a scalable basis to convert organic polymer materials into a clean synthesis gas and char containing the recoverable carbon and glass fiber reinforcement. The recoverable energy contained in the input polymers creates the synthesis gas that can be used to provide heat to the Thermolyzer TM primary reactor in a sustainable manner. That is, once the Thermolyzer TM is started with a small amount of external natural gas, the synthesis gas that is created from the polymers will continue to operate the burners so long as feedstock is supplied. The reinforcing fiber materials remaining in the solid phase char were separated and cleaned for re-use in other polymer systems based on the retained properties of the fibers. The study created reports (attached in the appendix) on the Mass and Energy Balances, syngas analytics, VOC assessment, yield analysis and other analytics necessary for a Techno-Economic Analysis (TEA) to quantify the economic impact of the recovery and sustainable re-use of the carbon and glass fibers. The process consisted of 4 steps: Selection of 4 samples of cured composite waste materials from project partners interested in materials recycling and recovering the reinforcing fibers for best case re-use. The materials included glass fiber (GF) polyester/vinyl ester automotive SMC from CSP, GF epoxy balsa/PVC foam wind blades from GE, carbon fiber (CF) epoxy wind blade laminated spar caps from GE, and GF/CF epoxy hybrid assembly from John Deere. Processing the waste composite samples into 1-2” shreds. Packaging the shredded composites into bulk sacks on international shipping pallets for shipment to KUG in Forst (Lausitz), Germany. Pyrolysis of the shredded composites under controlled conditions designed for each polymer system. Collecting samples of the gas and char for analysis. Shipping the char containing the CF/GF back to the US for the next steps of testing the fibers and developing protocols for sustainable re-use of the fibers in composite applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Technical Issues in the Comprehensive Nuclear Test Ban Treaty (CTBT) Ratification Debate: A 20 Year Retrospective

Two decades after the U.S. Senate declined in 1999 to give its consent to ratification of the Comprehensive Nuclear Test Ban Treaty (CTBT), the treaty remains in legal and political limbo. Legally, the treaty cannot enter into force without U.S. ratification. However, the Senate’s rejection does not strip the treaty of its force as an element of customary international law or alter the will of other signatories to see it enter into force. Politically, the debate over the virtues and flaws of the treaty remains as strong as ever, with some CTBT advocates pushing energetically for U.S. re-review while some opponents seek ways to “un-sign” the treaty. Meanwhile, despite the Senate’s rejection of the treaty, the United States acts in a manner consistent with its main obligations by maintaining a moratorium on explosive nuclear testing and providing financial support (as well as technical expertise) to the CTBT Organization (CTBTO)—in particular the CTBTO’s International Monitoring System (IMS). The CTBT may well remain in such limbo for a long time to come, unless some catalytic event comes along to re-shape national perceptions and priorities, one way or the other. The treaty’s future, whatever it might be, will be determined in part by how much perspectives might have changed in light of interim developments. Our purpose is to shed light on some of those developments and to assess their relevance. The 1999 ratification debate addressed a large number of issues. Rejection was driven by various policy and technical judgments. The purpose of this paper is to re-examine those technical judgments in light of what has been learned over the following two decades. On some technical matters, there was explicit recognition of extant uncertainties, as well as a conviction and hope that time would dispel them. To be doubly clear, our purpose is not to recommend a way forward on CTBT ratification. The policy judgments of 1999 and 2020 are beyond the scope of this paper. This technical re-examination proceeds as follows. It begins with a short background section to introduce the key technical matters in discussion in the U.S. ratification process. Then it moves systematically through each of those topics with a review of relevant background information, a discussion of key points in debate, an analysis of subsequent experience, and a current assessment. The historical analysis draws on many sources including the primary documents of the Congressional debate, the official article-by-article interpretation by the Department of State, and the statements of key players in the process. We also relied on key technical reports and publications by subject matter experts that have addressed in more detail many of the issues in our focus. These sources include the 2002 and 2012 reports of the National Academy of Sciences as well as publications by senior technical staff of Lawrence Livermore National Laboratory (LLNL) who were actively involved in the ratification debate, including then-Laboratory Director Bruce Tarter. We also conducted several interviews with government officials from the 1990s, past laboratory directors, and other members of the scientific community. But, except where individuals are specifically cited by name, the judgments offered here are our own and should not be attributed to any other individual or to LLNL as such.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2022

III-V Solar Cells with Novel Epitaxial Lift-off Architectures for Extended Substrate Reuse for Low-cost Manufacturing

The highest solar cell efficiencies have been achieved with III-V photovoltaics (PV). Still, the use of III-V materials in terrestrial applications has been very limited, mainly because of their high cost. The high cost is primarily due to the expensive Ge or GaAs wafers which could amount up to one-half of the total module cost! A prominent approach to reduce the impact of the high cost of substrates used for III-V PV is through re-use of the wafer substrates by Epitaxial Lift-Off (ELO). Typically, using a sacrificial layer such as AlAs, the device part of the cell is lifted off, leaving behind the substrate for re-use for fabrication of the next device. While conversion efficiency as high as 29.1% has been achieved by ELO method, chemical mechanical polishing (CMP) of the substrate is required which significantly adds to the overall solar cell cost. In this project, we have developed a novel ELO architecture for single junction gallium arsenide (GaAs) solar cells that will not require CMP of the substrate for re-use. Multiple reuses of GaAs wafers have been demonstrated with no CMP, without degradation in solar cell efficiency. Also, the solar cells have been successfully lifted off and transferred to inexpensive substrates with less than 2% change in efficiency. By elimination of the CMP process, which is the highest cost component of III-V solar cells made by conventional ELO method (~$10/W), and decreasing the substrate cost by multiple re-uses, the developed technology could be a leap forward in significantly reducing the cost of III-V photovoltaics.

14 SOLAR ENERGY↗
DOE OSTI2023

Study on Electrostatic Separation of Quinoline Insolubles from Coal Tar Pitch

The feasibility of electrical separation in the removal of quinoline insoluble (QI) particles from coal tar pitch (CTP) was experimentally investigated. QI particle involvement prohibits the effective fabrication of high-quality value-added products, such as carbon fibers, from CTP. A substantial and sustainable CTP market exists around the world; therefore, a strong incentive exists to develop a viable technical approach to effectively and economically remove QI particles from CTP. The electrical separation method shows promise to achieve this technical goal (Cao et al., 2012). Even with the given setup (wire- cylinder adapted), critical issues remain to be addressed for this method to be applicable to the CTP: (1) identifying the wash oil used in the original QI separation, (2) understanding the mechanism of QI separation, (3) characterizing the deposit, and (4) identifying the QI. This study integrated a set of experimental and analysis techniques into the electrical separation tests to address the aforementioned issues. Key findings are as follows: 1. Electric current responses: • The electric current level of the CTP–wash oil solution reported by Cao et al. (2012) can be attained by using a mixture of 25% quinoline and 75% toluene for the CTPs examined in this study under the same electrical load condition. • The electric current tends to decrease during the test period because of the decreasing number of charged particles. • The reversed field corresponded to the configuration of electrostatic precipitation for positive corona discharge. The high electric field can result in dielectric breakdown and lead to an abrupt current surge. 2 Deposit response and solvent candidates: • Deposit of particles in CTP mixture can be effectively implemented in a wire-cylinder configuration as proposed and examined in this study. • Deposit depends on the solvents. Among the solvents tested, two- and three-part solvents that included quinoline and ethanol (i.e., 25% quinoline and 75% toluene; 50% quinoline and 50% toluene; and 33% wash oil, 33% BTX, and 34% ethanol) produced the highest deposit weight. • The deposit process examined in this study is derived from the charged particles. An appreciable relation exists between deposit weight and electric charge. 3. QI removal efficiency (RE): • The RE of the electrostatic separation can reach as high as 76.2% for Carbores, and 61.6% for Koppers. • The RE can be further enhanced if the field level increases from 0.16 kV/mm that was used in the current study to 0.23 kV/mm, according to the relation established between the RE and the electric field. 4. Testing of the modeling system: • The motion of particles is originally driven by the charge-based electric force in the cases tested. The solid particle separation mechanism is similar to that of QI deposition in CTP. • The mechanical movement of solid particles can be strongly affected by the gravitational and viscous forces in the electric field. 5. EDS analysis and chemical compositions: • The main chemical composition of deposit QI matches that of as-prepared CTP QI. The deposit QI is derived from the same group of the CTP QI. • In addition to carbon, the QI contains oxygen, sodium, aluminum, silicon, iron, and sulfur. The work for the near future is also discussed.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Demonstration of Scaled-Production of Rare Earth Oxides and Critical Materials from U. S. Coal-Based Sources (Final Report)

The project objective was to demonstrate scaled production of high purity rare earth oxides (REO), nominally exceeding 90% grade, from coal refuse sources using innovative technologies that reduce cost and improve environmental outcomes relative to traditional rare earth processing technologies. The project utilized a critical material pilot plant constructed and tested as part of a previous U.S. Department of Energy project. Target performance criteria was a 50% reduction in production cost based on previous optimum values, 150% increase in recovery and greater than 2% concentrates of rare earth oxides, cobalt and manganese. Concentrate production goals were to produce a rare earth mix oxide product at a rate of 200 grams per day having a minimum purity of 50% as well as products of cobalt and manganese having a minimum purity of 2%. A previous pilot plant investigation identified acid cost as the major contributor to an operating cost that made the recovery of rare earth and other critical metals from bituminous coal sources economically challenging. As such, acid cost reduction was a major target using bio-oxidation reactors to produce sulfuric acid from naturally occurring coal pyrite. Based on laboratory data, a bio-oxidation circuit was designed for the pilot plant to produce 7.5 l/min of acid using two 11-m3 (3000 gallon) reactors equipped with 40 hp aerators for air dispersion. The pilot-scale tests revealed that acid concentration equivalent to as high as 1.0 M sulfuric acid could be continuously produced. However, the bio-acid contained exceptionally high iron concentrations, which complicated downstream processing of the pregnant leach solution (PLS). A TEA of the bio-oxidation circuit showed that production cost was approximately $0.13 per kg acid equivalent if produced using a four-day retention time in the reactors. This value represents a 48% reduction from that of purchased bulk sulfuric acid. Calcination (or roasting) studies were conducted on coarse refuse from West Kentucky No. 13 and Fire Clay coal seam sources. The test results revealed the potential to increase recovery by nearly 100% using temperatures between 500°C to 700°C with light REE recovery value being the most improved. Acid baking of the calcined products using sulfuric acid at 250°C increased heavy rare earth recovery from around 40% to 80% while decreasing the acid requirements by over 50%. The existing pilot plant was upgraded for the pilot scale demonstration of REE and CM recovery. The primary feedstocks were West Kentucky No.13 and heap leach pregnant leach solution (PLS) while a secondary feedstock was a lignite waste material from a construction sand operation. The pilot scale operation started with PLS generation through leaching followed by iron and aluminum removal, nominally at 3.3 and 4.5 pH, respectively. Leaching lixiviants used for the test were industrial grade sulfuric acid or bio-acid generated at the pilot scale facility. For most of the tests, the solid feed rate was 200 lb/hr whereas lixiviant was added at 2 gpm to provide an optimal residence time of 45 minutes. Following the contaminant removal step, several different process schematics were tested with the goal of maximizing REE recovery and purity. In the first test, direct processing of aluminum precipitation raffinate for REE recovery using oxalic acid at pH 1.5 was investigated. Overall REE recovery was approximately 45%. Unfortunately, elevated calcium content in the PLS significantly impacted the RE-Oxide product grade. Similarly, high calcium content decreased both the product purity and grades of CM products. As such, a new flowsheet was tested with the same initial process schematic but different precipitation stages for REEs and CMs at pH 6.0 and 9.0, respectively. It was noted that the overlapping precipitation behavior of Co, Ni and Zn with REEs limited the applicability of this process schematic. While this change increased the RE-Oxide grade from 36% in the first test to 87%, the loss of critical metals to the REE cake and bypass of the REEs to the CM cake significantly impacted the recovery of both REEs and CMs. Therefore, the modified process flowsheet combined oxalic acid precipitation stage raffinate and redissolved CM cake filtrate to maximize both the recovery and purity of the products. Consequently, a RE-Oxide product with 85% purity and CM cakes with over 19% Co, 38% Ni, 14% Zn and 9% Mn content were generated with significantly higher recoveries. While the modified process flowsheet improved recoveries and grades, elemental losses observed in separate precipitation and redissolution losses inspired the adaptation of a single precipitation stage at pH 9.0 for both REEs and CMs. This change was anticipated to maximize the REE recovery while minimizing the costs associated with separated redissolution and processing stages. As expected, REE recovery in this new circuit arrangement was over 56% with a product grade of over 87% RE-Oxide content. Similarly, Co, Ni, Mn, and Zn recoveries of 54%, 40%, 67%, and 66%, respectively, were achieved. Unfortunately, the elevated calcium content present in the solution due to its precipitation at pH 9.0 caused a decrease in the CM cake quality. Therefore, the final process flowsheet involved the addition of calcium oxalate precipitation following the oxalic acid precipitation stage, which effectively eliminated calcium contamination of the CM products. Finally, the pilot scale experiments conducted using bio-acid achieved comparable REE leaching recoveries to the conventional sulfuric acid leaching. Elevated iron concentration in the solution caused the co-precipitation of REEs with the iron and aluminum cake, resulting in the REE losses. Furthermore, elevated iron content bypassing the iron and aluminum precipitation stages contaminated the metal sulfide and manganese cake, respectively. A techno-economic analysis was performed based on a commercial facility capable of treating 500 tph of coal-based material. The production cost for West Kentucky No. 13 coarse refuse material ranged from approximately $500-$700/kg of total rare earth oxide whereas the lignite source had significantly lower production cost of $100-$300/kg. The significant difference in cost was due to the easier leaching characteristics of the lignite material and the higher feed concentrations. All process scenarios resulted in a negative net present value (NPV). For the lignite feedstock, laboratory REE leach recovery values were about 30% higher than the pilot plant data. Using the lab leach results, a positive net present value was achieved and the production cost decreased from $100-$300 $/kg to less than $150/kg of total REO.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Vitrification of Hanford Tank 241-AP-101 Waste and Simulant

Hanford tank 241-AP-101 (referred to herein as AP-101) is the second Hanford radioactive tank waste planned to be processed and vitrified. A simulant version of AP 101 waste was formulated from the best-basis inventory (BBI) for the Hanford Tank 241-AP-101 liquid with an assumed target dilution of the waste from the BBI sodium molarity of 8.61 M to the desired 5.5 M Na. After the addition of glass-forming chemicals (GFCs), the simulant melter feed was processed in a non-radioactive, continuous laboratory-scale melter (CLSM) system. The AP-101 simulant melter feed was charged into the CLSM for 6.11 h of processing, which produced 6.55 kg of glass, for an average glass production rate of 2275 kg m 2 d -1 . Since there were no processing issues with the AP-101 simulant melter feed, AP-101 melter feed made with actual waste was then processed in a CLSM system built into a contamination area in a radioactive environment. The melting behavior characteristics appeared similar for both the simulant and waste melter feeds. The AP-101 waste melter feed was charged into the CLSM for 12.14 h of processing, which produced 8.75 kg of glass, for an average glass production rate of 1530 kg m 2 d -1 . During the AP-101 waste melter feed charging, the pump used to move the feed reached a maximum and it is believed that if the pump had a greater capacity, a greater average glass production rate could have been achieved. A constituent of interest present in low quantities in the AP-101 waste is 99 Tc or its non-radioactive surrogate, Re, added to the AP-101 simulant. Analysis for the quantities of 99 Tc and Re in the AP-101 glass product resulted in an average single-pass retention from the melter feed during relative chemical steady state of 55 ± 2 % for 99 Tc and 45 ± 2 % for Re. Compared to the processing of other melter feeds, the retention of 99 Tc in the AP-101 glass was greater than in both AP-107 and AP-105 glass, while the retention of Re in the AP-101 was less than in the AP-107 glass, but greater than in the AP-105 glass. A spike of I was added into the AP-101 melter feed that could be detected above the analysis detection limits. However, the iodine was only detectable above the ~6 ppm limit in one glass pour: the pour immediately following the burn off of the cold cap, where the I level reached ~30 ppm. This event was significant because the glass was poured immediately after burn off and thus it is presumed that the iodine had yet to volatilize from the glass melt while idling. It is recommended to perform future tests with I spikes at greater levels so that it can be detected in additional glass pours to determine if the expected 50 % retention of I used in the Kim et al. glass models can be confirmed. Offgas liquid samples were analyzed for acetonitrile, which was present at greater concentrations in CLSM liquids than in other scaled melter systems. This result was expected based on unique conditions with the CLSM system including a small plenum space leading to low residence time for offgas and the rapidity of offgas cooling upon exiting the CLSM vessel due to the location and environment. About 90 % of the total acetonitrile captured during both the AP-101 simulant and waste CLSM runs was found in the offgas condensate and demister liquids, thus it is recommended that only those liquids be sent for analysis if future testing to study the presence of acetonitrile in offgas products is desired.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Characterizing the effect of hypersonic boundary layer turbulence on antenna performance: A computational approach

The degradation of antenna performance during hypersonic re-entry is a well known phenomenon that can lead to complete radio blackout. Recent additions to the Empire code establish it as a tool for the study and analysis of the problem. Coupling to the Sandia Parallel Aerodynamics and Reentry Code (SPARC) enables the electromagnetic analysis of realistic re-entry plasma profiles. The geometric flexibility afforded by both Empire and SPARC allow the consideration of arbitrary vehicle and antenna configurations. We have used this tool to study antenna performance during re-entry when the boundary layer becomes turbulent. A concise description of line-of-sight transmissions, which employs advanced statistical methods, was developed. New insights into the low altitude reflectometer readings of RAM-C2 are offered. Techniques for the reconstruction of the re-entry plasma profile from reflectometer data were explored.

42 ENGINEERING↗
DOE OSTI2026

Development of Industrial Scale Rare Earth Master Alloys from Their Native Oxides for Magnet Production

The objective of the project is to develop an energy-efficient, reduced cost, and single-step critical metal oxide reduction and alloying methodology for the production of NdFeB and SmCo magnets to facilitate the establishment of a sustainable domestic critical materials supply chain. The method consists of an immiscible molten salt flux layer and a higher density molten metal alloy pool (FeB or Co). The rare earth (RE) oxide and a reductant are added to the molten salt layer, where the reductant first strips the oxygen from the rare earth oxide. Subsequently, the separated RE metal diffuses into the molten metal pool below, creating a RE-saturated master alloy. Towards this end, thermodynamic calculations of the reactions between RE oxides, metallic reducing agent, and molten salt bath chemistry have been performed, and the ideal feeds and conditions for extraction and diffusion to produce master alloys were established. Small-scale and scaled experimentation was performed to validate and optimize the feasibility of viable reactions, temperatures, and process conditions with regards to yield, composition, and process efficiency. Finally, full-scale experiments for the production of NdFeB and SmCo magnets were performed, and their performance characteristics were established.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Applying Transfer Learning for Street-Scale Nuisance Flood Forecasting in Coastal-Urban Cities

An important challenge with Machine Learning (ML) is its transferability; that is, whether a ML model trained on one set of data can be applied to a second set of data without requiring a full re-training of the model. Transfer Learning (TL) addresses this challenge by transferring knowledge learned in the source domain (the data it was trained on) to the target domain (a second set of data that is statistically different but related, which the model was not trained on). This study investigates the use of TL for street-scale nuisance flood forecasting by exploring whether a ML model trained on data collected for one set of streets can effectively forecast flooding for another set of streets in the same city using TL. The envisioned use case is a city deploying a new flood depth monitoring sensor on a street and using TL to apply a ML model, trained on sensor data from an existing flood depth sensor network, to this new street. Eventually, the new flood depth sensor will have a sufficient dataset for training its own ML model, but TL can be used to fill the gap in time while this new dataset is being generated. This method is explored using a Long Short-Term Memory (LSTM) model trained on data for the flood-prone streets of Norfolk City, Virginia. The data used for training includes environmental time series (rainfall, tide), topographic features (Digital Elevation Model (DEM), Topographic Wetness Index (TWI), Depth To Water (DTW)), and street-scale flood depth time series obtained from a high-fidelity physics-based model, acting as a synthetic street-scale stream depth sensor dataset since actual stream depth sensor data is generally unavailable for most cities. A set of 180 flood-prone streets was used to train a base model, while another set of 180 flood-prone streets was used to re-train that model using different TL strategies. The results show that full-weight re-training proved most effective and minimal re-training of only the output layer was insufficient. The advantage of TL was most pronounced when target data was limited, meaning data collected at the new water depth sensor location included generally less than 18 flood events. As target data increased beyond 18 flood events, the benefit of TL diminished relative to training a ML model directly on the local flood events. These findings can assist cities as they implement street-scale flood sensing systems to create accurate forecasts for new sensing locations that do not yet have sufficient data records to train a local ML model.

Roy, Binata [Univ. of Virginia, Charlottesville, V↗
DOE OSTI2024

A Quantitative Phase Analysis by Neutron Diffraction of Conventional and Advanced Aluminum Alloys Thermally Conditioned for Elevated-Temperature Applications

As the issue of climate change becomes more prevalent, engineers have focused on developing lightweight Al alloys capable of increasing the power density of powertrains. The characterization of these alloys has been focused on mechanical properties and less on the fundamental response of microstructures to achieve these properties. Therefore, this study assesses the quality of the microstructure of two high-temperature Al alloys (A356 + 3.5RE and Al-8Ce-10Mg), comparing them to T6 A356. These alloys underwent thermal conditioning at 250 and 300 °C for 200 h. Time-of-flight neutron diffraction experiments were performed before and after conditioning. The phase evolution was quantified using Rietveld refinement. It was found that the Si phase grows significantly (13–24%) in T6 A356, A356 + 3.5RE, and T6 A356 + 3.5RE alloys, which is typically correlated with a reduction in mechanical properties. Subjecting the A356 3.5RE alloy to a T6 heat treatment stabilizes the orthorhombic Al4Ce3Si6 and monoclinic β-Al5FeSi phases, making them resistant to thermal conditioning. These two phases are known for enhancing mechanical properties. Additionally, the T6 treatment reduced the vol.% of the cubic Al20CeTi2 and hexagonal ᴨ-Al9FeSi3Mg5 phases by 13% and 23%, respectively. These phases have detrimental mechanical properties. The Al-8Ce-10Mg alloy cubic β-Al3Mg2 phase showed significant growth (82–101%) in response to conditioning, while the orthorhombic Al11Ce3 phase remained stable. The growth of the beta phase is known to decrease the mechanical properties of this alloy. These efforts give valuable insight into how these alloys will perform and evolve in demanding high-temperature environments.

Chemistry↗
DOE OSTI2022

Environmental effects on aerosol–cloud interaction in non-precipitating marine boundary layer (MBL) clouds over the eastern North Atlantic

Abstract. Over the eastern North Atlantic (ENA) ocean, a total of 20 non-precipitating single-layer marine boundary layer (MBL) stratus and stratocumulus cloud cases are selected to investigate the impacts of the environmental variables on the aerosol–cloud interaction (ACIr) using the ground-based measurements from the Department of Energy Atmospheric Radiation Measurement (ARM) facility at the ENA site during 2016–2018. The ACIr represents the relative change in cloud droplet effective radius re with respect to the relative change in cloud condensation nuclei (CCN) number concentration at 0.2 % supersaturation (NCCN,0.2 %) in the stratified water vapor environment. The ACIr values vary from −0.01 to 0.22 with increasing sub-cloud boundary layer precipitable water vapor (PWVBL) conditions, indicating that re is more sensitive to the CCN loading under sufficient water vapor supply, owing to the combined effect of enhanced condensational growth and coalescence processes associated with higher Nc and PWVBL. The principal component analysis shows that the most pronounced pattern during the selected cases is the co-variations in the MBL conditions characterized by the vertical component of turbulence kinetic energy (TKEw), the decoupling index (Di), and PWVBL. The environmental effects on ACIr emerge after the data are stratified into different TKEw regimes. The ACIr values, under both lower and higher PWVBL conditions, more than double from the low-TKEw to high-TKEw regime. This can be explained by the fact that stronger boundary layer turbulence maintains a well-mixed MBL, strengthening the connection between cloud microphysical properties and the below-cloud CCN and moisture sources. With sufficient water vapor and low CCN loading, the active coalescence process broadens the cloud droplet size spectra and consequently results in an enlargement of re. The enhanced activation of CCN and the cloud droplet condensational growth induced by the higher below-cloud CCN loading can effectively decrease re, which jointly presents as the increased ACIr. This study examines the importance of environmental effects on the ACIr assessments and provides observational constraints to future model evaluations of aerosol–cloud interactions.

54 ENVIRONMENTAL SCIENCES↗