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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Graphical User Interface for a Biasing Board for the PSEC6

The PSEC6 is an application-specific integrated circuit (ASIC) designed for a readout system for a large area picosecond photodetector (LAPPD). The PSEC6 is currently in fabrication and pending testing. The testing system for the PSEC5, the previous iteration of the ASIC, required expensive and non-portable equipment, because the ASIC needs twelve adjustable reference voltages. The new testing system consists of an low-cost, open-source, cross-platform graphical user interface (GUI), a digital system, and a biasing board. The digital system is the interface between the GUI and biasing board, and can be implemented on a microcontroller or field-programmable gate array (FPGA). The biasing board contains twelve digital-to-analog converters (DACs) that are configurable via the GUI, which gives users the ability to write voltage values to all or specific DACs. The GUI was developed in C on Linux using the widget library GTK4 and cross-compiled for Windows compatibility. I2C and SPI protocols were implemented on an Adafruit Feather ESP32-S3 microcontroller to write commands to the DACs and PSEC6. A hardware implementation of the I2C protocol is in development on an FPGA. Since LAPPDs will be used by the Accelerator Neutrino Neutron Interaction Experiment (ANNIE) at Fermilab, the PSEC6 testing system in this internship project can potentially benefit future neutrino research. The project is relevant to the Department of Energy’s microelectronics mission, because the PSEC6 is an ASIC that will handle fast time signals arriving from the detector for readout. It also provided experience with building a cross-platform user interface, practicing digital design and implementation in hardware description language (HDL), and using simulations to inform new design iterations.

Guerrero, Sasha Camila [North Central Coll.]↗
DOE OSTI2020

CiteSoft_Py

There is a need to provide a way for dev-users (Scientists, Engineers, and other Software Developers) to get credit (citations) when they contribute to an important software package - particularly a large package that is already established. Various solutions (including cross package) solutions do exist, but a simple standard format that can work between multiple packages and multiple languages in a modular way is not widely available. CiteSoft_py is a python implementation of CiteSoft. CiteSoft is a plain text standard consisting of a format and a protocol that exports the citations for the end-users for whichever softwares they have used. CiteSoft has been designed so that software dev-users can rely upon it regardless of coding language or platform, and even for cases where multiple codes are working in a coupled manner. The CiteSoft_py implementation includes python decorators to make wrappers for facile use. The purpose is that when dev-users (scientists, engineers and professional programmers) contribute to a collaborative software project, that the appropriate citations (e.g., journal article, conference proceeding) are provided to the end-user. The end-user does not need to know how to use a command line interface, API, etc.

Savara, Aditya↗
DOE OSTI2025

Welding investigation of a wrought FeMnAl steel for armor application

A new wrought FeMnAl steel contains high Mn content and high Al content. This steel has high strength. When it is compared to conventional steels with the similar strength, its density is lower. FeMnAl steels can be used in armor vehicle manufacturing, in which welding is a common practice to join the steel plates together. The welding of FeMnAl steels has not been sufficiently studied before. Here, this work studied the weldability and weld microstructure of an FeMnAl steel and provided useful data for the welding practice of FeMnAl steels. The influences of weld filler metals and shielding gases were studied, using single-pass bead-on-plate gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) two processes. The optimal filler metals and shielding gases have been determined to achieve the better weldability. Autogenous GTAW and electron beam welding were also conducted. Cracks were found in the HAZ in the GMAW welds and electron beam welds. Fewer or no cracks were found in the HAZ of GTAW welds. SEM, SEM/EDX, TEM, TEM/EDX, and EBSD were used to analyze the grain boundaries in the HAZ and the cracks. The grain boundaries of FeMnAl base metal are mostly high angle grain boundaries (HAGBs), which attract impurity and solute atoms and cause intergranular cracking. The proposed cracking mechanisms are liquation cracking and ductility-dip cracking. It was found that GTAW provides much better weldability for the FeMnAl steel than GMAW and EBW.

FeMnAl steel↗
DOE OSTI2025

Effect of post-weld heat treatment on microstructure and mechanical properties of rotary inertia friction welded dissimilar 422-4140 martensitic steel piston joints

The study investigated how post‐weld heat treatment (PWHT) temperature affects the microstructure and localized deformation/fracture during bend testing of rotary inertia friction welds (RIFW) between AISI 422 stainless steel and AISI 4140 steel. RIFW produced a fully martensitic interface with approximately 550 HV hardness in both the thermo-mechanically affected (TMAZ) and heat‐affected zones (HAZ). Due to differences in temper resistance, the 4140 TMAZ/HAZ softened progressively under PWHT temperatures from 525 °C to 700 °C, while the 422 TMAZ unexpectedly maintained about 550 HV up to 600 °C before significantly softening at temperatures ≥625 °C. This asymmetric softening generated steep hardness gradients across the interface at temperatures ≤600 °C. Furthermore, carbon migration across the interface was minimal up to 600 °C, moderate at 625 °C, and by 700 °C produced a carbide‐rich eutectoid layer in the 422 TMAZ alongside a carbon‐depleted soft ferrite layer in the 4140 TMAZ. Strain during bending was PWHT‐dependent, concentrating on the 4140 side; in as-welded joints, the high hardness led to deformation and crack initiation in the base metals, whereas in PWHT samples, cracking initiated in the softened 4140 TMAZ near the interface. The intermediate PWHT temperature of 625 °C offered the best balance of limited carbon diffusion across the interface, relatively low peak weld hardness and minimized hardness gradients across the interface, more homogenous deformation, and good bend test performance.

4140 low-alloy steel↗
DOE OSTI2026

Influence of microstructure and temperature on impact toughness of H13 steel produced by binder jet additive manufacturing

Binder Jet Additive Manufacturing (BJAM) is a promising manufacturing pathway to produce H13 steel dies and tooling with complex geometries for applications in high pressure aluminum die casting, hot stamping, and injection molding. While fully dense H13 coupons produced using BJAM have been subjected to detailed microstructure characterization, properties which are critical and relevant to the aforementioned applications, such as impact toughness, have not been reported. Here, this work evaluated the influence of microstructural characteristics and test temperature on the impact toughness of H13 produced by BJAM. Coupons were produced from three different powder size distributions (PSDs), with nominal powder size ranges of −22 μm, 10-32 μm, and 15-53 μm. Coupons were printed, sintered, hot isostatically pressed (HIPed), and heat treated by quenching and tempering. After HIPing, the measured porosities of the different PSDs were all less than 0.015 vol%. The −22 μm PSD BJAM material exhibited the best impact toughness of all three PSDs across the entire test temperature range from 25 to 400 °C, and also exhibited an ambient temperature impact toughness of 10.9 J at a hardness of 46 HRC, equivalent to minimum threshold requirements for premium grade H13. However, all three BJAM PSDs exhibited moderately lower impact toughness than premium grade wrought H13 from RT to 400 °C. We attribute this in part due to the very large prior-austenite grain (PAG) sizes near 400 μm and segregation from former liquid channels leading to greater amounts of carbide precipitation on PAG boundaries. Technical pathways for optimizing processing and chemistry of BJAM H13 to further improve impact toughness are discussed.

Binder jet additive manufacturing↗
DOE OSTI2025

Overcoming the thermal conductivity versus oxidation resistance barrier in high-temperature steels

Heat-resistant steels with high chromium additions (≥5 weight percent) are critical for many high temperature energy and manufacturing applications, including heat exchangers, pistons for engines, and dies for metal working and casting. However, while high chromium additions increase oxidation resistance at elevated temperatures, they also compromise thermal conductivity, resulting in a metallurgical trade-off between these two important properties. Here we show that a microstructure with both higher thermal conductivity and improved oxidation resistance at elevated temperatures is achieved in a unique steel with only 1 weight percent chromium, thereby overcoming the long-standing metallurgical trade-off. This is accomplished through a tailored thermal treatment that produces a tempered martensitic matrix with low solute content and a fine dispersion of copper precipitates and molybdenum enriched carbides. A further discovery is that the resultant thermally grown oxide includes an iron-copper-manganese-enriched outer layer that provides high-temperature oxidation protection equivalent to heat-resistant steels with five times the chromium content and 25% lower thermal conductivity.

Pierce, Dean T. [Oak Ridge National Laboratory (OR↗
DOE OSTI2026

Characterization of Pseudomonas aeruginosa and Acinetobacter calcoaceticus-baumannii complex traumatic wound isolates

Healing of traumatic wounds is complicated by infecting pathogens, with Pseudomonas aeruginosa and members of the Acinetobacter calcoaceticus-baumannii complex among the most common infectious agents. However, a full understanding of genotypic and phenotypic differences between circulating wound isolates is lacking. To address this, traumatic wounds were sampled at Emory University Hospital, and 24 isolates were characterized; we focused on P. aeruginosa and Acinetobacter due to their prevalence and tendency for antibiotic resistance. Even though these species are renowned for antibiotic resistance, only two of the tested isolates could be classified as multidrug resistant. Whole-genome sequencing and analysis revealed that isolates from different patients were genetically distinct; however, longitudinal isolates from the same patient were closely related and appeared to represent chronic colonization by the same strain. Phylogenetic analysis revealed that laboratory strains (PAO1 and AB5075) that were isolated decades previously and from different locations grouped closely to subsets of the recent wound isolates. Given the importance of biofilm formation in infection, the ability of the isolates to form biofilms was assessed; all isolates formed biofilms but showed temporal and magnitude differences. Analysis of a subset of isolates revealed that planktonic P. aeruginosa was resistant to human serum-mediated killing. While the same was true for the majority of Acinetobacter isolates, one showed planktonic sensitivity that was abrogated when grown in a biofilm. Taken together, these data reveal genotypic and phenotypic differences in circulating isolates of P. aeruginosa and A. baumannii.

Acinetobacter↗
DOE OSTI2025

Rotary Inertia Friction Welding of Dissimilar High-Strength 422 Martensitic Stainless Steel and 4140 Low Alloy Steel for Heavy-Duty Engine Piston Fabrication

AISI 422 martensitic stainless steel with superior high temperature performance (oxidation resistance and strength) is under evaluation for replacing current heavy-duty piston crown materials, AISI 4140 martensitic steel and micro alloyed steel (MAS) 38MnSiVS5, to fabricate a multimaterial piston. This multimaterial piston concept further improved power density and fuel economy by allowing heavyduty diesel engines to operate at higher temperatures and pressures. Joining AISI 422 steel piston crowns with AISI 4140 steel piston skirts is a key manufacturing step for this multimaterial piston. However, the significant differences in strength, elevated temperature flow stress, alloy chemistry, and temper resistance between these two martensitic steels cause some weldability issues (cracking) and metallurgical challenges (alloying element migration/segregation) when using conventional fusion-based welding processes. Rotary inertia friction welding (RIFW), a solid-state welding process, has been the preferred method to join 4140 crowns to 4140 skirts (and MAS crowns to MAS skirts) in high-volume production of current heavy-duty diesel engine pistons. It has been used to join these two materials with relatively comparable alloy chemistry to fabricate pistons with MAS skirts and 4140 crowns. Meanwhile, RIFW has also been a preferred method of dissimilar metal welding. However, RIFW of dissimilar high-strength martensitic steels has yet to be widely pursued. The interfacial microstructure complexities created by the thermomechanical process and highly nonequilibrium phase transformations during RIFW are a significant challenge for understanding and predicting their joining behavior and have not been reported in detail. Here, in this work, defect-free AISI 422 steel-AISI 4140 multimaterial pistons were successfully fabricated using the RIFW process. The interfacial microstructure and mechanical properties of dissimilar 422/4140 steel RIFW in the as-welded condition were experimentally studied in detail. The results provide critical baseline information for understanding RIFW mechanisms and guiding subsequent postweld heat treatment (PWHT) practice.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Hydrogen from low-density polyethylene via nonthermal plasma: Effects of energy density and process parameters

Nonthermal plasma processes are promising for the modular valorization of plastic waste, especially into hydrogen and carbon materials, due to their high intensity, lack of reliance on catalysts or consumables, and suitability to be directly powered by electricity. We investigate the production of hydrogen from low-density polyethylene (LDPE) as a plastic waste model using streamer Dielectric Barrier Discharge (sDBD) plasma in nitrogen at atmospheric pressure. Here, we examine the effects of process energy density (energy input per unit of feedstock mass), feedstock mass, and plasma intensity (electric voltage) on plasma properties, hydrogen yield and energy efficiency via gas chromatography, optical emission spectroscopy, and electrical diagnostics, together with reactor-scale and nonlinear electric circuit modeling. The characteristic temperature of free electrons in the sDBD plasma is approximately 15000 K (1.3 eV), and that of gas species 10 times lower, demonstrating strong thermal non-equilibrium that can lead to molecular bond scission via charged species impact rather than direct heating. Experimental results show that higher energy density leads to greater hydrogen production and diminishing energy efficiency, and that higher plasma intensity and larger feedstock mass lead to greater hydrogen yield due to higher plasma temperatures and enhanced energy fluxes to the feedstock.

08 HYDROGEN↗
DOE OSTI2025

Exploring 𝛽 decay and 𝛽-delayed neutron emission in exotic 46,47 Cl isotopes

In this paper, 𝛽 − and 𝛽-delayed neutron decays of 46,47 Cl are reported from an experiment carried out at the National Superconducting Cyclotron Laboratory using the Beta Counting System. The half-lives of both 46 Cl and 47 Cl were extracted. Based on the delayed 𝛾-ray transitions observed, the level structure of 𝑁=28 46 Ar was determined. Completely different sets of excited states above the first 2 + state in 46 Ar were populated in the 46 Cl 𝛽⁢0⁢𝑛 and 47 Cl 𝛽⁢1⁢𝑛 decay channels. Two new 𝛾-ray transitions in 47 Ar were identified from the very weak 47 Cl 𝛽⁢0⁢𝑛 decay. Furthermore, 46 Cl 𝛽⁢1⁢𝑛 and 47 Cl 𝛽⁢2⁢𝑛 were also observed to yield different population patterns for levels in 45 Ar, including states of different parities. Here, the experimental results allow us to address some of the open questions related to the delayed neutron emission process. For isotopes with large neutron excess and high 𝑄 𝛽 values, delayed neutron emission remains an important decay mode and can be utilized as a powerful spectroscopic tool. Experimental results were compared with shell-model calculations using the FSU and 𝑉 MU effective interactions.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Basin & Range Investigation for Developing Geothermal Energy

Hidden geothermal systems represent a potentially prolific energy resource that could support critical U.S. public and government energy priorities. Basin and Range Investigations for Developing Geothermal Energy (BRIDGE) addressed some the challenges associated with hidden system exploration by prioritizing cost-effective exploration early on through strategic workflow and informed decision-making that mitigates early risk and shifts resources to later exploration stages (e.g., drilling). Sandia National Laboratories partnered with U.S. Navy Geothermal Office, Geologic Geothermal Group, and independent consultants, with additional collaboration with U.S. Geological Survey and private industry. The primary tool of the BRIDGE project was to deploy a regional-scale airborne electromagnetic method to investigate the shallow resistivity structure in areas with high prospectivity. This was followed up at several prospects by a multidisciplinary exploration approach, including additional geologic, geophysical and geochemical studies. A central tenet to the BRIDGE methodology is that zones of low resistivity frequently occur over geothermal systems in the Basin and Range, and when paired with other data constraints, imaging these zones can enable discovery of these systems. In addition to exploring greenfield areas (i.e., Grover Point), the BRIDGE project also flew HTEM resistivity surveys over known geothermal systems including those with established power plants (Don A. Campbell and Salt Wells) and prospects that are known to the literature but remain undeveloped, at least in part, due to a lack of understanding on the location of their producible reservoirs. BRIDGE produced a comprehensive set of data from prospects identified in the Nevada Play Fairway Analysis along with conceptual models for top ranking prospects, wherein all of the observations are used to inform an interpreted model of the system. These models present a range of possible system parameters such as temperature and size, and they are further informed by system analogues in the Basin and Range province and elsewhere. The results of this work leave space for further exploration that may now occur at prospects ‘down the list’ rather than distribution exploration resources evenly across all prospects.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Effect of Zr and Sc additions on coarsening- and creep resistance of AlSi10Mg fabricated by laser powder bed fusion

Microstructure and creep properties are studied in a eutectic AlSi10Mg alloy modified with Zr and Sc additions (Al-9.8Si-0.32Mg-0.70Zr-0.23Sc, wt%) manufactured through laser powder-bed fusion (L-PBF). Three types of Zr/Sc-bearing powders - elemental, master-alloy, and pre-alloyed - are employed in the fabrication process, with the pre-alloyed powders providing the highest incorporation of Zr and Sc in the Al matrix. Here, the as-printed alloy exhibits a fine cellular Al-Si eutectic structure which fragments and coarsens into micron-sized Si particles during aging at 300 ºC, leading to a steady drop in alloy microhardness between 0.1 and 1000 h. Coarsening of the eutectic Si phase during aging is not measurably affected by Zr and Sc in solid solution, which precipitate during aging and increases strength, compensating weakening from Si coarsening between 1 and 200 h at 300 ºC. Atom-probe analysis in the peak-aged condition (96 h/300 °C) confirms the presence of Al 3 (Sc,Zr) secondary nano-precipitates with an average radius of 1.0 nm and some Si solubility. Micron-sized grains are present throughout the alloy, with ultra-fine-grained regions at the melt pool boundaries, neither of which coarsen during long-term aging at 300 ºC. Under creep conditions at 300 °C, the Zr/Sc-bearing alloy with Al 3 (Sc,Zr) nano-precipitates exhibits power-law behavior, with a high apparent stress exponent (n a = 9) and a high threshold stress (σ th = 43 MPa), exhibiting nearly double the strength of a Zr/Sc-free AlSi10Mg control alloy (σ th = 22 MPa).

36 MATERIALS SCIENCE↗
DOE OSTI2026

Correlation between microstructure and residual stress formation in friction stir welded armor steels characterized by neutron diffraction

Friction stir welding (FSW) is a solid-state joining process that minimizes the heat-affected zone (HAZ) compared with fusion-based arc welding, making it well suited for joining martensitic armor steels where hardness and ballistic resistance are critical. This study investigates residual stress formation in three defect-free FSW butt-joint configurations relevant to armored-vehicle fabrication: similar rolled homogeneous armor (RHA–RHA, Case 1), similar high-hardness armor (HHA–HHA, Case 2), and dissimilar HHA–RHA (Case 3) joints produced under temperature-controlled conditions (770 °C). Neutron diffraction was employed to quantify the magnitude and spatial distribution of residual stresses in the longitudinal, transverse, and normal directions and to correlate them with weld microstructure and hardness. Tensile residual stresses were concentrated in the softened HAZ, reaching approximately 300 MPa for Case 2 and 400 MPa for Case 1 (≈50–70 % of the base-metal yield strength; ∼581 MPa for RHA and ∼566 MPa for HHA), while compressive residual stresses dominated the stir zone. The spatial extent of tensile stresses scaled with the width of the softened HAZ, which was largest in the dissimilar HHA–RHA joint and smallest in the HHA–HHA joint. Full-width-at-half-maximum (FWHM) analysis revealed low microstrain in overtempered HAZ regions and high microstrain in the stir zone associated with severe plastic deformation and fresh martensite formation. This work demonstrates that residual stress evolution in FSW of martensitic armor steels is governed not primarily by peak temperature or thermal contraction, as inferred from fusion-welding analogies, but by the competition between transformation-induced volumetric expansion and tempering-induced stress relaxation. The relative dominance of these mechanisms is shown to depend on alloy hardenability and local thermal history, leading to more extensive HAZ softening and broader tensile stress regions in the lower-hardenability RHA steel. These findings establish a transferable mechanistic framework for optimizing solid-state joining strategies in high-strength steels and other transformation-hardening alloys beyond armor applications.

Friction stir welding↗
DOE OSTI2026

Multiple valence-space and core-excited band terminations in Ho and Er isotopes

High-spin structures of holmium (𝑍 = 67) and erbium (𝑍 = 68) isotopes are presented near mass 160, a region where collective and single-particle modes of excitation compete in the generation of angular momentum at the highest experimentally attainable spins in atomic nuclei. The level schemes of the 156,157,158 Ho isotopes have been significantly extended, reaching spins in the 40⁢ℏ to 55⁢ℏ range, through multiple experiments utilizing the Gammasphere spectrometer. In particular, several new noncollective band-terminating states are reported for these nuclei. The nature of these states, including both valence-space terminations and core-excited oblateconfigurations, is discussed in terms of proton particle-hole (p-h) excitations across the semimagic 𝑍 = 64 shell closure. Cranked-Nilsson–Strutinsky (CNS) calculations have been used to interpret the nature of these noncollective states. The corresponding terminating states in 154–159 Er are also included, providing a systematic description of band termination in this mass region. In addition, three weak rotational structures have been assigned to 157 Ho at the highest spins. These collective bands are proposed to be based on a triaxial strongly deformed nuclear shape, involving neutron p-h excitations across the 𝑁 = 82 shell gap.

150 ≤ A ≤ 189↗
DOE OSTI2026

High-spin states in 60 Cu and implications for states in the mirror nucleus 60 Ga

High-spin states in 60 Cu are investigated on the basis of reaction-channel-selected 𝛾-ray spectroscopy. Data stem from three experiments that used the same fusion-evaporation reaction at similar beam energies. The Gammasphere 𝛾-ray spectrometer was combined with the Microball CsI(Tl) detector array and sets of liquid-scintillator neutron detectors which allowed us to identify and tag on evaporated light charged particles and neutrons, respectively. A level scheme is proposed which comprises more than 300 𝛾-ray transitions connecting more than 100 excited states. Predictions from cranked Nilsson-Strutinsky calculations describe the observed high-spin collective structures in 60 Cu. Predictions of shell-model calculations are probed with a suite of low- to medium-spin states of both parities. Taking into account isospin-symmetry-breaking terms in these calculations, a case study of the yrast line of the weakly bound mirror nucleus 60 Ga is presented.

Rudolph, Dirk [Lund University (Sweden)] (ORCID:00↗
DOE OSTI2025

Deuteron Evaporation from N = Z Compound Nuclei

Deuteron evaporation was observed from the N = Z compound nuclei 52 Fe ⋆ , 56 Ni ⋆ , and 64 Ge ⋆ in an experiment conducted at Argonne National Laboratory, USA. The experiment included a novel combination of two highly pixelated double-sided Si-strip detectors inside the Microball chargedparticle detection array, allowing for unequivocal discrimination of evaporated deuterons from protons and α particles. In conjunction with the Gammasphere array, Neutron Shell, and additional ancillary detectors, decay paths into various residual nuclei were investigated. The study provides insights into the competition of deuteron vs. proton-neutron evaporation as a function of available excitation energy and populated angular momentum. Results are interpreted using a statistical evaporation formalism for multiple subsequent particle emissions. The decisive factor in the comparison appears to be the available excitation energy in the residual system, with single nucleon evaporation preferred over deuteron evaporation for higher excitation energies.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2014

Residential Energy Efficiency Demonstration: Hawaii and Guam Energy Improvement Technology Demonstration Project

In order to meet its energy goals, the Department of Defense (DOD) has partnered with the Department of Energy (DOE) to rapidly demonstrate and deploy cost-effective renewable energy and energy-efficiency technologies. The scope of this project was to demonstrate tools and technologies to reduce energy use in military housing, with particular emphasis on measuring and reducing loads related to consumer electronics (commonly referred to as 'plug loads'), hot water, and whole-house cooling.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗