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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Microscale drivers and mechanisms of fracture in post-processed additively manufactured Ti–6Al– 4 V

Herein, we focus on understanding the microstructure-fracture correlations in a Ti–6Al– 4 V alloy additively manufactured via electron beam melting (EBM) and subjected to various post-process heat-treatments. Specifically, the as fabricated material is subjected to a sub-transus heat-treatment followed by air-cooling and a super-transus heat-treatment followed by either air- or furnace-cooling. Next, a series of in-situ single edge notch tension (SENT) tests are carried out under a high-resolution digital optical microscope. The panoramic high-resolution images captured during the in-situ tests are then used to characterize the planar deformation on the specimen surface using microstructure-based digital image correlation (DIC). Additionally, the results of the in-situ SENT tests together with DIC and post-mortem fractographic analyses provided us with a better understanding of the microstructure-fracture correlations in these materials. Our results show that the fracture mechanism of the as fabricated and sub-transus heat-treated materials is essentially the same, while the changes in the microstructure following the super-transus heat-treatments significantly affects the fracture mechanism. In this case, several microcracks of hundreds of microns in length first nucleate away from the deformed notch following extreme plastic deformation at discrete locations. Furthermore, the location of these microcracks in the super-transus heat-treated materials is extremely sensitive to the details of the underlying microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Mechanical Characteristics of Additively Manufactured ODS 316L and 316H Alloys with and Without Post-build Processing

This research aims to explore an accelerated development path for oxide dispersion-strengthened (ODS) alloys by integrating additive manufacturing (AM) technologies with recent advances in ODS materials and traditional manufacturing methods. Novel AM and post-build processing routes have been developed for ODS austenitic alloys, specifically Fe-Cr-Ni alloys like 316L and 316H. Electron microscopy and mechanical characterizations were conducted to evaluate the effects of process variables on microstructure and properties, aiming for an economically feasible route property optimization. Traditionally, ODS alloy production involves multi-day high-energy mechanical milling of alloy powder with yttria (Y 2 O 3 ) followed by powder consolidation via extrusion or other methods and additional thermomechanical processing (TMP) for property control. Here, to address these challenges associated with this complex and costly approach, we propose exploring alternative, cost-effective processing routes focusing on AM and traditional TMP methods. The new ODS alloy processing routes have achieved up to a 400% increase in yield strength and a 60% increase in ultimate tensile strength compared to wrought stainless steels while still maintaining significant ductility and fracture toughness. This paper details the novel and economical AM-based processing routes for ODS austenitic alloys, combined with post-build TMPs, and discusses the mechanical and microstructural characteristics of the developed materials.

Byun, Thak Sang [Oak Ridge National Laboratory (OR↗
DOE OSTI2022

Using post-processing heat treatments to elucidate precipitate strengthening of additively manufactured superalloy 718

The poor machinability and extensive work hardening of Ni-based superalloys makes additive manufacturing an attractive option for producing geometrically complex components with distinct microstructures. Although previous studies show recovery of high strength at room temperature, very few studies demonstrate successful properties at elevated temperatures required for industrial applications. Here, the objectives of this study are to present a post-build heat treatment for high strength across a wide temperature range, determine the strength contribution of nanoscale precipitating phases to the overall mechanical properties of superalloy 718, and from these, provide a comprehensive microstructure-property relationship for wrought and AM 718 to guide efforts to simulate the properties of AM components. Laser powder bed fusion–produced superalloy 718 was characterized at multiple length scales using scanning electron microscopy and transmission electron microscopy in the as-built condition and with multiple heat treatments designed to form combinations of γ', γ", and δ precipitates. Uniaxial tensile tests performed from room temperature to 600 °C on subsize specimens determined the yield strength, elastic modulus, ultimate tensile strength, fracture stress, and uniform elongation. Precipitates in this work proved to be weak barriers to dislocation motion through a dispersed barrier model, but they provided strength to the alloy through their consistent high density. The relative contribution to the yield strength from γ" remained consistent between 48% and 57% of the total strength up to 600 °C, the primary influence on the high temperature strength of superalloy 718. The strength factors for γ" and δ precipitates were found to trend inversely with tensile test temperature and may be attributable to the differences in precipitate coherency. A post-build heat treatment is recommended to maintain high strength at elevated temperatures. A quantitative microstructure-property relationship, dependent on precipitate size, density, and morphology, was derived and can estimate the yield strength across a wide temperature range applicable to the operational regimes for superalloy 718.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Day-ahead photovoltaic power production forecasting methodology based on machine learning and statistical post-processing

A main challenge towards ensuring large-scale and seamless integration of photovoltaic systems is to improve the accuracy of energy yield forecasts, especially in grid areas of high photovoltaic shares. The scope of this paper is to address this issue by presenting a unified methodology for hourly-averaged day-ahead photovoltaic power forecasts with improved accuracy, based on data-driven machine learning techniques and statistical post-processing. More specifically, the proposed forecasting methodology framework comprised of a data quality stage, data-driven power output machine learning model development (artificial neural networks), weather clustering assessment (K-means clustering), post-processing output optimisation (linear regressive correction method) and the final performance accuracy evaluation. The results showed that the application of linear regression coefficients to the forecasted outputs of the developed day-ahead photovoltaic power production neural network improved the performance accuracy by further correcting solar irradiance forecasting biases. The resulting optimised model provided a mean absolute percentage error of 4.7% when applied to historical system datasets. Finally, the model was validated both, at a hot as well as a cold semi-arid climatic location, and the obtained results demonstrated close agreement by yielding forecasting accuracies of mean absolute percentage error of 4.7% and 6.3%, respectively. Finally, the validation analysis provides evidence that the proposed model exhibits high performance in both forecasting accuracy and stability.

42 ENGINEERING↗
DOE OSTI2026

Spatiotemporal 4D Whole-cell Modeling of a Minimal Autotroph Reveals Central Carbon Metabolism Regulated Locally by Protein Megacomplexes via Post-translational Modifications under Light Disturbance

Photosynthetic microorganisms rely on multiple pathways in central carbon metabolism to adapt to fluctuating light and energy availability across diel cycles. Mechanistic insight into the regulatory dynamics of this adaptation requires integrating processes spanning disparate timescales, from rapid redox-dependent post-translational modifications (PTMs) to slower changes in protein expression and metabolic pathway usage. To address this complexity beyond genome-based inference and traditional modeling, we develop a whole-cell four-dimensional (3D + time) model of the marine cyanobacterium Prochlorococcus marinus MED4 that explicitly represents the spatial organization of enzymatic and molecular processes in central carbon metabolism under light perturbation. We employ a perturbation-based research design to experimentally generate time-series, multi-omics measurements that provide molecular descriptors and cryo-ET derived 3D segmented volumes as constraints for this dynamic 4D framework. The integration of experiments and modeling across defined light regimes enables quantitative validation of system-level responses and forecasting under distinct light disturbances. We test the hypothesis that light-dependent redox PTMs regulating the structural assembly of a protein megacomplex, the “dark complex,” modulate metabolic flux at a conserved regulatory node of the Calvin–Benson cycle (CBC) in cyanobacteria. Our model shows that subcellular spatial organization buffers rapid light-induced changes in thylakoid reaction rates, which are followed by redox-PTM-mediated sequestration or release of CBC enzymes in the dark complex, ultimately impacting carbon fixation dynamics within carboxysomes. Comparison with an equivalently parameterized well-mixed stochastic model demonstrates that post-translational regulation not only buffers transcriptional noise and diffusion-driven fluctuations but also stabilizes phenotypic outcomes, underscoring the importance of spatial heterogeneity in phenotypic robustness. This ability to probe adaptive, spatiotemporally resolved mechanisms in photosynthetic machinery and central carbon metabolism addresses a critical gap in genotype-to-phenotype inference and expands modeling and design capabilities for understudied or genetically intractable autotrophs such as P. marinus MED4.

Johnson, Connah G.↗
DOE OSTI2022

Ce post-treatment for increased corrosion resistance of AA2024-T3 anodized in tartaric-sulfuric acid

Here, the effect of a post-treatment for short time in 50 mM Ce(NO 3 ) 3 solution, with or without H 2 O 2 , on the corrosion of AA2024-T3 anodized in tartaric-sulfuric acid was investigated. Electrochemical (EIS, polarization curves) and corrosion (immersion) tests showed improved performance for samples post-treated at 50 °C in the H 2 O 2 containing solution. Microstructural characterization (SEM, STEM, GDOES) evidenced the presence of Ce oxyhydroxides both at the surface and within the pores of the anodized layer, and their preferential interaction with defective sites both at micro and nanoscale. Important amounts of Ce-species were found near corrosion products, indicating active corrosion protection by Ce ions.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Post-irradiation examinations of annular mixed oxide fuels with average burnup 4 and 5% FIMA

In this paper, we present post-irradiation examination results on two type of annular mixed oxide fuel pins irradiated in the Fast Flux Test Facility (FFTF) sodium cooled reactor to an average burnup between 4% and 5% fission of initial heavy atom (FIMA). The pins differed only from the initial Pu content, which was 22 wt% and 26 wt%, respectively. The overall performance of the pins was excellent, in line with previous historical results. The pins with higher Pu content experienced higher irradiation temperatures which influenced the fission gas release, fuel swelling, and Cs distribution compared to the other pins. All the post-irradiation examinations results are discussed against the irradiation parameters. In particular, the pins with higher initial Pu content, i.e., 26 wt%, experienced higher power that resulted in enhanced fission gas release compared to the other two pins with 22 wt% initial Pu content. For the pins with higher fission gas release, onset of Cs redistribution was observed. The two pins that had lower initial Pu content and burnup showed a Cs axial distribution similar to the as-produced one.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Post-irradiation examination of AGR-3/4 TRISO fuel compacts using three-dimensional X-ray computed tomography

The AGR-3/4 irradiation tests combined the third and fourth planned irradiation experiments in the US Department of Energy’s Advanced Gas Reactor (AGR) testing campaign of tri-structural isotropic (TRISO) fuel compacts. In this article, we present post-irradiation examination (PIE) using X-ray computed tomography (XCT) of two unirradiated and two irradiated compacts from the AGR-3/4 irradiation tests. The irradiated compacts studied (compact 7–1 and compact 12–4) represent the upper and lower limit of burnup within the AGR-3/4 irradiation experiment. This article presents a detailed quantitative analysis on the post-irradiation structure of TRISO fuel compacts. Various quantitative parameters including shape, size, and packing of kernels, and their spatial distribution, were utilized to gain insights into the structural changes caused by irradiation. The equivalent diameter and sphericity were found to increase and decrease, respectively, in irradiated compact 7–1 due to its higher burnup. Nearest neighbor distance between fuel kernels decreased after irradiation, suggesting irradiation-induced shrinkage of graphitic matrix. Furthermore, each compact in AGR-3/4 irradiation tests contained 20 designed-to-fail (DTF) fuel particles that were meant to act as a source of fission product release to the experiment test train. Furthermore, in the present work, all DTF fuel particles in the four compacts studied were identified, and it was found that they exhibited larger kernel swelling in compact 12–4 and smaller kernel swelling in compact 7–1, compared to the driver particles.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Implications of post-processing induced microstructural changes on the deformation and fracture response of additively manufactured Ti–6Al–4V

Ti–6Al–4V parts fabricated via electron beam melting (EBM) powder bed fusion are often subjected to hot isostatic pressing below the β-transus temperature to mitigate defects. During which the pressure aids in pore closure and the thermal exposure results in coarsening of α phase while retaining the columnar prior-β phase grain morphology present in the as-fabricated condition. The same post-processing treatment can also be carried out above β-transus temperature which is an effective way to modify both the grain morphology and the associated α textures. Here, the objective of this work is to correlate thermally induced microstructural changes to the deformation and fracture response of the EBM processed Ti–6Al–4V. To this end, we have carried out both sub-transus and super-transus heat-treatments of the as-fabricated material. The mechanical response of the as-fabricated and all heat-treated materials are characterized by in-situ tensile tests under a high-resolution digital optical microscope. This enabled us to capture large-scale panoramic images of the deforming microstructure, and overcome the trade-off between the image resolution and the field of view during in-situ experiments. The series of images captured throughout the imposed deformation are subsequently used to perform microstructure-based digital image correlation to measure microstructural-scale strains over a large area. The results of the in-situ tests together with detailed fractographic analyses are then used to elucidate how the heterogeneous deformation spanning over multiple microstructural length-scales, for example, at the scale of lamellae, colonies of lamellae and grain boundaries, affect the overall deformation and fracture response of the post-processed materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

DeepONet-grid-UQ: A trustworthy deep operator framework for predicting the power grid’s post-fault trajectories

This paper proposes a novel data-driven method for the reliable prediction of the power grid’s post-fault trajectories, i.e., the power grid’s dynamic response after a disturbance or fault. Here, the proposed method is based on the recently proposed concept of Deep Operator Networks (DeepONets). Unlike traditional neural networks that learn to approximate functions, DeepONets are designed to approximate nonlinear operators, i.e., mappings between infinite-dimensional spaces. Under this operator framework, we design a novel and efficient DeepONet that (i) takes as inputs the trajectories collected before and during the fault and (ii) outputs the predicted post-fault trajectories. In addition, we endow our method with the much-needed ability to balance efficiency with reliable/trustworthy predictions via uncertainty quantification. To this end, we propose and compare two novel methods that enable quantifying the predictive uncertainty. First, we propose a Bayesian DeepONet (B-DeepONet) that uses stochastic gradient Hamiltonian Monte-Carlo to sample from the posterior distribution of the DeepONet trainable parameters. Then, we design a Probabilistic DeepONet (Prob-DeepONet) that uses a probabilistic training strategy to enable quantifying uncertainty at virtually no extra computational cost. Finally, we validate the proposed methods’ predictive power and uncertainty quantification capability using the New York-New England power grid model.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Investigation of post-injection strategies for diesel engine Catalyst Heating Operation using a vapor-liquid-equilibrium-based spray model

Most multidimensional engine simulations spend much time solving for non-equilibrium spray dynamics (atomization, collision, vaporization). However, their accuracy is limited by significant grid dependency, and the need for extensive calibration. This is critical for modeling cold-start diesel fuel post injections, which occur at low temperatures and pressures, far from typical model validation ranges. At the same time, resolving micron-scale spray phenomena would render full Eulerian multiphase calculations prohibitive. In this study, an improved phase equilibrium based approach was implemented and assessed for simulating diesel catalyst heating operation strategies. A phase equilibrium solver based on the model by Yue and Reitz [1] was implemented: a fully multiphase CFD solver is employed with an engineering-size engine grid, and fuel injection is modeled using the standard Lagrangian parcels approach. Mass and energy from the liquid parcels are released to the Eulerian multiphase mixture according to an equilibrium-based liquid jet model. An improved phase equilibrium solver was developed to handle large real-gas mixtures such as those from accurate chemical kinetics mechanisms. The liquid-jet model was improved such that momentum transfer to the Eulerian solver better reproduces the physical spray jet structure. Validation of liquid/vapor penetration predictions showed that the model yields accurate results with very limited tuning and low sensitivity to the few calibration constants. In-cylinder simulations of diesel catalyst heating operation strategies showed that capturing spray structure is paramount when short, transient injection pulses and low temperatures are present. Furthermore, the EP model provides improved predictions of post-injection spray structure and ignitability, while conventional spray modeling does not capture the increase of liquid penetration during the expansion stroke. Finally, the only important EP model calibration constant, Cliq, does not affect momentum transfer, but it changes the local charge cooling distribution through the local energy transfer, which makes it candidate to additional research. The results confirm that non-equilibrium spray processes do not need to be resolved in engineering simulations of high-pressure diesel sprays.

42 ENGINEERING↗
DOE OSTI2020

Challenges in the post-licensing stage of U.S. hydropower development: Current status and some potential solutions

The issuance of a Federal Energy Regulatory Commission (FERC) license is an important milestone in the development process of new U.S. hydropower projects. The complexity and uncertain timeline of the licensing process have been often cited as a key deterrent to new hydropower installations in the United States. However, very little attention has been paid to post-licensing timelines and attrition rates. This article explores the challenges faced by developers in bringing their FERC-licensed hydropower projects to the construction stage. Post-licensing activities to be completed before starting construction include obtaining additional permitting from other federal or state agencies, completing the technical design, securing financing, and in most cases, negotiating a power purchase agreement. For the set of projects that obtained a FERC license between 2007 and 2018, we assembled a dataset—combining information from FERC dockets and responses from a questionnaire to developers—to calculate attrition rates and development timelines and to examine the reasons for delays and cancellations.

13 HYDRO ENERGY↗
DOE OSTI2024

Chemical recycling of post-consumer polyester wastes using a tertiary amine organocatalyst

Recycling diverse waste plastics poses challenges due to complex sorting and processing, resulting in high costs and inefficiency. To tackle this, we present a metal-free catalytic sorting method for targeted deconstruction of polyester from post-consumer plastic waste, encompassing textiles, plastic mixtures, and multilayer packaging materials. This method employs N-methylpiperidine, a tertiary amine catalyst in methanol, to depolymerize polyethylene terephthalate (PET). Operating under these conditions (160°C, 1 h), we achieve 100% yields of dimethyl terephthalate and ethylene glycol. This technique also effectively breaks down other polyesters, including polylactic acid, polycarbonate, and polybutylene terephthalate, yielding high-yield monomers at relatively low temperatures. Through comprehensive nuclear magnetic resonance (NMR) analysis, we propose that N-methylpiperidine’s role is in enhancing methanol nucleophilicity and activating PET’s ester bond. Our insights advance the chemical recycling of post-consumer plastic waste, offering a potentially simple and efficient path to closing the polyester production loop.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

A Note to Reviewers Suggesting Post-reaction Catalyst Characterization: Know What You’re Asking For

Here, we highlight examples of post-reaction characterization in thermo- and electrocatalysis to present the challenges in obtaining reliable data to answer specific questions about the true identity of the active site and/or catalyst deactivation/degradation. We use this editorial to suggest to reviewers that, when formulating comments to authors that involve materials characterization after reaction testing, they should consider what specific, meaningful information can be attained or what targeted question can be answered that adds value to the individual paper and to the field in general, and how to reasonably obtain that data. In contrast, reviewers should avoid vague, open-ended comments that suggest unguided post-reaction characterization that would not add significant value to the report and, similarly, avoid comments that are substantial enough that they could form the basis of an entirely separate report.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Elucidating the Location of Cd 2+ in Post-synthetically Treated InP Quantum Dots Using Dynamic Nuclear Polarization 31 P and 113 Cd Solid-State NMR Spectroscopy

Indium phosphide quantum dots (InP QD) are a promising alternative to traditional QD materials that contain toxic heavy elements such as lead and cadmium. However, InP QD obtained from colloidal synthesis are often plagued by poor photoluminescence quantum yields (PL-QYs). In order to improve the PL-QY of InP QD, a number of post-synthetic treatments have been devised. Recently, it has been shown that InP post-synthetically treated with Lewis acid metal divalent cations (M-InP) exhibit enhanced PL-QY; however, the molecular structure and mechanism behind the improved PL-QY are not fully understood. Here, to determine the surface structure of M-InP QD, dynamic nuclear polarization surface-enhanced nuclear magnetic resonance spectroscopy (DNP SENS) experiments were employed on a series of InP magic size clusters treated with Cd ions, InP QD, cadmium phosphide (Cd 3 P 2 ) QD, and Cd-treated InP QD (Cd–InP QD). With the use of DNP SENS, we were able to obtain the 1D 31 P and 113 Cd NMR spectra, 113 Cd{ 31 P} rotational-echo double-resonance (REDOR) NMR spectra, and 31 P{ 113 Cd} dipolar heteronuclear multiple quantum correlation (D-HMQC) sequence. Changes in the phosphide 31 P chemical shifts after Cd treatment provide indirect evidence that some Cd alloys into the sub-surface regions of the particle. DNP-enhanced 113 Cd solid-state NMR spectra suggest that most Cd ions are coordinated by oxygen atoms from either carboxylate ligands or surface phosphate groups. 113 Cd{ 31 P} REDOR and 31 P{ 113 Cd} D-HMQC experiments confirm that a subset of Cd ions are located on the surface of Cd–InP QD and coordinated with phosphate groups.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Post-Hydration Crosslinking of Ion Exchange Membranes to Control Water Content

The utilization of crosslinking as a technique to limit excess water uptake in ion exchange membranes is a well-established approach. However, traditional methods involve performing the crosslinking reaction before the membrane self-segregates into hydrophilic and hydrophobic domains upon exposure to water. In this study, we employ numerical and molecular simulations to explore the potential of post-hydration crosslinking of the polymer at subsaturated conditions. This process allows for the development of a nanosegregated morphology, which establishes well-connected but narrow water channels, while limiting additional sorption of water. The significant reduction in membrane swelling observed in our study indicates that post-hydration crosslinking could be a promising approach to regulate water uptake in ion exchange membranes. Here based on our analyses, we propose chemical crosslinking strategies that may yield high membrane gel fractions.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Post-Modification of Crystalline Peptoid Nanomembranes with Active Nanoparticles for Efficient Photooxidation of a Mustard Gas Simulant

Peptoids (or poly-N-substituted glycines) hold immense potential for assembling into hierarchically structured functional materials via controlled molecular interactions. To create self-assembled materials with tailored functionalities, peptoid sequences are often conjugated with reactive or recognition motifs to enable applications including specific binding, biomimetic catalysis, and fluorescence imaging. However, the direct integration of bulky functional motifs into peptoid sequences can disrupt assembly processes and structural outcomes. Herein, we present a post-modification strategy for functionalizing pre-formed 2D crystalline assemblies. Through introducing clickable active sites, such as azide, alkyne, or thiol groups into a peptoid sequence, site-specific conjugation is achieved post-assembly via efficient “click”-type reactions. This strategy enables the ordered alignment of functional groups and gold nanoparticles (Au NPs) on the surface of 2D peptoid nanomaterials with controlled density, while preserving their high crystallinity and structural integrity. Furthermore, we demonstrated that nanomembranes functionalized with both Au NPs and porphyrins enhance the efficiency and selectivity of the photooxidation of 2-chloroethyl ethyl sulfide, a simulant of sulfur mustard. This innovative strategy lays the groundwork for advancing peptoid-based functional materials across diverse applications, from catalysis to biomedicine.

Chemistry↗
DOE OSTI2026

Photooxidative Upcycling of Post-Consumer Polystyrene Plastics into Phenol Using Eosin Y

Phenol is a commodity chemical frequently used in the manufacturing of resins, pharmaceuticals, and polymers. Yet, its industrial production from cumene requires harsh oxidative conditions followed by the Hock rearrangement. Polystyrene (PS) is a widely manufactured commodity polymer; however, it is among the least recycled plastics. Intriguingly, it is composed of contiguous cumene repeats that could serve as a phenol source, enhancing its value as a waste material. In this work, we leverage the similarity between cumene and PS to drive phenol production via a mild photooxidative HAT mechanism. Using Eosin Y under blue light irradiation and atmospheric pressure of oxygen, commercial PS resin was converted into hydroperoxyl PS. Subsequent acid-catalyzed Hock rearrangement afforded up to 21% yield of phenol. The photooxidation system was successfully applied to 8 post-consumer PS plastics, achieving phenol yields up to 23%, comparable to those of the current industrial Hock process. Our method introduces a mild catalytic strategy for converting post-consumer PS into phenol, offering a potential pathway for PS waste valorization.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗