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At least 1,513 records · Page 84
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Files and scripts to support manuscript Needham et al. Canopy Gradients of Respiration

This dataset includes the parameter files, relevant output files, and scripts to perform analysis with Jupyter notebooks that support the manuscript Needham et al 2025 “Canopy Gradients of Respiration Drive Plant Carbon Budgets and Leaf Area Index.” We add functionality to the Functionally Assembled Terrestrial Ecosystem Simulator (FATES) to allow flexible vertical gradients of leaf maintenance respiration (Rdark) and maximum carboxylation rate (Vcmax) through the canopy. We test the sensitivity of FATES to canopy gradients in Rdark, both in global simulations to assess broad scale impacts on leaf area index (LAI) and vegetation carbon, and in single site simulations where we assess impacts on plant functional type (PFT) competitive dynamics. Parameter files are netcdf files that can be converted to human readable .cdl files using NCO tools. Analysis scripts are Jupyter notebook files. These can be opened and run using the open source Jupyter notebook software. Model outputs are netcdf files.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Innovating Distributed Embedded Energy Prize (InDEEP): A Lessons Learned Report

The U.S. Department of Energy's Water Power Technologies Office (WPTO) launched the Innovating Distributed Embedded Energy Prize (InDEEP) in March 2023 to accelerate innovation in Distributed Embedded Energy Conversion Technologies (DEEC-Tec) for ocean wave energy. Administered by the National Laboratory of the Rockies (NLR) with technical support from Sandia National Laboratories (SNL), InDEEP focused on the development of small, distributed, and embeddable energy converters (DEECs) and their integration into scalable DEEC-Tec metamaterials for marine renewable energy applications. Spanning three phases over two years, InDEEP awarded approximately $2.3 million to teams from academia, industry, and startups. Phase I emphasized conceptual design. Phase II moved into the prototyping of individual DEECs. Phase III required integration into functional DEEC-Tec metamaterial prototypes. Across 60 submissions, teams explored a wide range of energy conversion mechanisms - including piezoelectric, variable-capacitance, ionic, and inductive methods. Note, the prize did not include the design nor demonstration of ocean wave energy conversion systems. Rather, the prize only required participants to design and demonstrate individual DEECs and corresponding DEEC-Tec metamaterials. This prize utilized a mix of novel and proven techniques to attract participants from outside marine energy, including an engagement leaderboard, robust recruitment, technical expert mentorship, and a suite of technical trainings. Key insights from the competition emphasized that DEEC-Tec metamaterials must be intentionally designed to produce beneficial emergent behaviors - advantages that go beyond simply combining multiple DEEC units. Top-performing teams showed that thoughtful design of system architecture, coordinated deformation, and systems adaptabilities could unlock meaningful performance gains both at the DEEC system level and DEEC-Tec metamaterial system level. A critical realization was that many DEEC-Tec metamaterials could benefit from being designed to accept lower-frequency energy inputs and shift those into higher-frequencies per each DEEC making up the respective DEEC-Tec metamaterial. Other important takeaways included the need for rigorous and quantitative performance testing, effective integration of power conditioning electronics, and the pivotal role of material science in enabling innovative, adaptive DEEC-Tec-based energy conversion designs. InDEEP also helped establish a growing DEEC-Tec community of practitioners, attracting participants from beyond traditional marine energy sectors. Through a strong support infrastructure, InDEEP fostered early-stage innovation and laid a foundation for future DEEC-Tec-based ocean wave energy conversion solutions - positioning DEEC-Tec as a promising pathway toward scalable, resilient ocean wave energy conversion. Through focused R&D of individual DEECs and their integration into DEEC-Tec metamaterials, alongside a growing, multidisciplinary community catalyzed by InDEEP, there is a strong opportunity to drive a disruptive shift in ocean wave energy conversion design and development. This convergence of novel architectures, emergent behaviors, and collaborative innovation positions DEEC-Tec as a transformative approach, moving the field from rigid, centralized energy conversion-based designs to resilient, modular systems highly adaptable for real-world ocean wave energy conversion applications.

16 TIDAL AND WAVE POWER↗
DOE OSTI2019

Impact of Catalyst Ink Dispersing Methodology on Fuel Cell Performance Using in-Situ X-ray Scattering

This work presents a study of the effects of ultrasonic dispersing methodology and time on catalyst agglomerate size in polymer electrolyte membrane fuel cell catalyst ink dispersions. Cathode catalyst inks were prepared and characterized to elucidate the influences of ultrasonic dispersing method and time on catalyst ink particle size and CCL electrochemical properties. In situ ultra-small-, small-, and wide-angle X-ray scattering analyses were used to study the impact of ultrasonication time and methodology on changes in the agglomerate, aggregate, and particle size and distribution during the dispersing process. Ex-situ transmission electron microscopy was also used to investigate the particle size of these inks. Fuel cell membrane electrode assemblies (MEAs) were prepared and tested to determine the influence of ink properties on CCL electrochemical properties, including the electrochemical active surface area, mass activity, H2/air polarization curves, and oxygen mass-transport resistances. It was found that a combination of brief tip sonication followed by bath sonication was most effective at breaking up agglomerates, leading to maximum catalyst activity and MEA performance. Extended tip sonication was found to be too aggressive and resulted in detachment of the platinum nanoparticles from the carbon black support, which decreased electrochemical surface area and MEA performance. Quantification of oxygen mass transport resistance showed that electrodes with large catalyst agglomerates due to insufficient sonication had a higher non-Fickian (pressure independent) than properly dispersed catalyst. Through correlation of the performance with catalyst particle size, the desired CCL structure was proposed, which will provide insight into dispersion strategies for lab-scale spray coating and other processing techniques, as well as for large-scale manufacturing.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Nitric oxide molecular tagging velocimetry of a free-flight model in a reflected shock tunnel

Nitric oxide molecular tagging velocimetry (NO MTV) is used to characterize the wake behind a free-flight spherical model in the test section of a free-piston reflected shock tunnel using a burst-mode laser operated at 100 kHz. A novel (to our knowledge) multi-delay timing scheme was implemented to measure velocity in a varying collisional environment in the wake of the free-flight model. Four simultaneous velocity profiles were measured in the wake of the model from -600 to 3600 m/s for flow enthalpies of 10.3 and 12.0 MJ/kg. Finally, the measured velocity distributions show good agreement when compared to computational fluid dynamics (CFD) modeling.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

A Comprehensive Machine Learning Model for Metal–Ligand Binding Prediction: Applications in Chemistry and Biology

A machine-learning (ML) model that predicts metal–ligand binding constants was developed using the open-source Chemprop software. The model was trained on over 30,000 experimental log K 1 values, which include both protonation and metal–ligand stability constants, comprising over 3500 ligands and 10 2 metal ions from 73 total elements, thus generalizing beyond existing limited approaches, which focus only on specific metals or ligand families. The best-performing model included a combination of SMILES-based molecular representations along with descriptors for the metal ion and experimental conditions. It had an external test R 2 value of 0.942, and MAE value of 0.834. A “SMILES-only” simpler version also produced accurate predictions and preserved the binding trends, serving as a quick and easily accessible alternative for users without computational expertise. The SMILES-only model performed comparably to density functional theory (DFT) calculations but utilized a fraction of the computational resources. The model was successfully applied across diverse domains, including bioinorganic chemistry, heavy metal remediation, and sensor development and demonstrated its effectiveness as a rapid and reliable screening tool for both academic and industrial uses.

Ligands↗
DOE OSTI2025

pdas-experiments

SAND2025-04589O pdas-experiments automates computational experiments of fluid flow simulations. It uses the pressio-demoapps-schwarz package as a basis to break down complex simulations into smaller, manageable parts. This application is an extension of the Sandia Pressio software which uses domain decomposition to work with complex simulations more efficiently. Users can test different simulation setups, while keeping a detailed record of their experiments so they can be reproduced later. The software includes a C++ program that runs individual experiments based on user-defined settings in a YAML file, as well as a Python script that can manage multiple simulations at once. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Tezaur, Irina [Sandia National Lab. (SNL-CA), Live↗
DOE OSTI2026

Deliberate Motion Analytics Applied to CUAS Sensor Fusion

The Advanced Reactor Safeguards and Security (ARSS) program in the Department of Energy’s Office of Nuclear Energy (DOE-NE) seeks to identify new technology solutions for safeguards and security challenges associated with domestic deployment of advanced nuclear reactors. Research in the ARSS program is investigating alternative physical protection system (PPS) approaches that leverage new detection technologies. This report shows test results from a new form of artificial intelligence (AI) that is called deliberate motion analytics (DMA) when used to spatially and temporally fuse active radar and passive radio frequency (RF) detection that significantly improves detection of uncrewed aircraft systems (UASs). DMA is designed to filter out false positive alarms yet provide highly reliable intrusion detection at nuclear power plants (NPPs) and advanced small modular reactor (ASMR) perimeters. This form of AI is considered to be an enabling technology for security of the future and supports the ARSS investigation of alternative PPSs.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2026

Department of Transportation PHMSA Aerosol Spray Project: Phase-0

This report discusses the work conducted at Sandia National Laboratories during the preliminary phase (Phase-0) of the Department of Transportation (DOT) Pipeline and Hazardous Materials Safety Administration (PHMSA) project tasked to better understand what happens to a high-pressure liquid canister or vessel during a fire in which an accidental instantaneous release occurs. Phase 0 had two main objects: (1) to establish a methodology for the high temperature and pressure spray vessel release and (2) to characterize the spray droplet formation. For this test series, diagnostic equipment such as the Malvern Spraytec, high-speed photometric cameras, pencil gauges, and thermocouples were used. Additionally, the effect of surface tension on the particle size distribution was evaluated with 1-liter of distilled water and with the same including the addition of 0.5% soap/water mixture. Results from this effort indicated that the plume formed from the instantaneous release in all conditions primarily included two distinct particle size distributions including 217-312µm and 0.53µm on average. Soapy water formed a higher concentration of smaller mist (0.53µm) than distilled water, potentially due to decreased surface tension with the added surfactant. Though results showed good correlation to certain particle size distributions it is encouraged to conduct additional tests like this with a wider range of liquids with different properties, which could affect the overall particle size distribution when released.

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

Improved creep performance of CoCrFeNi high entropy alloys by Mo addition

The CoCrFeNi family of high entropy alloys has good mechanical and corrosion properties, performing like stainless steels with low yield stresses. They could, however, benefit from hardening methods for structural and high temperature applications. Here, this work investigates the potential for the CoCrFeNi alloy to be hardened with the addition of Mo. A series of CoCrFeNiMo alloys and their CoCrFeNi counterparts were subsequently manufactured at NETL and then mechanically creep tested at 650°C. The alloys were designed to possess a range of stacking fault energies which influence the mechanical properties of the alloys via the motion of their dislocations under stress. Results show that Mo-containing variants have creep rupture lives ranging from 4000 to 8000 hours, i.e., about two orders of magnitude longer than those for Mo-free variants. The significantly improved creep performance of the Mo-containing alloys is due to a combination of solid solution strengthening and precipitation strengthening from µ-phase and carbides.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Single channel PICOSEC Micromegas detector with improved time resolution

This paper presents design guidelines and the experimental verification of a single-channel PICOSEC Micromegas (MM) detector with an improved time resolution. The design encompasses the detector board, vessel, auxiliary mechanical parts, and electrical connectivity for high voltage (HV) and signals, focusing on improving the stability, reducing noise, and ensuring signal integrity to optimize timing performance. A notable feature is the simple and fast reassembly procedure, facilitating quick replacement of the detector internal components that allows for an efficient measurement strategy involving different detector components. The paper also examines the influence of parasitic capacitance and inductance on the output signal integrity. To validate the design, a prototype assembly and three interchangeable detector boards with varying readout pad diameters were manufactured. Detectors were initially tested in the laboratory. Finally, the timing performance of the detectors with different pad sizes was verified using 150 GeV muons. Notably, a record time resolution for a PICOSEC Micromegas detector technology with a CsI photocathode of 12.5 ± 0.8 ps was achieved for a detector with 10 mm diameter readout pad size.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

Pulsed-focusing recirculating linacs for muon acceleration

Since the muon has a short lifetime, fast acceleration is essential for high-energy applications such as muon colliders, Higgs factories, or neutrino factories. The best one can do is to make a linear accelerator with the highest possible accelerating gradient to make the accelerating time as short as possible. However, the cost of such a single linear accelerator is prohibitively large due to expensive power sources, cavities, tunnels, and related infrastructure. As was demonstrated in the Thomas Jefferson Accelerator Facility (Jefferson Lab) Continuous Electron Beam Accelerator Facility (CEBAF), an elegant solution to reduce cost is to use magnetic return arcs to recirculate the beam through the accelerating RF cavities many times, where they gain energy on each pass. In such a Recirculating Linear Accelerator (RLA), the magnetic focusing strength diminishes as the beam energy increases in a conventional linac that has constant strength quadrupoles. After some number of passes the focusing strength is insufficient to keep the beam from going unstable and being lost. In this project, the use of fast pulsed quadrupoles in the linac sections was considered for stronger focusing as a function of time to allow more successive passes of a muon beam in a recirculating linear accelerator. In one simulation, it was shown that the number of passes could be increased from 8 to 12 using pulsed magnet designs that have been developed and tested. This could reduce the cost of linac sections of a muon RLA by 8/12, where more improvement is still possible. The expense of a greater number of passes and corresponding number of return arcs was also addressed in this project by exploring the use of ramped or FFAG-style magnets in the return arcs. A better solution, invented in this project, is to use combined-function dipole-quadrupole magnets to simultaneously transport two beams of different energies through one magnet string to reduce costs of return arcs by almost a factor of two. A patent application was filed for this invention and a detailed report published in Physical Review Special Topics. A scaled model using an electron beam was developed and proposed to test the concept of a dog bone RLA with combined-function return arcs. The efforts supported by this grant were reported in a series of contributions to particle accelerator conferences that are reproduced in the appendices and summarized in the body of this report.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Advanced truck and bus radial materials for fuel efficiencies (Final Report)

PPG Industries, Inc. and Bridgestone Americas Tire Operations (BATO) propose to develop a novel surface-modified silica technology and demonstrate 4-6% improved fuel efficiency of Truck and Bus Radial (TBR) tires built from the technology. The proposed fuel efficiency increase will be achieved while maintaining or improving tear strength and tread wear. During rubber mixing, distributing silica in the rubber matrix is a challenge. This is because silica has a very polar surface, while rubbers have little polarity. It was hypothesized that surface treatments could cover part of the surface by hydrophobic groups, and reduce the surface polarity, thus helping to wet the silica with rubber during mixing and improving silica dispersion. During the project, the effect of different silica surface treatments on the surface energy of silica were determined, and related to the silica dispersion in rubber compounds. The results demonstrated that reducing the surface energy of silica samples improved dispersion in rubber compounds. Also, the preference for silica to migrate to the different phases in polymer blends was determined. The studies performed in binary polymer blends showed that carbon black has a preference to distribute in the different polymer phases in the order: SBR>BR~NR. Commercially available silica samples (treated and untreated) showed a preference in the order of SBR>NR>BR. Finally, the silica prototypes showed a preference in the order SBR=NR>BR. The knowledge gained regarding dispersion of treated silicas in rubber compounds was used to perform a series of studies to develop a silica – rubber compound combination with optimum performance for TBR treads. Initially, two silica prototypes (BXR-990 and BXR-991) were developed and used for a tire build at BATO’s tire plant in Warren County, TN. Results were evaluated and further silica and compound optimization was performed, prior to a final tire build. Manufacturing of the final silica prototype (BXR-1006) for the final tire build was performed at the PPG Silicas Pilot Plant in Monroeville, PA. Afterwards, experimental tires with silica-filled treads and control tires with carbon black-filled treads were built at BATO’s Warren County tire plant. The experimental TBR tires with silica-filled treads achieved the project goals for lab performance indicators, tread hardness and tear strength. The tires showed a 2.2% improvement in fuel efficiency compared to the control tires. While this improvement is lower than the 4% goal set initially, the improvement is significant and there are indicators that up to a 5% improvement in fuel efficiency could be achieved. This is supported by the confirmation of the validity of the fuel efficiency indicators made at the beginning of the project, and by the improvement in hysteresis and rolling resistance from tires built earlier in the project. The experimental tires produced using the BXR-990 silica prototype showed 47% improvement in tan δ at 60°C and 16% improvement in rolling resistance. Based on the results obtained, it is valid to estimate that the tires built with BXR-990 could provide around a 5% improvement in fuel efficiency, should we perform a fuel efficiency test. Tire wear for the experimental tires was 31% worse than for the control tires with the carbon black-filled tread compound. Other tools and further analysis of factors affecting wear are necessary to be evaluated to produce a silica tire with wear comparable to carbon black. Experimental and control tires were provided to the DOE for independent testing.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

SoLID Program at JLab

An overview of the Solenoidal Large Intensity Device (SoLID) and its scientific program will be given in this talk. SoLID is a spectrometer/detector system proposed to exploit the full potential of the Jefferson Lab (JLab) 12 GeV energy upgrade. SoLID will push the limit of luminosity frontier in hadronic physics with its unique capability to handle very high rates with large acceptance under high luminosity (1037-39/cm2/s). A rich and vibrant scientific program has been developed for SoLID, including but not limited to the precision study of the 3d nucleon structure in both momentum space using Semi-Inclusive Deep Inelastic Scattering (SIDIS) and coordinate space using Deep Virtual Exclusive Reactions (DVER), probing physics beyond the Standard Model with Parity Violating Deep Inelastic Scattering (PVDIS), and investigating the gluonic field contribution to the proton structure and proton mass via J/¿ threshold production. The SoLID collaboration has developed a robust, low risk and flexible conceptual design, with a base line design capable of accomplishing its scientific goals and flexibility to adopt the cutting-edge technology. Detector subsystems have been tested with prototypes in realistic high luminosity conditions and are demonstrated to function well under extremely challenging environment to satisfy the requirements of planned experiments.

Chen, Jian-Ping [Thomas Jefferson National Acceler↗
DOE OSTI2020

Microfluidic Fabrication Techniques for High-Pressure Testing of Microscale Supercritical CO 2 Foam Transport in Fractured Unconventional Reservoirs

Pressure limitations of many microfluidic platforms have been a significant challenge in microfluidic experimental studies of fractured media. As a result, these platforms have not been fully exploited for direct observation of high-pressure transport in fractures. This work introduces microfluidic platforms that enable direct observation of multiphase flow in devices featuring surrogate permeable media and fractured systems. Such platforms provide a pathway to address important and timely questions such as those related to CO 2 capture, utilization and storage. This work provides a detailed description of the fabrication techniques and an experimental setup that may serve to analyze the behavior of supercritical CO 2 (scCO 2 ) foam, its structure and stability. Such studies provide important insights regarding enhanced oil recovery processes and the role of hydraulic fractures in resource recovery from unconventional reservoirs. This work presents a comparative study of microfluidic devices developed using two different techniques: photolithography/wet-etching/ thermal-bonding versus Selective Laser-induced Etching. Both techniques result in devices that are chemically and physically resistant and tolerant of high pressure and temperature conditions that correspond to subsurface systems of interest. Both techniques provide pathways to high-precision etched microchannels and capable lab-on-chip devices. Photolithography/wet-etching, however, enables fabrication of complex channel networks with complex geometries, which would be a challenging task for laser etching techniques. This work summarizes a step-by-step photolithography, wet-etching and glass thermal-bonding protocol and, presents representative observations of foam transport with relevance to oil recovery from unconventional tight and shale formations. In conclusion, this work describes the use of a high resolution monochromatic sensor to observe scCO 2 foam behavior where the entirety of the permeable medium is observed simultaneously while preserving the resolution needed to resolve features as small as 10 μm.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Industry Level Feasibility of LiDAR Data into Fire Modeling Using Fire Risk Investigation in 3D (FRI3D)

Many evaluation, assessment, and modeling tasks at nuclear power plants require spatial information this often requires physical visits to locations within the facility because the 2D or 3D schematics and current models do not contain enough detail or do not capture as-built and real-world conditions. These visits require extensive manual labor for not only the requesting party, but support groups such as security. LIDAR mapping is trying to solve that problem by providing very detailed 3D models for low costs. However, the use of these models can be very limited because either component reference information is missing and too costly to add, or there is no way to extract specific spatial data needed for other tools. This report presents Idaho National Lab's work with Environmental Intellect (Ei) covering two main efforts. First, to reduce the effort of "tagging" data in large 3D models. By using both existing plant database information, and artificial intelligence (AI) to find and read equipment labels. This research explores the ability of to provide a simple way for the user to tag items and verify plant data, capturing both the speed of AI and human verification. The second part of the work is the development of an interface for importing pieces needed for Modeling & Simulation. Analysis work such as that for fire, flood, or physical security all require spatial or 3D models in various levels of detail. This interface will allow for the retrieval of item location or boundaries, enabling the auto generation of models for varying tools. The application program interface (API) of the fire risk investigation in 3D (FRI3D) was used to test feasibility of exporting the LiDAR tagged spatial information. Outcomes from this work provide preliminary data to determine if the tools and methods could provide substantial industry benefit if fully matured.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Microbead Encapsulation for Protection of Electronic Components

Here, this study investigates the application of microbeads as an innovative encapsulation technique to protect electronic components from harsh mechanical strain. Traditional encapsulation methods using hard epoxy provide substantial mechanical support but create thermal expansion mismatch issues, potentially leading to electronic component failure. We explore the use of finely powdered microbeads to achieve protective structures combining stiffness and energy absorption. The research focuses on key variables, including microbead size, microbead roughness, compaction of microbeads, and circuit board mounting in the encapsulation, all of which influence the encapsulation’s effectiveness. Experimental setups and testing protocols were developed to assess the performance of various microbead materials under different impact conditions. Results demonstrate that microbead encapsulation significantly reduces strain on circuit boards, minimizing the risk of damage during mechanical shocks. However, challenges remain, such as optimizing microbead characteristics and modeling their behavior within large-scale circuit board assemblies. Despite these challenges, the findings suggest that microbead encapsulation offers a promising alternative to conventional methods, enhancing the durability and reliability of electronic components in high-stress environments.

42 ENGINEERING↗
DOE OSTI2019

Real-Time Monitoring of Selenium Species in Power Plant Wastewaters via Optical Spectroscopy

Energy Research Company (ERCo) and Lehigh University are developing a new rapid sensor for measuring trace amounts of selenium in coal-fired power plant wastewater streams down to the single parts-per-billion (ppb) level. With EPA regulations pending on releases of selenium in wastewaters from power plants, plant operators are finding that commercially available technology is not suitable for ensuring compliance with the new regulations. These regulations require monitoring selenium at the single ppb level. There are several important advantages of our instrument as compared to other potential methods such as ICP-MS or ICP-OES. First, the method is rapid, allowing for analyses within minutes. Second, the method is amenable to automation, so dedicated lab personnel are not required. Third, the apparatus is compact and comprised of off-the-shelf components that are inexpensive compared to other laboratory instruments. Fourth, our instrument is designed to be used in the field and will collect data from any water source in near real time. Fifth, maintenance is minimal and finally, the cost is quite low. Furthermore, selective concentration of different ionization states of selenium was also demonstrated. Selenium is present in wastewaters in two main ionization states, +4 and +6. The fraction of each ionization state is important to know because it affects selenium treatment technologies. We were able to measure each one with a single instrument. The Phase II work plan will automate our instrument and expand the measurements to other heavy metals such as mercury and arsenic, the two other heavy metals covered in the new EPA regulations. We will also field test the instrument at an operating coal fired power plant.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Optimizing Bendability and Hardness of Age-Hardenable Aluminum Sheets through Local Thermo-Mechanical Processing

This paper introduces a novel thermo-mechanical process to modify the local mechanical properties of 6xxx aluminum (Al-Mg-Si-Cu) alloy sheets. In this process, two pairs of rollers travel along the length of a sheet while locally bending and unbending it so that the final shape and thickness of the sheet remains unchanged. Room temperature bending/unbending (B/U) produces a deformation gradient through thickness and local hardening in both T4 and T6 sheets (with 41% and 18% greater Vickers hardness, respectively). High temperature bending/unbending performed at ~ 500°C via induction heating, produces significant improvements in local formability as measured by bend testing. Formability levels equivalent to the as-received T4 temper are achieved within the processed zones of T6 sheets with bend angles of ~ 150°, without disturbing the T6 temper in the remainder of the sheet. Finite element simulations and characterization explained the mechanical property improvements and the heterogenous microstructure with weakened Cube texture. Due to its similarity with the roller hemming process, and its compact dimensions, the apparatus developed for B/U has the potential for seamless integration with roller hemming robots to selectively process high strength aluminum sheet materials within mass-production settings.

Efe, Mert [BATTELLE (PACIFIC NW LAB)]↗