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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 1,531 records · Page 85
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Functional approach to exploring climatic and landscape controls on runoff generation: 2 Timing of runoff storm response

Abstract Hortonian overland flow, Dunne overland flow, and subsurface stormflow are the three most dominant mechanisms contributing to both the volume and timing of streamflow in headwater catchments. In this paper, guided by the Dunne diagram, we explore the impacts of climate, soil, and topography on estimated probability distributions of the travel times of each of these three runoff components. In each case, these are expressed in terms of the Connected Instantaneous Response Functions (CIRF) and account for the dynamics of their individual partial effective contributing areas that retain the connectivity to the outlet (instead of the whole catchment area). A spatially distributed hydrological model is used to derive the CIRFs numerically under multiple combinations of climate, soil, and topographic properties. The mean travel times and dimensionless forms of the CIRFs (i.e., scaled by their respective mean travel times) are used to examine both advective and dispersive aspects of catchment's runoff routing response. It is found that the CIRFs, upon nondimensionalization, collapsed to common characteristic shapes, which could be explained in terms of the relative contributions of hillslope and channel network flows, and the size of runoff contributing areas. The contributing areas, particularly for the Dunne overland flow, are themselves found to be governed by the competition between drainage of and recharge to the water table, and could be explained by a dimensionless drainage index which quantifies this competition. The study also reveals simple indicators based on landscape properties that can explain the magnitude of travel times in different catchments.

Li, Hong‐Yi↗
DOE OSTI2022

Alternate Synthesis Method for High-Performance Manganese Rich Cation Disordered Rocksalt Cathodes

Cation-disordered rocksalt (DRX) cathodes have recently emerged as a promising class of cobalt-free, high-capacity cathodes for lithium-ion batteries. To facilitate their commercialization, the development of scalable synthesis techniques providing control over composition and morphology is critical. To this end, a sol-gel synthesis route to prepare Mn-rich DRX cathodes with high capacities is presented here. Several compositions with varied Mn content and nominal F doping are successfully prepared using this technique. In-situ X-ray diffraction measurements demonstrate that DRX formation proceeds at moderate temperature (800 °C) through the sol-gel route, which enables intimate mixing among reactive intermediate phases that form at lower temperatures. All synthesized compositions possess cation short-range order, as evidenced by neutron pair distribution function and electron diffraction analysis. These DRX materials demonstrate promising electrochemical performance with reversible capacities up to 275 mAh g. Compared to the baseline oxide (Li 1.2 Mn 0.4 Ti 0.4 O 2 ), the Mn-rich compositions exhibit improved cycling stability, with some showing an increase in capacity upon cycling. Finally, this study demonstrates the feasibility of preparing high-capacity DRX cathodes through a sol-gel based synthesis route, which may be further optimized to provide better control over the product morphology compared to traditional synthesis methods.

25 ENERGY STORAGE↗
DOE OSTI2025

Battery‐Grade Lithium Materials: Virgin Production and Recycling, a Techno‐Economic Comparison

Lithium has been identified as an essential mineral to the economic and national security of the United States. It is vital for rechargeable batteries that surround us daily from the personal electronics to large-scale energy storage. With a comprehensive techno-economic analysis, the cost of battery-grade lithium compounds production, i.e., lithium carbonate (LC) is evaluated and lithium hydroxide monohydrate (LHM), from both virgin (spodumene ore and brine) and recycled feedstocks (spent lithium-ion batteries). The goal of this study is to inform about the economics of lithium compounds production with comprehensive insights into differences in manufacturing routes and pave a pathway to explore more innovative, domestic manufacturing processes in future for their cost competitiveness and environmental impact. The study includes details on mining and extraction operations as well as unit level operation in the refining process. Moreover, process level information has been collected for pyrometallurgical and hydrometallurgical battery recycling routes. This analysis shows that brine and direct lithium extraction are the cheapest pathways to produce LC or LHM (between $\$3.39$ and 6.20 kg −1 ). The cost of production in the ore and recycling routes can range between $\$4.17$ and $\$53.41$ kg −1 and is highly depending on capital equipment investment, plant location, and the price of spodumene concentrate SC6.0.

battery recycling↗
DOE OSTI2024

A One‐Pot Biocatalytic Cascade to Access Diverse l ‐Phenylalanine Derivatives from Aldehydes or Carboxylic Acids

Abstract Nonstandard amino acids (nsAAs) that are l ‐phenylalanine derivatives with aryl ring functionalization have long been harnessed in natural product synthesis, therapeutic peptide synthesis, and diverse applications of genetic code expansion. Yet, to date, these chiral molecules have often been the products of poorly enantioselective and environmentally harsh organic synthesis routes. Here, we reveal the broad specificity of multiple natural pyridoxal 5′‐phosphate (PLP)‐dependent enzymes, specifically an l ‐threonine transaldolase, a phenylserine dehydratase, and an aminotransferase, toward substrates that contain aryl side chains with diverse substitutions. We exploit this tolerance to construct a one‐pot biocatalytic cascade that achieves high‐yield synthesis of 18 diverse l ‐phenylalanine derivatives from aldehydes under mild aqueous reaction conditions. We demonstrate the addition of a carboxylic acid reductase module to this cascade to enable the biosynthesis of l ‐phenylalanine derivatives from carboxylic acids that may be less expensive or less reactive than the corresponding aldehydes. Finally, we investigate the scalability of the cascade by developing a lysate‐based route for preparative‐scale synthesis of 4‐formyl‐ l ‐phenylalanine, a nsAA with a bio‐orthogonal handle that is not readily market‐accessible. Overall, this work offers an efficient, versatile, and scalable route with the potential to lower manufacturing costs and democratize synthesis for many valuable nsAAs.

Anderson, Shelby R. [Department of Chemical and Bi↗
DOE OSTI2017

Evaluation of aromatic radiobromination by nucleophilic substitution using diaryliodonium salt precursors

Radiobromine-labeled compounds can be used for positron emission tomography (PET) imaging (ie, 76 Br) and for radiation therapy (ie, 77 Br). However, the commonly used electrophilic substitution reaction using no-carrier-added radiobromide does not always afford the desired product due to the high reactivity of the brominating intermediate. A nucleophilic substitution by bromide, such as radiobromination of iodonium precursors, provides an alternative route for the synthesis of bromo-radiopharmaceuticals. The applicability of aromatic radiobromination by nucleophilic substitution using diaryliodonium salt precursors was evaluated using iodonium model compounds and [ 76 Br]/[ 77 Br]bromide. Radiobromination was observed under all conditions tested, in up to quantitative yields. A QMA cartridge treatment method and a base-free method have been developed, and no extra base is needed for either methods. The base-free conditions are mild and afford much cleaner reactions. Up to 20% water is tolerated in the reactions without reducing the radiochemical yields. No-carrier-added and carrier-added reactions afforded similar results. 4-Bromobenzaldehyde and 4-bromobenzoate have been radiosynthesized reliably and in good yields. Finally, these results indicate that this method is robust and efficient and thus will provide a route for radiobromination of electron-deficient arenes and an alternative route for the synthesis of bromo-radiopharmaceuticals for biological evaluations.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2019

Double-Barreled and Branched Endografting for Thoracoabdominal Aortic Aneurysm: The Hexapus Technique

Objective: To treat thoracoabdominal aortic aneurysm (TAAA), we introduced an alternative “Hexapus” technique by double-barreled and branched endografting. Technique and Result: We established 2 transfemoral and 2 transaxillary access routes first and then deployed two abdominal bifurcated stentgrafts landing at the descending thoracic aorta through transfemoral routes, respectively. Two pairs of parallel stentgrafts were deployed via bilateral transaxillary route from each of contralateral limbs of main body stentgrafts to visceral arteries. Finally, we extended the ipsilateral limbs of main body stentgrafts to bilateral common iliac arteries as distal landings. The creation of six branches (four viscerals and two iliacs) resembles a hexapus. We have executed this Hexapus technique in three patients, and the final angiography during operation and postoperative 12-month image follow-up showed patent visceral branches and no any endoleaks. Conclusion: Our Hexapus technique is feasible in treating TAAA if patient is inoperable or no commercial fenestrated or branched stentgraft is available.

62 RADIOLOGY AND NUCLEAR MEDICINE↗
DOE OSTI2017

Quantum chemical studies of azoles

The results of theoretical search for model transition states of the electrophilic substitution reaction in 2H-tetrazole (1) without the preliminary formation of N-protonated azolium salts are presented for two routes that were previously suggested by the authors and thermodynamically investigated: A, the attack of molecule 1 by the nucleophile (HO{sup –}(aq)) to form the anion to which the electrophile H{sub 3}O{sup +}(aq)) is added and B, the attack of molecule 1 by the same electrophile followed by the addition of the same nucleophile to the specifically solvated protonated species formed in the preceding reaction step. The calculations were performed using the DFT/B3LYP/6-31G(d) method and the scanning procedure of the potential energy surface (PES). Both steps of route A turned out to be nearly barrierless, while in route B only its first step is barrierless and the second one is conjugated with passing an activation barrier of ∼45 kcal mol{sup –1} between non-interacting or weakly interacting reactants and electrophilic substitution products. Unlike the specifically solvated protonated species of 1H-tetrazole in an aqueous solution, a similar species of 2H-tetrazole does not form a prereaction complex with the attacking nucleophile (HO{sup –}(aq)) and the five-membered ring is destroyed in fact in the nitrogen-containing reaction product formed after passing the activation barrier. The optimized structure of the transition state differs strongly from the nitrogen-containing structure of the reaction product with the destroyed ring, which was found by scanning of the PES.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Workability Limits of Magnesium Alloy AZ31B Subjected to Equal Channel Angular Pressing

Equal channel angular pressing (ECAP) is an important severe plastic deformation process to produce ultrafine grained microstructures in metals and alloys. Magnesium and its alloys generally possess poor workability at temperatures below 250 °C. This investigation examines the influence of different passes and processing routes of ECAP on improving the workability of Mg alloy AZ31B. ECAP was carried out for three passes using a die of angle 120° using processing routes Bc and C. The operating temperature was 523 K for the first pass and 423 K for the subsequent two passes. The resultant microstructure and mechanical properties were determined. Workability of the alloy at 423 K (150 °C) was determined using upsetting experiments on cylindrical specimens machined from the annealed and ECAPed samples. Workability limit diagrams have been constructed for the various processed conditions. The workability data generated were also analyzed using five different workability criteria (also referred to as ductile fracture models) and the material constants for these five models were evaluated. Specimens processed by two passes through route C (pass 2C) exhibits better workability compared to other passes since the workability limit line after this pass shows maximum safe working area and lies above the other workability lines. Among the five different workability criteria investigated, the Freudenthal workability criterion is more suitable for prediction of failure in this alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Mechanical Alloying and Powder Forging of 18%Cr Oxide Dispersion-Strengthened Steel Produced Using Elemental Powders

Oxide dispersion-strengthened (ODS) ferritic steels are potential materials for cladding tubes in fast breeder fission reactors. These are mostly prepared by mechanical alloying of yttria powder with pre-alloyed powders. Using elemental powders offers flexibility in the choice of alloy compositions. Here we report mechanical alloying of Fe-18Cr-2W-0.2Ti-0.35Y{sub 2}O{sub 3} (compositions in wt.%) ODS steel using elemental powders of Fe, Cr, W and Ti with yttria powder. After 5 h of milling, no significant changes in particle size and crystallite size were observed. Powders milled for 5 and 7 h were consolidated through powder forging route. The optimum milling time for mechanical alloying could be determined only after evaluating the forgings. It is difficult to achieve recrystallization in ODS alloys. The forging process parameters were optimized to achieve a dense alloy with a fine recrystallized microstructure. Factors leading to recrystallization are discussed. It is shown that recrystallization in ODS steels is more likely to occur during forging as compared to extrusion/rolling. The powder forging route offers several advantages over the conventional extrusion or HIP routes.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Torsion on Precipitation and Hardening Effects during Aging of an Extruded AZ91 Alloy

The effect of torsional deformation by various routes prior to artificial aging treatment on the microstructure of extruded AZ91 rods was investigated. The tension and compression properties along the extruded direction were tested to evaluate the hardening effect. The results showed that torsional deformation can largely enhance the subsequent age-hardening effect. A detailed microstructural characterization revealed that torsional deformation produced a high density of dislocations and {10-12} twins, which can promote continuous precipitation and increase the number density of the Mg{sub 17}Al{sub 12} phase. In addition, part of dislocations and the {10-12} twins were retained after aging treatment. The combination of the increased precipitation hardening by Mg{sub 17}Al{sub 12}, dislocation strengthening and refinement strengthening contributed to the high hardening effect. Moreover, the hardening effect can be further increased by tailoring the torsion route. The torsion route exhibited little influence on the age-hardening effect, while it remarkably affected the texture of the twisted AZ91 rods. Reciprocating torsion had little influence on the texture. In contrast, unidirectional torsion caused the c-axis of the texture to rotate toward the extrusion direction, resulting in a texture softening effect. Therefore, combining reciprocating torsion and aging caused a higher hardening effect than combining unidirectional torsion and aging. The detailed strengthening mechanism was analyzed and is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Creation of hollow silica-fiberglass soft ceramics for thermal insulation

Hollow-structured materials show promise in thermal insulation because the shells encapsulating gaseous voids can interrupt heat transport pathways. Here, in this study, we present two low-cost routes to fabricate hollow silica nanoshells, via gas-phase and liquid-phase methods. The gas-phase synthesis method generates hollow shells by a droplet surface precipitation mechanism in a flame aerosol reactor. The liquid-phase synthesis route forms hollow shells by removal of a carbon template, which is produced by hydrothermal reaction of glucose. Both approaches (gas- and liquid-phase) provide hollow silica with amorphous structure, low thermal conductivity (0.023 and 0.026 W m –1 K –1 ), small particle size (442 and 383 nm), thin shell (35 and 36 nm), and low density (0.015 and 0.033 g cm –3 ). We employed high shear mechanical mixing to fabricate hollow silica-fiberglass composite ceramics. The resulting three-dimensional network provides the ceramics with robust mechanical elasticity and fire-retardancy while maintaining low thermal conductivity, dramatically outperforming an analogous material using commercial silica gel in place of the hollow nanoshells. Our findings provide two practical routes to synthesize hollow silica, either of which can be used to manufacture a class of hollow shell-fiber nanocomposite soft ceramics for energy-saving applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

A multi criteria analog model for assessing the vulnerability of rural catchments to road spills of hazardous substances

Road spills of hazardous substances are common in developing countries due to increasing industrialization and traffic accidents, and represent a serious threat to soils and water in catchments. There is abundant literature on equations describing the wash-off of pollutants from roads during a storm event and there are a number of watershed models incorporating those equations in storm water quality algorithms that route runoff and pollution yields through a drainage system towards the catchment outlet. However, methods describing catchment vulnerability to contamination by road spills based solely on biophysical parameters are scarce. These methods could be particularly attractive to managers because they can operate with a limited amount of easily collectable data, while still being able to provide important insights on the areas more prone to contamination within the studied watershed. The purpose of this paper was then to contribute with a new vulnerability model. To accomplish the goal, a selection of medium properties appearing in wash-off equations and routing algorithms were assembled and processed in a parametric framework based on multi criteria analysis to define the watershed vulnerability. However, parameters had to be adapted because wash-off equations and water quality models have been developed to operate primarily in the urban environment while the vulnerability model is meant to run in rural watersheds. The selected parameters were hillside slope, ground roughness (depending on land use), soil permeability (depending on soil type), distance to water courses and stream density. The vulnerability model is a spatially distributed algorithm that was prepared to run under the IDRISI Selva software, a GIS platform capable of handling spatial and alphanumeric data and execute the necessary terrain model, hydrographic and thematic analyses. For illustrative purposes, the vulnerability model was applied to the legally protected Environmental Protection Area (APA), located in the Uberaba region, state of Minas Gerais, Brazil. In this region, the risk of accidents causing chemical spills is preoccupying because large quantities of dangerous materials are transported in two important distribution highways while the APA is fundamental for the protection of water resources, the riverine ecosystems and remnants of native vegetation. In some tested scenarios, model results show 60% of vulnerable areas within the studied area. The most sensitive parameter to vulnerability is soil type. To prevent soils from contamination, specific measures were proposed involving minimization of land use conflicts that would presumably raise the soil's organic matter and in the sequel restore the soil's structural functions. Additionally, the present study proposed the preservation and reinforcement of riparian forests as one measure to protect the quality of surface water. - Highlights: • A multi criteria analog model was developed to assess rural catchment vulnerability along roads. • Model parameters were defined by analogy with urban wash-off equations and routing algorithms. • The model mixes up various biophysical and socio-economic parameters. • Model application was based on a scenario analysis. • The study is focused on the Environmental Protection Area of Uberaba River, Brazil.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Plasma catalytic non-oxidative methane conversion to hydrogen and value-added hydrocarbons on zeolite 13X

Non-thermal plasma has unfolded highly efficient, safe to operate novel routes for methane conversion to hydrogen. In this work, methane conversion is performed under atmospheric dielectric barrier discharge (DBD) plasma with and without 13X zeolite-based catalysts i.e., 13X, Ga/13X, Pd/13X, and Pd-Ga/13X. Experimental results indicate that the plasma catalytic process delivered almost twofold higher product yield than the plasma only route. The binary Pd-Ga catalyst possesses highest catalytic performance with about 40 % CH 4 conversion at an input flowrate of 5 cm 3 min -1 and 2W due to the formation of the Pd-Ga alloy, which acts as catalytic active centre for activating C–H bonds. Product yield can be tailored by the catalyst design where the bimetallic Pd-Ga/13X preferably favours the hydrocarbon formation while H 2 is the dominant product obtained over the Pd/13X. The cleavage of C–H bonds of methane molecule over the plasma only route is mainly governed by energetic electrons in the gaseous phase the catalyst activity, and plasma-catalyst synergism play a significant role in the plasma catalysis process. Further, the findings from this work provide significant insights into the methane activation for subsequent optimization of the methane conversion processes operated on floating production, storage, and offloading vessels (FPSOVs). Exploiting untapped offshore natural gas reserves, where conventional pipeline systems are less economical.

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

Carbon dioxide pipeline network transportation cost model: evaluating economic and geographic factors for efficient carbon capture, storage, and utilization

This study presents a comprehensive pipeline network modeling framework to estimate the CO 2 delivery cost for CO 2 utilization and geologic CO 2 storage across the United States. We developed a Python-based CO 2 pipeline transportation cost model leveraging Argonne National Laboratory’s pipeline engineering expertise and detailed natural gas transmission pipeline cost data across U.S. regions. Using existing road corridors as practical routing guides, the model designs pipeline networks that aggregate CO 2 from one or multiple sources and deliver it to selected destinations. It then minimizes the total transportation cost by optimizing pipeline diameters and incorporating booster pumps. A key contribution is the incorporation of up-to-date, region-specific cost factors with itemized components for materials, labor, miscellaneous construction expenses, and right-of-way acquisition. Results emphasize that regional variation and economies of scale associated with CO 2 pipeline costs are significant and should be explicitly accounted for in screening and planning studies. By combining realistic routing constraints with regionalized cost inputs, the model provides transparent design methodology and location-specific insights into source–destination delivery costs, including the effects of routing complexity along existing road networks. We demonstrate the model with two illustrative case studies – one for CO 2 storage and one for CO 2 utilization – in which the model designs pipeline networks spanning hundreds of miles across the states, collecting CO 2 from multiple sources and delivering it to designated endpoints while minimizing levelized cost of delivery via diameter and compression optimization. The model offers a practical, scalable approach for alternative design option screening and early-stage CO 2 transportation planning.

CCS↗
DOE OSTI2012

A first principles analysis of the hydrogenation of C1C4 aldehydes and ketones over Ru(0001)

The structure and degree of substitution of C₁–C₄ oxygenate molecules can influence their chemisorption and reactivity on metal surfaces. Gradient-corrected periodic density functional theory calculations were carried out to analyze alkyl substituent effects on the hydrogenation of C₁–C₄ aldehydes and ketones to their corresponding alcohols. All of these aldehydes along with acetone were found to adsorb in a di-ση1η2(C,O) mode onto the Ru(0001) surface and result in rehybridization of the C=O bond. Steric hindrance from two alkyl substituents on the carbonyl backbone of methyl ethyl ketone (MEK), however, prevents it from binding di-ση1η2(C,O). It adsorbs instead atop a Ru atom in an g1(O) configuration through its oxygen atom. Hydrogenation of both aldehydes and ketones can occur through either a hydroxy or an alkoxy mechanism. The hydroxy route proceeds via the formation of the hydroxyalkyl intermediate R₁R₂C*OH by the addition of hydrogen to the oxygen of the carbonyl, whereas the alkoxy mechanism proceeds by the addition of hydrogen to the carbon end to form the alkoxy intermediate R₂CHO*). DFT calculations indicate that the activation barrier for the initial addition of hydrogen to the carbon to form the C–H bond in the alkoxy mechanism is independent of the substituent groups that are attached to the carbon center as these groups are oriented away from the surface in the transition state and thus have little influence on the activation energies. The activation barriers for the addition of hydrogen to the oxygen of the carbonyl to form the O–H bond in the hydroxy mechanism, however, was found to linearly correlate with the binding energy of the hydroxyalkyl intermediate that forms. This trend can be explained through the Brønsted–Evans–Polanyi relationship and the fact that both the hydroxyalkyl products and carbonyl reactants interact via their carbon centers and are correlated with one another. All of the carbonyls follow a similar trend in that the addition of hydrogen to the carbon of the carbonyl has a much lower barrier on Ru(0001) than the addition of hydrogen to the oxygen. The carbonyls thus readily react to form their alkoxy intermediates. Simple kinetic analyses and firstprinciple- based kinetic Monte Carlo simulations for formaldehyde over Ru(0001) show that the alkoxy is the most abundant surface intermediate and that the alkoxy route is more favorable than the hydroxy route.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2014

Mechanisms of catalytic cleavage of benzyl phenyl ether in aqueous and apolar phases

Catalytic pathways for the cleavage of ether bonds in benzyl phenyl ether (BPE) in liquid phase using Ni- and zeolite-based catalysts are explored. In the absence of catalysts, the C-O bond is selectively cleaved in water by hydrolysis, forming phenol and benzyl alcohol as intermediates, followed by alkylation. The hydronium ions catalyzing the reactions are provided by the dissociation of water at 523 K. Upon addition of HZSM-5, rates of hydrolysis and alkylation are markedly increased in relation to proton concentrations. In the presence of Ni/SiO 2 , the selective hydrogenolysis dominates for cleaving the C aliphatic -O bond. Catalyzed by the dual-functional Ni/HZSM-5, hydrogenolysis occurs as the major route rather than hydrolysis (minor route). In apolar undecane, the non-catalytic thermal pyrolysis route dominates. Hydrogenolysis of BPE appears to be the major reaction pathway in undecane in the presence of Ni/SiO 2 or Ni/HZSM-5, almost completely suppressing radical reactions. Density functional theory (DFT) calculations strongly support the proposed C-O bond cleavage mechanisms on BPE in aqueous and apolar phases. These calculations show that BPE is initially protonated and subsequently hydrolyzed in the aqueous phase. Finally, DFT calculations suggest that the radical reactions in non-polar solvents lead to primary benzyl and phenoxy radicals in undecane, which leads to heavier condensation products as long as metals are absent for providing dissociated hydrogen.

Alkylation↗
DOE OSTI2026

Process-level cost analysis of hybrid manufacturing pathways for aerospace structural components

Hybrid manufacturing is a promising route for producing complex aerospace components, yet systematic cost benchmarking across multiple additive-subtractive pathways remains limited. This study presents a comprehensive process-based cost analysis of seven hybrid manufacturing routes, including laser powder bed fusion (L-PBF), powder- and wire-directed energy deposition (DED), wire arc additive manufacturing (WAAM), additive friction stir deposition (AFSD), metal binder jetting (MBJ), and agility forging, followed by scanning and finish machining. Parametric cost models incorporating direct material, labor, and energy costs were developed. L-PBF results are discussed in detail for a pickle fork component and directly compared with commercial pricing. Across all hybrid routes, labor emerged as the dominant cost driver, contributing more than 70% of total manufacturing cost in some cases. AFSD exhibited the lowest cost for aluminum components, with MBJ being its 316 L stainless steel counterpart, after accounting for geometric scaling. Benchmarking against industrial quotes suggests that hybrid manufacturing can achieve cost levels comparable to those of commercial services, although labor-intensive processes exhibit greater deviation. The analysis highlights automation of material handling, setup, and supervision as key opportunities for improving economic competitiveness. Overall, the proposed framework provides a quantitative basis for evaluating and optimizing hybrid manufacturing pathways for aerospace applications.

Baruah, Sweta [ORNL] (ORCID:0009000174256207)↗
DOE OSTI2025

A snapshot of high-entropy alloy processing techniques and their effects on resulting mechanical properties

High-entropy alloys (HEAs) exhibit exceptional strength, corrosion resistance, and thermal stability, making them promising candidates for nuclear, aerospace, and other extreme applications. While most prior work has focused on compositional design, manufacturing techniques themselves can alter microstructure and mechanical properties as dramatically as alloy chemistry. This review compiles and compares the effects of processing routes—including arc melting, induction melting, mechanical alloying with spark plasma sintering, and additive manufacturing—on the structure and properties of HEAs. Quantitative comparisons highlight, for example, that SPS-processed alloys can achieve ∼20–45 % higher yield and tensile strength than arc-melted counterparts, while Bridgman solidification produces nearly single-crystal structures with elongation to failure exceeding 80 %. Additive manufacturing routes such as selective laser melting offer fine microstructures but also introduce anisotropy and porosity, leading to yield strengths spanning 100–600 MPa for the same composition. By synthesizing such results, this review provides actionable insight into how processing routes interact with HEA core effects (high entropy, lattice distortion, sluggish diffusion, and cocktail effect) to determine performance, thereby offering a practical guide for optimizing manufacturing strategies.

36 MATERIALS SCIENCE↗