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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Using Hardware-In-The-Loop Methodology to Develop Test Systems

Hardware in the Loop (HIL) testing methodologies have become widespread in industry. Typically, they focus on developing control algorithms for systems such as autonomous vehicles or aircraft. An oft overlooked aspect of product development is the design and fabrication of a test system for validating that the product meets requirements. Abstractly, a test system differs little from a control system—testers provide signals to the unit, monitor feedback, and base decisions on the results. While the time scales may differ, the functionalities are conceptually similar. Viewed in this light, it becomes natural to extend HIL approaches to tester development. By replacing a physical unit with a proxy model deployed to a real-time or pseudo real-time target, test systems can be developed in parallel with the design and fabrication of a first production unit. This saves considerable time in the life cycle from conceptual design to realized product. This manuscript demonstrates the process flow using a capacitive discharge unit as an exemplar.

42 ENGINEERING↗
DOE OSTI2025

CHELAX-BNF: Fast Response Temperature by airborne measurements

The original data were collected on board the ARM Aerial Facility ArcticShark uncrewed aerial system (UAS; https://www.arm.gov/capabilities/observatories/aaf/uas ) during the “Characterizing HEterogeneous Land-Atmosphere eXchanges at BNF” field campaign (CHEAX-BNF; https://arm.gov/research/campaigns/aaf2025CHELAX-BNF ). The ARM Aerial Facility ArcticShark UAS was based at the public-use airport of Posey Field, AL (FAA LID: 1M4, 34.28027778° N, 87.60055556° W, 283m MSL) from May 28 to June 23, 2025. The ArcticShark UAS performed 5 flights, including 4 research flights over the BNF Main Site (ARM Mobile Facility 3, https://arm.gov/capabilities/observatories/amf ) and Supplemental Facilities to measure atmospheric state, turbulence, surface IR temperature and imagery, aerosol number concentration, and aerosol size distribution. The current data set presents fast response temperature in the atmospheric boundary layer and lower free troposphere measured on the airborne platform throughout the field campaign. The primary instruments used to create the current data set were the fine wire thermocouple probe, the Aircraft Integrated Meteorological Measurement System (AIMMS-30), the Pitot-static system (part of UAS flight control), and the infrared gas analyzer sensor for H2O and CO2 (LI-840). All parameters used in temperature calculations (static pressure, True Air Speed, and absolute humidity in the form of dew point temperature) were included in the data set. For user convenience, one additional parameter was also included: the type of flight flag (level, up, down, turn, and combination of thereof).

Air temperature, fast response↗
DOE OSTI2025

Fast Response Temperature by airborne measurements over BNF

The original data were collected during the AAF Engineering Flights (AEF2025) in the vicinity of the ARM Bankhead National Forest (BNF) Atmospheric Observatory (https://www.arm.gov/capabilities/observatories/bnf ) in northwestern Alabama in March 2025. The ARM Aerial Facility ArcticShark uncrewed aerial system (UAS, https://www.arm.gov/capabilities/observatories/aaf/uas) was based at the public-use airport of Posey Field, Alabama (FAA LID: 1M4, 34.28027778° N, 87.60055556° W, 283m MSL) from March 9 through March 24, 2025. The ArcticShark UAS performed nine flights, including eight research flights over the AMF3 (BNF Main Site) and Supplemental Facilities to measure atmospheric state, turbulence, surface IR temperature and imagery, and aerosol number concentration and size distribution. The current data set presents fast response temperature in the atmospheric boundary layer and lower free troposphere measured on the airborne platform throughout the field campaign. The primary instruments used to create the current data set were the fine wire thermocouple probe, the Aircraft Integrated Meteorological Measurement System (AIMMS-30), the Pitot-static system (part of UAS flight control), and the infrared gas analyzer sensor for H2O and CO2 (LI-840). All parameters used in temperature calculations (static pressure, True Air Speed, and absolute humidity in form of dew point temperature) were included in the data set. For user convenience, one additional parameter was also included: the type of flight flag (level, up, down, turn, and combination of thereof).

Air temperature, fast response↗
DOE OSTI2024

Large spatiotemporal variability in aerosol properties over central Argentina during the CACTI field campaign

Abstract. Few field campaigns with extensive aerosol measurements have been conducted over continental areas in the Southern Hemisphere. To address this data gap and better understand the interactions of convective clouds and the surrounding environment, extensive in situ and remote sensing measurements were collected during the Cloud, Aerosol, and Complex Terrain Interactions (CACTI) field campaign conducted between October 2018 and April 2019 over the Sierras de Córdoba range of central Argentina. This study describes measurements of aerosol number, size, composition, mixing state, and cloud condensation nuclei (CCN) collected on the ground and from a research aircraft during 7 weeks of the campaign. Large spatial and multiday variations in aerosol number, size, composition, and CCN were observed due to transport from upwind sources controlled by mesoscale to synoptic-scale meteorological conditions. Large vertical wind shears, back trajectories, single-particle measurements, and chemical transport model predictions indicate that different types of emissions and source regions, including biogenic emissions and biomass burning from the Amazon and anthropogenic emissions from Chile and eastern Argentina, contribute to aerosols observed during CACTI. Repeated aircraft measurements near the boundary layer top reveal strong spatial and temporal variations in CCN and demonstrate that understanding the complex co-variability of aerosol properties and clouds is critical to quantify the impact of aerosol–cloud interactions. In addition to quantifying aerosol properties in this data-sparse region, these measurements will be valuable to evaluate predictions over the midlatitudes of South America and improve parameterized aerosol processes in local, regional, and global models.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Abrasive Waterjet Machining

The abrasive waterjet machining process was introduced in the 1980s as a new cutting tool; the process has the ability to cut almost any material. Currently, the AWJ process is used in many world-class factories, producing parts for use in daily life. A description of this process and its influencing parameters are first presented in this paper, along with process models for the AWJ tool itself and also for the jet–material interaction. The AWJ material removal process occurs through the high-velocity impact of abrasive particles, whose tips micromachine the material at the microscopic scale, with no thermal or mechanical adverse effects. The macro-characteristics of the cut surface, such as its taper, trailback, and waviness, are discussed, along with methods of improving the geometrical accuracy of the cut parts using these attributes. For example, dynamic angular compensation is used to correct for the taper and undercut in shape cutting. The surface finish is controlled by the cutting speed, hydraulic, and abrasive parameters using software and process models built into the controllers of CNC machines. In addition to shape cutting, edge trimming is presented, with a focus on the carbon fiber composites used in aircraft and automotive structures, where special AWJ tools and manipulators are used. Examples of the precision cutting of microelectronic and solar cell parts are discussed to describe the special techniques that are used, such as machine vision and vacuum-assist, which have been found to be essential to the integrity and accuracy of cut parts. The use of the AWJ machining process was extended to other applications, such as drilling, boring, milling, turning, and surface modification, which are presented in this paper as actual industrial applications. To demonstrate the versatility of the AWJ machining process, the data in this paper were selected to cover a wide range of materials, such as metal, glass, composites, and ceramics, and also a wide range of thicknesses, from 1 mm to 600 mm. The trends of Industry 4.0 and 5.0, AI, and IoT are also presented.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Forecasting for ESCAPE: A Multi-Institution Hybrid Forecasting and Nowcasting Operation for Sea-Breeze Convection Supporting a Ground-Based and Airborne Field Campaign

The Experiment of Sea-Breeze Convection, Aerosols, Precipitation and Environment (ESCAPE) field project deployed two aircraft and ground-based assets in the vicinity of Houston, Texas, between 27 May and 2 July 2022, examining how meteorological conditions, dynamics, and aerosols control the initiation, early growth stage, and evolution of coastal convective clouds. To ensure that airborne- and ground-based assets were deployed appropriately, a forecasting and nowcasting team was formed. Daily forecasts guided real-time decision-making by assessing synoptic weather conditions, environmental aerosol, and a variety of atmospheric modeling data to assign a probability for meeting specific ESCAPE campaign objectives. During the research flights, a small team of forecasters provided “nowcasting” support by analyzing radar, satellite, and new model data in real time. The nowcasting team proved invaluable to the campaign operation, as sometimes changing environmental conditions affected, for example, the timing of convective initiation. In addition to the success of the forecasting and nowcasting teams, the ESCAPE campaign offered a unique “testbed” opportunity where in-person and virtual support both contributed to campaign objectives. The forecasting and nowcasting teams were each composed of new and experienced forecasters alike, where new forecasters were given invaluable experience that would otherwise be difficult to attain. Both teams received training on forecast models, map analysis, Hybrid Single-Particle Lagrangian Integrated Trajectory model (HYSPLIT), and thermodynamic sounding analysis before the beginning of the campaign. In this article, the ESCAPE forecasting and nowcasting teams reflect on these experiences, providing potentially useful advice for future field campaigns requiring forecasting and nowcasting support in a hybrid virtual/in-person framework.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Cybersecurity Considerations for Hydrogen Infrastructure in Airport Environments

This report explores key cybersecurity concerns and best practices within environments that serve as reference points for the development of hydrogen fueling infrastructure for aviation. This cybersecurity analysis leverages prior NREL studies: 1) hydrogen fueling station component validation to identify vulnerabilities and failure events documented in physical equipment, and 2) electric aircraft charging infrastructure analysis to explore primary cybersecurity vulnerabilities. It reviews the criticality of digitized technologies in sustaining hydrogen fuel production, storage, and fueling systems, noting cybersecurity concerns that are universal to power systems and industrial control systems in general. In considering cybersecurity vulnerabilities within a future landscape of hydrogen energy for aviation applications, a reference architecture was intended to reveal the points of connection between assets and the potential sensors that are vulnerable to manipulation in the event of compromised access or communication within a SCADA system. A generalized reference architecture can help stakeholders, engineers, or strategists understand connections, criticalities, and standard practices when it comes to designing and planning for new systems. There are several gaps to account for in assessing the future of hydrogen production, storage, and fueling for aviation. Engaging stakeholders, including aircraft manufacturers, electric utilities, site property owners, and local communities, will inform decision-making around site structure, operations, and resources for future hydrogen fueling infrastructure to understand operational needs and cybersecurity awareness. Cybersecurity mitigation strategy must consider physical attack vectors that emerge with the integration of hydrogen systems into existing airport security requirements. The cybersecurity risk assessment contained in this report is an entry point into potential future granular-level analyses to be conducted as part of hazard and risk assessments for safe aviation hydrogen infrastructure, determining how the scale of hydrogen fuel infrastructure for aviation impacts the volume of cyber attack vectors, and what, if any, are the vulnerabilities associated with different types of on-board hydrogen systems. In this nascent development phase, assessing how best to integrate cybersecurity practices into an evolving U.S. aviation landscape provides critical insights into building increased awareness and stakeholder engagement to support a cyber-resilient infrastructure.

08 HYDROGEN↗
DOE OSTI2025

Aircraft in-situ measurements from SOCRATES constrain the anthropogenic perturbations of cloud droplet number

Aerosol-cloud interactions (ACI) in warm clouds alter reflected shortwave radiation by influencing cloud microphysical and macrophysical properties. The variable of state controlling ACI is the cloud droplet number concentration (N d ). Here, we examine the perturbations in N d due to anthropogenic aerosols (ΔN d, PD-PI ) using a perturbed parameter ensemble (PPE) hosted in the sixth Community Atmosphere Model (CAM6). Surrogate models are created for the CAM6 PPE outputs and are used to generate 1 million model variants of CAM6 by sampling 45 sources of parameter uncertainty. The range of uncertain physical parameters related to ACI are constrained with observations of aerosol and cloud properties from SOCRATES. The likely range of uncertain parameters and the associated range of ΔN d, PD-PI are more strongly constrained with observations of N d relative to observations of cloud condensation nuclei. We conduct sensitivity tests of how constraints on ΔN d, PD-PI are affected by systematic uncertainties in observations and our limitations in our surrogate models created for CAM6 PPE outputs. Based on this, we provide guidance on the impact of reducing systematic uncertainty in airborne microphysical observations and in surrogate models.

Song, Ci [Univ. of Wyoming, Laramie, WY (United St↗
DOE OSTI2025

Chemical imaging of individual stratospheric particles sampled over North America

The increasing size, severity, and frequency of wildfires have led to dramatic increases in particulate matter concentrations in the troposphere. Severe wildfires can generate intense convective systems capable of transporting large quantities of biomass burning organic aerosols (BBOA) to the upper troposphere and lower stratosphere (UTLS). Chemically complex organic matter and light-absorbing carbonaceous material is introduced into stratospheric regions that were historically isolated from direct surface emissions. In this study, stratospheric particles were sampled over North America during the Dynamics and Chemistry of the Summer Stratosphere (DCOTSS) campaign, an aircraft-based research project designed to characterize convective perturbation in the UTLS. Particle samples collected from six research flights during summer 2022 were analyzed using Computer-Controlled Scanning Electron Microscopy and Scanning Transmission X-ray Microscopy to investigate particle size distributions, morphology, chemical composition, and mixing state of stratospheric particles along transects across the continental United States and adjacent Pacific Ocean airspace. Analysis revealed that all sampled particles contained detectable levels of carbon, with most exhibiting organic volume fractions of 0.37 ± 0.20. Notably, about 5% of the particles also contained soot inclusions, which indicates the presence of refractory black carbon transported to stratospheric altitudes and provides direct evidence of wildfire-derived black carbon reaching the UTLS. Typical particle morphology exhibits organic shells over soot and inorganic cores and suggests secondary processing and aging of BBOA during transport to and within the UTLS. These findings provide compelling evidence that wildfire emissions play a critical role in affecting the long-term composition and radiative properties of stratospheric particles.

Sharpe, Steven [Purdue Univ., West Lafayette, IN (↗
DOE OSTI2026

Updated Commercial Aviation Non-Airport Crash Density Values Using Data Obtained from the U.S. National Transportation Safety Board for 2000 through 2019

This report documents the calculation of the commercial aviation (CA) non-airport crash density for Air Route Traffic Control Center (ARTCC) area associated with the Contiguous United States (CONUS) using the methodology outlined in the Department of Energy (DOE) Standard 3014-2006, Accident Analysis for Aircraft Crash Into Hazardous Facilities. For analytical purposes, the CA aircraft fleet is comprised of aircraft engaged in operations under Title 14 of the Code of Federal Regulations (CFR) Part 121 (i.e., Air Carrier) and Part 135 (i.e., Air Taxi).

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Three-Channel Sunphotometer Cloud Mode Value-Added Product Report

A primary source of uncertainty in Earth system model (ESM) predictions is the representation of cloud processes and associated cloud feedback. Several fundamental cloud properties critical to the understanding of aerosol-cloud interactions are poorly constrained by observations, with key deficiencies in our observations of cloud and precipitation droplet sizes and cloud optical depth. Observations of these cloud properties are often challenging to estimate from remote-sensing platforms and costly to obtain from in situ aircraft. Nevertheless, observations of boundary-layer clouds, and improved knowledge of stratocumulus cloud (Sc) processes, are especially important to ESM advancement. This is because these clouds have extensive coverage and exert controls on boundary-layer dynamics and the global radiative energy balance.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

SCILLA Secondary Aerosol Volume Concentration Airborne Data

This data set contains secondary aerosol volume concentration in cubic micrometers per cubic centimeter (um^3/cm^3). The aerosol was generated in an oxidation flow reactor (OFR) and its volume concentration measured with a scanning mobility particle sizer (SMPS). Both components were designed and built at the University of California Riverside. Ambient particles were removed with a Teflon filter upstream of the OFR and then pure ammonium sulfate particles were added to create a stable aerosol surface area on which low-volatility oxidation products condense. High concentrations of hydroxyl radical (OH) formed inside the OFR accelerate the oxidative chemistry that would typically occur over a period of several days in the atmosphere, resulting in the production of secondary aerosol from precursor gases present in the ambient air. Concentrations of added ozone and water vapor were controlled to produce the desired and approximately constant level of photochemical aging. The reactor temperature was controlled, while the pressure was not, and was always slightly lower than that of the sampled outside air. Sampled air was pulled from above the Naval Postgraduate School’s (NPS) Twin Otter aircraft through a rear-facing, ¼” OD PFA Teflon tube. The sample stream was split between the OFR and several gas analyzers (NOx, CO, O3, and H2O). Though not contained in these files, data from an aerosol mass spectrometer intermittently operated downstream of the OFR are also available.

{"secondary aerosol concentration",aerosol_concent↗
DOE OSTI2025

Advancing Development of Emissions Detection (Final Report)

This document is the final report to the U.S. Department of Energy (DOE for contract DE-FE0031873) awarded to Colorado State University (CSU). CSU and partners at Harrisburg University of Science and Technology, University of Texas Arlington, and University of Texas at Austin organized several testing rounds to provide knowledge focused on advancing the detection capabilities of emissions monitoring devices. With this funding opportunity the research group began by establishing the Advancing the Development of Emission Detection (ADED) program, with the goal focused on enhancing the accuracy, reliability, and field applicability of methane detection technologies. This effort aimed to address the critical challenges of identifying and quantifying methane emissions while enabling industry stakeholders to meet regulatory compliance and environmental sustainability goals. The program engaged with industry, government, and technology stakeholders to promote adoption and consensus on testing techniques for methane detection solutions. Methane, a potent greenhouse gas, contributes significantly to global warming, and the oil and natural gas (O&G) sector is a primary source of methane emissions. Regulatory measures such as leak detection and repair (LDAR) programs have been implemented to address emissions. However, traditional LDAR approaches, reliant on handheld and component-level measurements, are resource-intensive. To address these limitations and move with evolving regulations, advanced methane technologies are emerging. These solutions include ground-based sensors, mobile systems (e.g., drones, vehicles, and aircraft), and satellite-based platforms. They offer innovative capabilities for autonomous monitoring, larger spatial coverage, and emission quantification using methods such as tracer gas techniques and inverse modeling with Gaussian plume analysis. The ADED program began with creating protocols for methane controlled release (CR) testing these continuous monitoring (CM) and survey technologies that detect and monitor methane emissions at O&G facilities. The protocols were then implemented throughout testing of CM and survey devices at CSU’s Methane Emissions Technology Evaluation Center (METEC) facility from 2021 through 2024. As apart of the protocol, solutions that tested under the ADED program installed their solutions at METEC, documented their system under test, and provided detection reports to the METEC team for analysis. The METEC team would provide the solutions with analyzed reports of their emissions and ground truth data of the releases conducted during their testing session. Under the ADED program, CMs were also tested at O&G facilities for a six week test run of challenge release (ChR) releases. The findings from the ADED program underscore the critical role of collaborative research and innovation in tackling methane emissions, offering a pathway for the oil and gas sector to achieve significant environmental and economic benefits. Results from METEC testing saw improvement of performance and accuracy across all solutions over the extent of the ADED experiments. The results also showed a variance in CM solution performance between CRs and ChRs. That variance pushed the team to further analyze the differences between CR testing environments and field conditions. With the drive from regulations and that variance in field conditions, the ADED team began designing a new CR testing protocol and additions to the METEC testing facility. The METEC team is furthering the progress made through the ADED program with awarded funding from DE-FE0032276. This funding pushes the development of METEC’s addition with new equipment, allowing for an updated facility layout. METEC still facilitates for traditional facilities, with a legacy pad, while expanding an new design based on how O&G infrastructure has Final Report - Contract Number: DE-FE0031873 been changed over the last decade. Throughout the ADED program the team has also been working with international partners to ensure staying in the trend globally. International partners have been essential in moving the new protocol forward to implement into CR testing at the METEC facility in Spring 2025.

42 ENGINEERING↗
DOE OSTI2024

ARM Aerial Facility (AAF) - Unmanned Aircraft Systems, Cloud Droplet Probe with QC and lat/lon/alt

The Cloud Droplet Probe (CDP) is designed to measure cloud droplet size distribution from 2 µm to 50 µm. The CDP and an appropriate data system can also calculate various other parameters including particle concentrations, effective diameter (ED), Median Volume Diameter (MVD), and Liquid Water Content (LWC). The b1 level adds standard quality control flags, and merges in flight navigation data.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Measurements of TRACER pre-convective conditions and mesoscale circulations using small unmanned aircraft systems (sUAS)

Improved comprehension of the physical processes governing convective cloud formation and lifecycle are of critical importance for understanding and predicting future climate states. The influence of these clouds on the planetary energy budget, including on precipitation, is significant. Things are particularly complex in coastal regimes, where gradients in aerosol particle properties, localized circulations such as sea breezes, and large population centers are found. To date, numerical models struggle to accurately represent these critical clouds and are therefore challenged to provide a realistic view on the planetary energy budget. Through the proposed research, we deployed two uncrewed aircraft systems (UAS) equipped with a variety of instruments alongside sensors deployed by the US Department of Energy Atmospheric Radiation Measurement (ARM) program for the TRACER (Tracking Aerosol Convection Interactions Experiment) field campaign. The two small UAS platforms consisted of a CU RAAVEN fixed-wing airplane and an OU CopterSonde system, with the copter collecting frequent vertical profiles of thermodynamic and kinematic variables such as temperature, pressure, wind and humidity. At the same time, the fixed-wing captured horizontal gradients of these quantities and aerosol size distribution. These systems were deployed south of the Houston metro area, in an area that is impacted by the Gulf of Mexico sea breeze on a daily basis. These observations offer enhanced and complementary perspectives to those provided by the DOE ARM Mobile Facility (AMF) which is was deployed in southeast Houston, and an ancillary site in a more rural location west of the urban Houston area. Quality-controlled versions of the UAS data were collected and posted on the DOE ARM data archive after the conclusion of the campaign where they are accessible by the research community and general public. The UAS perspective offers revolutionary insight into key spatial and temporal effects that have not been evaluated previously.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Chemical Imaging of Atmospheric Biomass Burning Particles from North American Wildfires

The effects of biomass burning aerosols (BBA) on radiative forcing and cloud formation depend on chemical composition and the internal structures of individual particles within smoke plumes. To improve our understanding of the chemical and physical properties of BBA emitted at different times of the day and their evolution during atmospheric aging, we conducted a study as a part of the Fire Influence on Regional to Global Environments and Air Quality field campaign. Particle samples were collected onboard a research aircraft from smoke plumes from a wildfire in eastern Oregon during late afternoon and nighttime flights on August 28, 2019. A time-resolved aerosol collector was used to collect samples on substrates for offline spectromicroscopic imaging to investigate the single-particle characteristics of BBA particles. Approximately 20,400 individual particles from 10 selected samples were analyzed using computer-controlled scanning electron microscopy coupled with energy-dispersive X-ray microanalysis, revealing their elemental composition, morphology, and viscosity. Elemental microanalysis indicated that aged potassium is likely found in the form of K 2 SO 4 , KNO 3 , and possible K-organic salts. Further chemical speciation and carbon bonding mapping within individual particles were conducted using synchrotron-based scanning transmission X-ray microscopy (STXM) coupled with near edge X-ray absorption fine structure (NEXAFS) spectroscopy. Real-time, water-soluble light absorption measurements were acquired using a particle-into-liquid sampler instrument coupled to a liquid waveguide capillary cell and total organic analyzer. In the late afternoon samples, 65% of the total particle number population consisted entirely of organic components, compared to 46% in the nighttime particles. These differences were attributed to discrepancies in composition at the time of emission and to the daytime condensation and accumulation of photochemically formed secondary organic material on existing BBA particles, a process that halts at night. Microscopy images indicated that particle viscosity was lower in the nighttime particles (<10 1 Pa·s), likely due to increased relative humidity and a higher contribution from hygroscopic inorganic components. The chemical heterogeneity of individual particles was quantified using STXM-derived mixing state parameters. The nature of carbon bonding within individual particles was inferred from the extent of carbon sp 2 hybridization derived from NEXAFS spectra. Average percentages of sp 2 hybridization range between 40% and 60%, with no noticeable differences between late afternoon and nighttime flights. These findings were compared with the online optical properties of both late afternoon and nighttime smoke plumes, providing valuable insights into the complex relationship between chemical composition and optical properties of BBA particles at different times of the day.

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

Unlocking the Future of Aircraft Manufacturing: The Environmental Benefits of Laser Patterning for Surface Enhancement of Aircraft-Certified Alloys

Surface protection and functional modification of aircraft-certified aluminum alloys are essential for corrosion resistance, durability, and long-term airworthiness. At the same time, increasingly restrictive environmental regulations motivate the development of alternatives to legacy wet-chemical surface treatments. This study presents an integrated assessment of ultrafast femtosecond laser surface texturing as a surface functionalization approach for Aluminum 6061 alloys within an aerospace manufacturing and sustainability context. Ultrashort-pulse laser processing enables controlled micro- and nano-scale surface topographical modification with limited thermal impact, allowing adjustment of wettability and surface functionality while preserving bulk material integrity. As a dry and contactless process, femtosecond laser treatment eliminates the use of hazardous chemicals, reduces consumable inputs, and generates minimal secondary waste. A streamlined cradle-to-gate life cycle assessment conducted in accordance with ISO 14040/14044 indicates a lower global-warming potential per functional unit compared with conventional surface treatments, including anodization, plasma-assisted coatings, and organic coating systems. Complementary qualitative analyses addressing environmental health and safety, supply-chain risk, and ESG alignment indicate potential advantages related to occupational safety, regulatory compliance, waste management, and end-of-life recyclability. The investigation is performed on planar Aluminum 6061 reference surfaces with a treated area of 25 mm 2 , providing a controlled laboratory-scale basis for analyzing process behavior, functional surface modification, and associated environmental metrics. Within this defined scope, the results support further evaluation of femtosecond laser surface texturing as a surface engineering option for future aerospace manufacturing.

corrosion resistance↗
DOE OSTI2025

Observational ozone datasets over the global oceans and polar regions (version 2024)

Studying tropospheric ozone over the remote areas of the planet, such as the open oceans and the polar regions, is crucial to understand the role of ozone as a global climate forcer and regulator of atmospheric oxidative capacity. A focus on the pristine oceanic and polar regions complements the available land-based datasets and provides insights into key photochemical and depositional loss processes that control the concentrations and spatiotemporal variability in ozone as well as the physicochemical mechanisms driving these patterns. However, an assessment of the role of ozone over the oceanic and polar regions has been hampered by a lack of comprehensive observational datasets. Here, we present the first comprehensive collection of ozone data over the oceans and the polar regions. The overall dataset consists of 77 ship cruises/buoy-based observations and 48 aircraft-based campaigns. The dataset, consisting of more than 630 000 independent ozone measurement data points covering the period from 1977 to 2022 and an altitude range from the surface to 5000 m (with a focus on the lowest 2000 m), allows systematic analyses of the spatiotemporal distribution and long-term trends over the 11 defined ocean/polar regions. The datasets from ships, buoys, and aircraft are complemented by ozonesonde data from 29 launch sites or field campaigns and by 21 non-polar and 17 polar ground-based station datasets. The datasets contain information on how long the observed air masses were isolated from land, as estimated by backward trajectories from the individual observation points. To extract observations representative of oceanic conditions, we recommend using a subset of the data with an isolation time of 72 h or longer, from the analysis with coincident radon observations. These filtered oceanic and polar data showed typically flat diurnal cycles at high latitudes, whereas daytime decreases in ozone (11 %–16 %) were observed at lower latitudes. The ship/buoy- and aircraft-based datasets presented here will supplement the land-based ones in the TOAR-II (Tropospheric Ozone Assessment Report Phase II) database to provide a fully global assessment of tropospheric ozone. The described dataset is available at https://doi.org/10.17596/0004044 (Kanaya et al., 2025).

Kanaya, Yugo [Japan Agency for Marine-Earth Scienc↗