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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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DOE OSTI2021

Technical note: AQMEII4 Activity 1: evaluation of wet and dry deposition schemes as an integral part of regional-scale air quality models

We present in this technical note the research protocol for phase 4 of the Air Quality Model Evaluation International Initiative (AQMEII4). This research initiative is divided into two activities, collectively having three goals: (i) to define the current state of the science with respect to representations of wet and especially dry deposition in regional models, (ii) to quantify the extent to which different dry deposition parameterizations influence retrospective air pollutant concentration and flux predictions, and (iii) to identify, through the use of a common set of detailed diagnostics, sensitivity simulations, model evaluation, and reduction of input uncertainty, the specific causes for the current range of these predictions. Activity 1 is dedicated to the diagnostic evaluation of wet and dry deposition processes in regional air quality models (described in this paper), and Activity 2 to the evaluation of dry deposition point models against ozone flux measurements at multiple towers with multiyear observations (to be described in future submissions as part of the special issue on AQMEII4). The scope of this paper is to present the scientific protocols for Activity 1, as well as to summarize the technical information associated with the different dry deposition approaches used by the participating research groups of AQMEII4. In addition to describing all common aspects and data used for this multi-model evaluation activity, most importantly, we present the strategy devised to allow a common process-level comparison of dry deposition obtained from models using sometimes very different dry deposition schemes. The strategy is based on adding detailed diagnostics to the algorithms used in the dry deposition modules of existing regional air quality models, in particular archiving diagnostics specific to land use–land cover (LULC) and creating standardized LULC categories to facilitate cross-comparison of LULC-specific dry deposition parameters and processes, as well as archiving effective conductance and effective flux as means for comparing the relative influence of different pathways towards the net or total dry deposition. This new approach, along with an analysis of precipitation and wet deposition fields, will provide an unprecedented process-oriented comparison of deposition in regional air quality models. Examples of how specific dry deposition schemes used in participating models have been reduced to the common set of comparable diagnostics defined for AQMEII4 are also presented.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Coupling a Lagrangian–Eulerian Spark-Ignition (LESI) model with LES combustion models for engine simulations

In the United States transportation sector, Light-Duty Vehicles (LDVs) are the largest energy consumers and CO 2 emitters. Electrification of LDVs is posed as a potential solution, but SI engines can still contribute to decarbonization. Car manufacturers have turned to unconventional engine operation to increase the efficiency of Spark-Ignition (SI) engines and reduce the carbon emissions of their fleets. Dilute, lean, and stratified-charge engine operation has the potential for engine efficiency improvements at the expense of increased cyclic variability and combustion instability. At such demanding engine conditions, the spark ignition event is key for flame initiation and propagation and for enhanced combustion stability. Reliable and accurate spark ignition models can help design ignition systems that reduce cyclic variability. Multiple computational spark-ignition models exist that perform well under conventional conditions, but the underlying physics needs to be expanded, for unconventional engine operation. In this paper, a hybrid Lagrangian–Eulerian Spark-Ignition (LESI) model is coupled with different turbulent flame propagation models for engine simulations. LESI relies on Lagrangian arc tracking and Eulerian energy deposition. The LESI model is coupled with the Well-Stirred Reactor (WSR), Thickened Flame Model (TFM), and g-equation model and used to simulate several cycles of a Direct-Injection Spark-Ignition (DISI) engine using a commercial Computational Fluid Dynamics (CFD) engine solver. The results showcase the successful coupling of LESI with the combustion models. Global engine metrics, such as pressure and Apparent Heat Release Rate (AHRR), for each simulation setup are compared to experimental engine results, for validation. In addition, results highlight the successful prediction of spark channel movement by comparing simulation images to experimental optical engine images. Finally, the successful coupling of LESI to combustion models, making it a usable model in the engine modeling community, is emphasized and future development details are discussed.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Long-term leaf C:N ratio change under elevated CO 2 and nitrogen deposition in China: Evidence from observations and process-based modeling

Climate change, elevating atmosphere CO 2 (eCO 2 ) and increased nitrogen deposition (iNDEP) are altering the biogeochemical interactions between plants, microbes and soils, which further modify plant leaf carbon-nitrogen (C:N) stoichiometry and their carbon assimilation capability. Many field experiments have observed large sensitivity of leaf C:N ratio to eCO 2 and iNDEP. However, the large-scale pattern of this sensitivity is still unclear, because eCO 2 and iNDEP drive leaf C:N ratio toward opposite directions, which are further compounded by the complex processes of nitrogen acquisition and plant-and-microbial nitrogen competition. Here, we attempt to map the leaf C:N ratio spatial variation in the past 5 decades in China with a combination of data-driven model and process-based modeling. These two approaches showed consistent results. Over different regions, we found that leaf C:N ratio had significant but uneven changes between 2 time periods (1960-1989 and 1990-2015): a 5% ± 8% increase for temperate grasslands in northern China, a 3% ± 6% increase for boreal grasslands in western China, and by contrast, a 7% ± 6% decrease for temperate forests in southern China, and a 3% ± 5% decrease for boreal forests in northeastern China. Additionally, the structural equation models indicated that the leaf C:N change was sensitive to ΔNDEP, ΔCO 2 and ΔMAT rather than ΔMAP and ecosystem types. In this work, process-based modeling suggested that iNDEP was the main source of soil mineral nitrogen change, dominating leaf C:N ratio change in most areas in China, while eCO 2 led to leaf C:N ratio increase in low iNDEP area. This study also indicates that the long-term leaf C:N ratio acclimation was dominated by climate constraint, especially temperature, but was constrained by soil N availability over decade scale.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Modeling Interactive Effects of Manganese Bioavailability, Nitrogen Deposition, and Warming on Soil Carbon Storage

Manganese (Mn) is a redox–active micronutrient that has been shown to accelerate plant litter decomposition; however, the effect of Mn–promoted decomposition on soil C storage is unclear. We present a novel biogeochemical model simulating how Mn bioavailability influences soil organic C (SOC) stocks in a soil profile (<50 cm) within a temperate forest. In our model, foliar Mn increased in response to increasing soluble Mn released through Mn–oxide (birnessite) dissolution in mineral soil layers. The ensuing Mn enrichment in leaf litter redistributed Mn to the surface forest floor layer, promoted enzymatic oxidation of lignin, and decreased SOC stocks. Total SOC loss was partially mitigated by accumulation of lignin–oxidation products as mineral–associated organic C. We also explored how Mn–driven changes to C storage interacted with effects of N deposition and warming. Nitrogen enrichment inhibited Mn–dependent lignin degradation, increasing SOC stocks and weakening their dependence on Mn bioavailability. Warming stimulated decomposition and reduced C stocks but was less effective at low Mn bioavailability. Our model results suggest that SOC stocks are sensitive to Mn bioavailability because increased plant uptake redistributes Mn to surface soils where it can enhance litter decomposition. Finally, based on our simulations, we predict that Mn becomes limiting to litter decomposition where Mn is poorly soluble. Depletion of bioavailable Mn or other cofactors that are critical to decomposition could limit the response of organic C stocks to warming over time, but quantitative projections of the role of Mn bioavailability in regulating decomposition requires additional measurements to constrain model uncertainties.

58 GEOSCIENCES↗
DOE OSTI2025

Multi-physics melt pool modeling and process optimization for laser direct energy deposition of Nb-based refractory C103: Defect formation, geometric precision, and process mapping

Recent developments in additive manufacturing (AM) technology have reignited interest in the fabrication of the Nb-based refractory C103 alloy offering solutions to the challenges posed by traditional manufacturing methods. However, the limited numerical and experimental studies on laser direct energy deposition (DED) of C103 have hindered the understanding of the relationships between process parameters and build quality. This has made it challenging to consistently produce parts with the desired quality and microstructure suitable for critical applications. In this study, we focus on optimizing the laser DED process for C103 by employing a hybrid approach that combines experimental techniques and computational fluid dynamics (CFD). This approach facilitates the development of process maps for defect detection and geometric precision. To achieve this, multi-layer C103 samples were fabricated using laser DED under various process parameters, enabling the creation of a process map for defect detection. Additionally, a multi-physics, multiphase simulation framework was developed within a high-performance computing (HPC) environment to establish process maps for geometric precision. Using these process maps, printability windows were identified for achieving both the desired geometric accuracy and defect-free prints. It was observed that prints with a power-to-velocity (P/V) ratio close to unity resulted in defect-free outcomes. This study provides a foundation for reducing design lead time and rejected parts, ultimately optimizing the laser DED process for C103.

Defect formation and geometric precision↗
DOE OSTI2020

Understanding Microstructure Variability in Vapor-Deposited Energetic Materials by Using Phase-Field Methods

Critical components, such as detonators, in Sandia's stockpile contain heterogeneous materials whose performance and reliability depend on accurate, predictive models of coupled, complex phenomena to predict their synthesis, processing, and operation. Ongoing research in energetic materials has shown that microstructural properties, such as density, pore-size, morphology, and specific surface area are correlated to their initiation threshold and detonation behavior. However, experiments to study these specific characteristics of energetic materials are challenging and time consuming. Therefore, in this work, we turn to mesoscale modeling methods that may be capable of reproducing some observed phenomena to refine and predict outcomes beforehand. Even so, we have no physics-based modeling capability to predict how the microstructure of an energetic material will evolve over near- and long-term time scales. Thus, the goal of this work is to (i) identify any knowledge gaps in how the underlying microstructure forms and evolves during the synthesis process, and (ii) develop and test a mesoscale phase-field model for vapor deposition to capture critical mechanisms of microstructure formation, evolution, and variability in vapor-deposited energetic materials, such as processing conditions, material properties, and substrate interactions. Based on this work, the phase-field method is shown to be a valuable tool for developing the necessary models containing coupled, complex phenomena to investigate and understand the synthesis and processing of energetic materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Observational constraints on wet and dry deposition of black carbon to land surfaces (Final Report)

This project focused on providing observational constraints on dry deposition of black carbon and aerosol particles, and the extent to which wet and dry deposition impacts the lifetime of aerosols in the atmosphere. The proposed work tackled the following questions: To what extent dry versus wet deposition controls the removal of BC from the atmosphere, and thus atmospheric BC concentrations? Is BC dry deposition controlled by the same processes as non-refractory aerosol dry deposition? We successfully made eddy covariance flux measurements at the DOE Southern Great Plains site of size-resolved aerosol number fluxes with an ultra high sensitivity aerosol spectrometer (UHSAS) and of black carbon mass and number fluxes using a single particle soot photometer (SP2). We also collected precipitation samples for off-line measurement of rBC using a wet deposition collector. Using these measurements, we identified that wet deposition was the dominant control for black carbon lifetime, but that dry deposition was poorly constrained in models. We developed a new parameterization for particle dry deposition, and applied it to global models to demonstrate the importance of dry deposition in air pollution and radiative effect estimates.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

A semi-analytical model of RF condensation that can handle localized power depositions

A nonlinear effect, RF (radio frequency) condensation, can be used to facilitate RF stabilization of magnetic islands. Previously studied semi-analytical models for RF condensation are suited mainly for broad deposition profiles and are unable to handle power depositions that are localized in the interior of a magnetic island. The power deposition profile of electron cyclotron waves, in particular, can be highly localized near a cyclotron resonance. Here, a model is developed that can handle both localized profiles and broad profiles. This allows a comparison of RF condensation for narrow vs broad deposition profiles, and it allows a study of the dependence of RF condensation of localized deposition profiles on key parameters.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

A quality-agnostic combinatoric cost estimation model for large-format directed energy deposition metal additive manufacturing

Directed energy deposition (DED) additive manufacturing (AM) processes are amenable to synergistic combination into multi-process AM systems due to similar requirements for automation and energy sources. This work analyzes the economic performance of such DED AM systems from a quality-agnostic combinatoric standpoint with a model that calculates lowest-cost system combinations based on part geometry and process performance metrics. Common DED AM systems research focuses on a single process and does not consider the process, system, and application in the context of all possible system combinations (e.g., the combined set of process selection(s), motion system(s), and process hardware), leading to limited applicability of the resulting DED AM systems to cost-sensitive components such as those found in energy generation applications. The model developed herein incorporates the capital, material, and energy costs associated with DED AM system combinations into a predictive tool for estimating part and system cost, the output of which is intended to guide deployment of finite research and development resources towards DED AM system combinations with the lowest costs and greatest likelihood of economic impact. The DED AM systems identified by this framework may enable domestic production of the large conventionally cast and forged components necessary for energy generation.

Shanafield, Alexandra [ORNL]↗
DOE OSTI2023

Additive manufacturing as a processing route for steel-aluminum bimetallic structures

Here we present results on the fabrication of steel-aluminum bi-metallic structures using directed energy deposition additive manufacturing. The challenges associated with the fabrication of a sharp transition from steel to aluminum are uncovered using ex-situ characterization techniques and thermo-mechanical modeling of the deposition process. It was found that the fabrication of a sharp steel-aluminum transition is challenging with extensive cracking observed at the interface. The cracking was attributed to the combined effect of residual stress development due to thermal expansion coefficient mismatch and the presence of ordered intermetallics with low ductility at the interface. Using a coupled thermodynamic and thermo-mechanical modeling approach, potential pathways to enable the fabrication of steel-aluminum bi-metallic structures using additive manufacturing are proposed. The results presented here can lay the foundation for future work on the fabrication of bi-metallic steel-aluminum structures using directed energy deposition.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Progress Report on Model Development for the Transport of Aerosol through Microchannels

This report summarizes the current progress in the development of a phenomenological model of aerosol transport, deposition, and plugging through microchannels. The purpose is to introduce a generic, reliable numerical model for the prediction of aerosol transport, deposition, and plugging in leak paths while accounting for potential plugging formation, to a user community involving researchers, regulators, and industry. In that regard, a Graphical User Interface (GUI) was generated by integrating the individual MATLAB scripts that make up the model and adding additional features to aid the general understanding of the problem to a user. This report focuses on the model development and features included. Further, predictions from the GUI are compared with experimental data for validation. The strength of the GUI is the ability of a user to plug in basic parameters such as the initial pressure conditions and canister model specifications in order to obtain a first principal approximation of vital information such as the blowdown pressure differential, aerosol penetration, and deposition as a function of time. The user can obtain this without the know-how of the underlying MATLAB scripts and thus enables the model to be readily applied by regulators, industry, and shareholders to reduce the uncertainty in the off-site radiological consequences. The report also lists future tasks under this work scope. This includes ongoing efforts to include additional crack geometries (divergent and divergent-convergent slots) to the model; GUI development and improvement based on feedback from users, and integration of aerosol source term data from Sibling Pin tests into the model as we approach realistic canister stress corrosion cracking–induced aerosol release scenarios.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Benchmarking large language models for materials synthesis: The case of atomic layer deposition

In this work, we introduce an open-ended question benchmark, ALDbench, to evaluate the performance of large language models (LLMs) in materials synthesis, and, in particular, in the field of atomic layer deposition, a thin film growth technique used in energy applications and microelectronics. Our benchmark comprises questions with a level of difficulty ranging from the graduate level to domain expert current with the state of the art in the field. Human experts reviewed the questions along the criteria of difficulty and specificity, and the model responses along four different criteria: overall quality, specificity, relevance, and accuracy. We ran this benchmark on an instance of OpenAI’s GPT-4o. The responses from the model received a composite quality score of 3.7 on a 1–5 scale, consistent with a passing grade. However, 36% of the questions received at least one below average score. An in-depth analysis of the responses identified at least five instances of suspected hallucination. Finally, we observed statistically significant correlations between the difficulty of the question and the quality of the response, the difficulty of the question and the relevance of the response, the specificity of the question, and the accuracy of the response as graded by the human experts. Furthermore, this emphasizes the need to evaluate LLMs across multiple criteria beyond difficulty or accuracy.

Artificial intelligence↗
DOE OSTI2022

Analysis of Conduction Cooling Strategies for Wire Arc Additive Manufacturing

Metal additive manufacturing (AM) processing consists of numerous parameters which take time to optimize for various geometries. One aspect of the metal AM process that continues to be explored is the control of thermal energy accumulation during component manufacturing due to the melting and solidification of the feedstock. Excessive energy accumulation causes thermal failure of the component while minimal energy accumulation causes lack of fusion with the build plate or previous layer. The ability to simulate the thermal response of an AM component can increase research efficiency by reducing the time to optimize thermal energy accumulation. This paper presents an effective implementation of finite element analysis to determine the thermal response of a wire arc additive manufactured component with various build plate sizes and cooling methods including, integral build plate cooling, oversized build plates with passive cooling, and non-integral build plate cooling. The use of integral build plate cooling channels was shown to decrease the interpass temperature at the conclusion of the build process by 55% and build plate temperature by 96% compared to the conventionally deposited sample with 20 second dwell time. The use of a tall build plate with passive cooling was shown to reduce the interpass temperature by 32% as compared to the conventionally deposited sample with 20 second dwell time. Each cooling strategy evaluated decreased the interpass temperature within a range of 20–55% which enables higher deposition rates and decreased dwell times during depositions. The cooling strategies are designed to be implemented in a hybrid or retrofit AM platform to mitigate concerns of the thermal input from the additive process having detrimental effects on the precision of the machining process. This paper shows that accurate simulations of all strategies can be used to accurately predict the thermal response of the various strategies discussed. These cooling strategies will allow for increased deposition rates with comparable interpass temperature and decreased dwell time, increasing deposition efficiency. This model and these simulations are verified by experimental results. It is concluded that passive strategies, such as the over-sized tall build plate, can be used when liquid coolant in the AM environment could negatively affect the deposition process. Active cooling strategies, such as the integral build plate cooling could be used if low thermal conductivity materials are deposited or higher material deposition rates are desired. This paper discusses the use of active and passive cooling used during AM and shows how a simulation model can be used to make design choices for cooling strategies. The model also enables verification of select critical process parameters such as dwell times for a desired interpass temperature.

Heinrich, Lauren↗
DOE OSTI2026

Deposition Height Prediction in Directed Energy Deposition

Using 316L stainless steel as a model material, reduced-order models are developed to predict capture efficiency, deposition height, and site-specific hardness in directed energy deposition. Capture efficiency is predicted over a 15 to 55 pct range using a dimensionless number derived from processing conditions and thermophysical properties. Deposition height is predicted over a 0.3 to 1.3 mm range without in situ sensing or prior training data, using two models based on the same mass and energy-balance principles. Predictions are compared with machine learning approaches. A quantitative relationship links deposition height, primary dendrite arm spacing (PDAS), and hardness: heights of 0.3 to 1.1 mm correspond to PDAS values of 2.7 to 5.1 µm and Vickers hardness (HV) of 160 to 219. Thinner layers cool more rapidly, producing finer microstructures and higher hardness. Samples fabricated with in situ variations in deposition height exhibited up to 55 HV differences between thick and thin regions, demonstrating that local control of deposition height enables predictive, site-specific hardness within a single build. These results establish deposition height prediction as a pathway for a priori process design and property control in directed energy deposition for 316L stainless steel.

Kunkel, William [Univ. of Wisconsin, Madison, WI (↗
DOE OSTI2025

A Curated Dataset of Regional Meteor Events with Simultaneous Optical and Infrasound Observations (2006–2011)

We present a curated, openly accessible dataset of 71 regional meteor events simultaneously recorded by optical and infrasound instrumentation between 2006 and 2011. These events were captured during an observational campaign using the all-sky cameras of the Southern Ontario Meteor Network and the co-located Elginfield Infrasound Array. Each entry provides optical trajectory measurements, infrasound waveforms, and atmospheric specification profiles. The integration of optical and acoustic data enables robust linkage between observed acoustic signals and specific points along meteor trajectories, offering new opportunities to examine shock wave generation, propagation, and energy deposition processes. This release fills a critical observational gap by providing the first validated, openly accessible archive of simultaneous optical–infrasound meteor observations that supports trajectory reconstruction, acoustic propagation modeling, and energy deposition analyses. By making these data openly available in a structured format, this work establishes a durable reference resource that advances reproducibility, fosters cross-disciplinary research, and underpins future developments in meteor physics, atmospheric acoustics, and planetary defense.

astrometry↗
DOE OSTI2026

Computationally inexpensive part-scale thermal history of additive friction-stir deposition

This study presents an analytical model for steady-state power generation and tool heat loss in additive friction-stir deposition (AFSD), developed to enable part-scale thermal simulation while remaining computationally inexpensive. The model predicts total generated power, yielding 3.7–4.7 kW across deposition temperature setpoints of 400–460 °C for the deposition of AA6061 with a Be-Cu tool. This corresponds to 90–95% of the reported spindle power. Tool heat loss is experimentally determined by calibrating a steady-state energy balance between the generated power, the substrate-deposition thermal gradient, and a temperature dependent tool heat loss term: q tool (T) = a + b (T - 400°C) with a = 2.7 x 10 6 Wm -2 and b = 9.5 x 10 3 Wm -2 K -1 . The calibration indicates that about 69% of the generated heat is conducted into the tool for this configuration, which is much higher than previously reported. The calibrated heat-source is implemented in finite element software (Adamantine) to simulate the transient thermal history of a 100 cm 3 representative build in 8 min on a standard desktop (at 0.635 mm build-height resolution). For the first three layers, the substrate temperatures between simulation and experiment are within 10% mean absolute percentage error. Sensitivity analysis indicates that uncertainties in average deposition temperature and deformation localization (stir-zone geometry, depth, and spatial dependance of strain-rate and flow stress) dominate model variance, motivating additional experimental verification.

Additive Friction-Stir Deposition↗