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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Stiff and strong, lightweight bi-material sandwich plate-lattices with enhanced energy absorption

Plate-based lattices are predicted to reach theoretical Hashin–Shtrikman and Suquet upper bounds on stiffness and strength. However, simultaneously attaining high energy absorption in these plate-lattices still remains elusive, which is critical for many structural applications such as shock wave absorber and protective devices. In this article, we present bi-material isotropic cubic + octet sandwich plate-lattices composed of carbon fiber-reinforced polymer (stiff) skins and elastomeric (soft) core. This bi-material configuration enhances their energy absorption capability while retaining stretching-dominated behavior. We investigate their mechanical properties through an analytical model and finite element simulations. Our results show that they achieve enhanced energy absorption approximately 2–2.8 times higher than their homogeneous counterparts while marginally compromising their stiffness and strength. When compared to previously reported materials, these materials achieve superior strength-energy absorption characteristics, making them an excellent candidate for stiff and strong, lightweight energy absorbing applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

An Initial Assessment of the Design Margins of Different ASME Section III, Division 5 Design Rules

This report develops a method for assessing the design margin of the ASME Section III, Division 5 Class A design rules, focusing on a definition of margin as the ratio between the actual, expected component life and the ASME design life. Full inelastic finite element simulations with a complete damage model capturing the available creep, creep-fatigue, fatigue, and tension test failure data produce the expected component lives, which can then be compared to corresponding ASME design calculations. The focus of this particular work is on Alloy 617 and the ASME creep-fatigue design rules, but the approach is general and could be applied to other design limits and to other materials. A margin assessment of a representative Alloy 617 component shows the ASME creep-fatigue design rules applied to this component have a margin of 10 on design life. The report describes several challenges in completing a more comprehensive margin assessment of the ASME rules, in particular challenges in developing probabilistic assessment methods for high temperature structural components. The report details these challenge and discusses the immediate possibilities of the deterministic margin assessment method developed here.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Microstructural Model for Creep-Fatigue Interaction in Grade 91 Steel

This report describes the completion of a crystal plasticity finite element simulation framework for creep-fatigue deformation and damage in Grade 91 steel. In addition to a description of the framework and a set of verification calculations, the report details an initial set of simulations applying the framework to examine low cycle fatigue and creep-fatigue interaction in Grade 91 at 600° C. Grade 91 is a likely material for future advanced microreactors and creep-fatigue will be a limiting structural damage mechanism, particularly for mobile reactors or load following systems. The framework described here could provide a better understanding of creep-fatigue damage mechanisms and directly examine creep, fatigue, and creep-fatigue interaction for Grade 91 at realistic component service conditions. This in turn could lead to improved design methods and component life estimation approaches, leading to more efficient and economical component designs.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Experimental Study of Mechanical Response of Polyurethane Rubber at Varying Strain Rates for W80-4 System

This report describes an experimental study to determine the mechanical behavior of the polyurethane rubber material that was used in the W80-4 MCC Shock/Breach Phase 1 test series. Compression experiments were conducted on cylindrical specimens over a wide range of loading rates to characterize the material over the range of strain rates that were experienced in the shock/breach testing. Additionally, specimen diameter was varied to determine the effect of confinement on the material response and was found to be significant. This data is used to populate a material model to enable accurate analyses and finite element simulations of the shock/breach test series.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Revisiting Multi-Material Composite Structures with Homogenized Composite Properties

Composite structures inherently develop residual stresses during their curing process. Driven predominately by mismatched thermal strains between differing materials or ply orientations, but also affected by curing process phenomena like polymer shrinkage, these residual stresses can lead to failure within composite structures. There are several methods varying in complexity that can be used to model the development of residual stresses, all of which are capable of capturing sufficient detail to understand the residual stress state at the ply level. However, explicitly modeling all plies of a layup in a composite structure can be prohibitively expensive based on the number of plies, structure size, and required element size. The computational cost can be reduced through the homogenization of the composite layup without losing much fidelity of the overall response of the structure. The homogenization process reduces the many plies of a laminate to a single lamina that reduces complexity and increases the mesh size where a single element can span multiple plies. This report focuses on verification and validation efforts for a homogenization process using a suite of finite element simulations rather than an analytic solution derived from classical laminate theory. Initial verification using representative element volumes indicated there was minimal error in the homogenization process; however, this compounded to a small, but acceptable error in strip and split ring experimental composite structures. The error does under predict the residual stress state in the strip and split ring and should be accounted for when simulating composite structures with homogenized properties.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Improved Axisymmetric and High Temperature Material Structural Modeling in MOOSE and NEML

This report describes improvements made to the solid mechanics formulation in the MOOSE open source finite element simulation environment and the open source Nuclear Engineering Material model Library (NEML) for mechanical constitutive models. The focus of these improvements is to improve the usability and performance of simulations involving one or both pieces of software. Specifically, this work completes a new system for solid mechanics simulations in the MOOSE ecosystem providing exact linearizations and optimal (quadratic) convergence, for a variety of coordinate systems and material types, including large deformation simulations. This work then provides users a framework to build highly efficient mechanical simulations of structures or materials or to couple in additional MOOSE physics modules to build complex, scalable multiphysics simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2025

White Paper: Scalable Digital Twin Capabilities for Aging and Surveillance of Engineered Systems

This white paper presents a multi-year initiative to develop practical, secure, and scalable digital twin capabilities for engineered systems in aging and surveillance contexts—an approach pioneered at the National Nuclear Security Administration (NNSA) Lawrence Livermore National Laboratory (LLNL) that maps directly onto the needs and ambitions of the Navy for ship- and fleet-level digital twins. LLNL’s work in building part- and process-level digital twins for advanced manufacturing, with a vision to scale up to entire factory floors and, ultimately, enterprise-wide digital twins, offers an adaptable pathway for the Navy as it seeks to modernize lifecycle management, readiness, and predictive maintenance across ships and fleets. For our application, we integrate physics-based modeling with automated data ingestion, processing, and AI-driven calibration, creating hybrid models that are both interpretable and data responsive. We modernized legacy workflows, established centralized data infrastructure, automated experimental pipelines, and demonstrated end-to-end coupling of accelerated aging data with finite element simulations via optimization and surrogate modeling. The result is a generalizable framework that supports part-level digital twins today and lays the groundwork for future system-level twins suitable for Navy applications.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Dynamic Multipoles in the RCS

The Rapid Cycling Synchrotron (RCS) of the Electron--Ion Collider (EIC) will accelerate polarized electrons up to 18 GeV at a repetition rate of 1 Hz. Dynamic multipoles driven by eddy currents in the vacuum chamber can affect beam dynamics and polarization preservation during the energy ramp. Building on the analytical treatment of S.Y. Lee for a ramped normal-conducting dipole magnet, we use conformal transformations to derive compact expressions for dynamic multipoles in higher-order ramped magnets with circular beam pipes. We further derive analytical frequency-domain transfer functions for both self-response and cross-response multipoles, providing compact dynamical models for their evolution during arbitrary ramp waveforms. The resulting analytical predictions are benchmarked against finite-element simulations, including the effects of practical pole geometry and beam-pipe misalignment. Finally, the expected dynamic multipoles in the RCS magnets are estimated and their implications for beam dynamics and polarization preservation are discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

AL-CRADA-2025-01 Final Report: American-Made Wind Turbine Materials Recycling Prize Accelerate! Phase 2

This report summarizes the Phase 2 achievements of the Wind Turbine Materials Recycling Prize project led by Critical Materials Recycling (CMR) in partnership with Ames National Laboratory. The team demonstrated the technical feasibility and economic viability of recovering and reusing rare-earth Nd-Fe-B magnets from end-of-life (EOL) wind turbine generators. Through mechanical disassembly, demagnetization, and precision processing, magnets were harvested and characterized to assess structural, compositional, and magnetic properties. Results showed that recovered magnets performed on par with commercial-grade counterparts, enabling their integration into actuator and motor prototypes without redesign. System-level modeling and finite-element simulations validated operational performance, while Life Cycle Cost (LCC) analysis revealed up to 20% material cost savings and 2–3% reductions in overall motor system costs. Life Cycle Assessment (LCA) further confirmed substantial environmental benefits, including a ~94% reduction in global warming potential relative to virgin magnet production. The project’s success was enabled by a tightly integrated partnership between industry and national lab experts, illustrating a viable path for domestic magnet-to-magnet recycling. These findings support a scalable, circular solution for rare-earth material recovery, reducing dependence on imported critical minerals and advancing sustainable clean energy technologies.

Lograsso, Thomas [Ames Laboratory (AMES), Ames, IA↗
DOE OSTI2023

A perfused multi-well bioreactor platform to assess tumor organoid response to a chemotherapeutic gradient

There is an urgent need to develop new therapies for colorectal cancer that has metastasized to the liver and, more fundamentally, to develop improved preclinical platforms of colorectal cancer liver metastases (CRCLM) to screen therapies for efficacy. To this end, we developed a multi-well perfusable bioreactor capable of monitoring CRCLM patient-derived organoid response to a chemotherapeutic gradient. CRCLM patient-derived organoids were cultured in the multi-well bioreactor for 7 days and the subsequently established gradient in 5-fluorouracil (5-FU) concentration resulted in a lower IC 50 in the region near the perfusion channel versus the region far from the channel. We compared behaviour of organoids in this platform to two commonly used PDO culture models: organoids in media and organoids in a static (no perfusion) hydrogel. The bioreactor IC 50 values were significantly higher than IC 50 values for organoids cultured in media whereas only the IC 50 for organoids far from the channel were significantly different than organoids cultured in the static hydrogel condition. Using finite element simulations, we showed that the total dose delivered, calculated using area under the curve (AUC) was similar between platforms, however normalized viability was lower for the organoid in media condition than in the static gel and bioreactor. Our results highlight the utility of our multi-well bioreactor for studying organoid response to chemical gradients and demonstrate that comparing drug response across these different platforms is nontrivial.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Nanoindentation Stress Relaxation to Quantify Dislocation Velocity–Stress Exponent

This work reports a new methodology using indentation stress relaxation to characterize the dislocation velocity–stress exponent. Through the indentation stress relaxation process, the dislocation structure builds up at the rate governed by dislocation velocity, which is a function of the externally applied stress. The relationship between the dislocation velocity and stress can thus be derived from the indentation stress relaxation data of the stress as a function of time. In this study, instrumented nanoindentation stress relaxation experiments were performed on pure aluminum samples, following three different initial displacement rates of 100, 400, and 800 nm/s. Based on the scaling properties of dislocation kinetics, the data were interpreted to derive a dislocation velocity–stress exponent of 2.5 ± 0.5 for room-temperature aluminum. Crystal plasticity finite-element simulations were performed to illustrate the sensitivity of the proposed nanoindentation stress relaxation methodology to the dislocation velocity–stress exponent value.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Study of the Printability, Microstructures, and Mechanical Performances of Laser Powder Bed Fusion Built Haynes 230

The nickel-based superalloy, Haynes 230 (H230), is widely used in high-temperature applications, e.g., heat exchangers, because of its excellent high-temperature mechanical properties and corrosion resistance. As of today, H230 is not yet in common use for 3D printing, i.e., metal additive manufacturing (AM), primarily because of its hot cracking tendency under fast solidification. The ability to additively fabricate components in H230 attracts many applications that require the additional advantages leveraged by adopting AM, e.g., higher design complexity and faster prototyping. In this study, we fabricated nearly fully dense H230 in a laser powder bed fusion (L-PBF) process through parameter optimization. The efforts revealed the optimal process space which could guide future fabrication of H230 in various metal powder bed fusion processes. The metallurgical analysis identified the cracking problem, which was resolved by increasing the pre-heat temperature from 80 °C to 200 °C. A finite element simulation suggested that the pre-heat temperature has limited impacts on the maximum stress experienced by each location during solidification. Additionally, the crack morphology and the microstructural features imply that solidification and liquation cracking are the more probable mechanisms. Both the room temperature tensile test and the creep tests under two conditions, (a) 760 °C and 100 MPa and (b) 816 °C and 121 MPa, confirmed that the AM H230 has properties comparable to its wrought counterpart. The fractography showed that the heat treatment (anneal at 1200 °C for 2 h, followed by water quench) balances the strength and the ductility, while the printing defects did not appreciably accelerate part failure.

14 SOLAR ENERGY↗
DOE OSTI2023

Investigation of Goubau Wave Propagation on Large Pipes for Sensing Applications

We examine the application of guided waves on a single conductor (Goubau waves) for sensing. In particular, the use of such waves to remotely interrogate surface acoustic wave (SAW) sensors mounted on large-radius conductors (pipes) is considered. Experimental results using a small-radius (0.0032 m) conductor at 435 MHz are reported. The applicability of published theory to conductors of large radius is examined. Finite element simulations are then used to study the propagation and launching of Goubau waves on steel conductors up to 0.254 m in radius. Simulations show that waves can be launched and received, although energy loss into radiating waves is a problem with current launcher designs.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Investigating the Electromechanical Sensitivity of Carbon-Nanotube-Coated Microfibers

The piezoresistance of carbon nanotube (CNT)-coated microfibers is examined using diametric compression. Diverse CNT forest morphologies were studied by changing the CNT length, diameter, and areal density via synthesis time and fiber surface treatment prior to CNT synthesis. Large-diameter (30–60 nm) and relatively low-density CNTs were synthesized on as-received glass fibers. Small-diameter (5–30 nm) and-high density CNTs were synthesized on glass fibers coated with 10 nm of alumina. The CNT length was controlled by adjusting synthesis time. Electromechanical compression was performed by measuring the electrical resistance in the axial direction during diametric compression. Gauge factors exceeding three were measured for small-diameter (<25 μm) coated fibers, corresponding to as much as 35% resistance change per micrometer of compression. The gauge factor for high-density, small-diameter CNT forests was generally greater than those for low-density, large-diameter forests. A finite element simulation shows that the piezoresistive response originates from both the contact resistance and intrinsic resistance of the forest itself. The change in contact and intrinsic resistance are balanced for relatively short CNT forests, while the response is dominated by CNT electrode contact resistance for taller CNT forests. These results are expected to guide the design of piezoresistive flow and tactile sensors.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Limiting Rotation Rate of Neutron Stars from Crust Breaking and Gravitational Waves

Abstract Neutron stars are not observed to spin faster than about half their breakup rate. This limiting rotational frequency may be related to the strength of their crusts. As a star spins up from accretion, centrifugal forces stress the crust. We perform finite-element simulations of rotating neutron stars and find that the crust fails at rotation rates about half the breakup rate. Given uncertainties in microphysics, we have not determined the crust configuration after this failure. Instead, we argue that the crust may fail in an asymmetric way and could produce a configuration with a significant ellipticity (fractional difference in moments of inertia). If the ellipticity is large, a rotating star will radiate gravitational waves that may limit further spin-up. These stars may be promising sources for LIGO/VIRGO and next-generation gravitational-wave detectors.

Morales, J. A.↗
DOE OSTI2022

Local Thermomechanical Processing for Improving Formability of High Strength Aluminum Sheets

Limited room temperature formability hinders the wide-spread use of high strength aluminum alloys in structural body-in-white parts. Stamping or extrusion at warm temperatures or from softer tempers are the current solutions. In this work, our approach is to start with age-hardened sheets from 7xxx and 6xxx family of alloys and improve their formability using local thermomechanical processing only in the regions demanding highest ductility in the forming processes. We achieved local formability improvements with friction stir processing and introduce another process named roller-bending as a concept and showed its feasibility through finite element simulations. Initial results from FSP indicated significant deformation in the processed zones with minimal sheet distortion. FSP also resulted in dynamically recrystallized, fine grained (d < 5 µm) microstructures in the processed regions with textures significantly different from the base material. This resulted in formability improvements of > 30% in 7085-T76 and > 50% in 6111-T6 alloys as measured by minimum bend radius (r/t) ratios established with V-bending tests performed at 90° and 180° bend angles. Based on the encouraging initial results, we envision applicability of these processes in both pre- and post-stamping stages through integration of the process tools as end-effectors to robotic arms.

Nasim, Wahaz↗
DOE OSTI2022

pyvisco [SWR-22-30]

pyvisco is a Python library that supports the identification of Prony series parameters for linear viscoelastic materials described by a Generalized Maxwell model. The necessary material model parameters are identified by fitting a Prony series to the experimental measurement data. pyvisco allows for the identification of Prony series parameters from experimental data measured in either the frequency-domain (via Dynamic Mechanical Thermal Analysis) or time-domain (via relaxation measurements). The experimental data can be provided as raw measurement sets at different temperatures or as pre-processed master curves. An optional minimization routine is included to reduce the number of Prony elements. This routine is helpful in Finite Element simulations where reducing the computational complexity of the linear viscoelastic material models can shorten the simulation time. See also, https://pypi.org/project/pyvisco/

Springer, Martin↗
DOE OSTI2020

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

The emergence of wide-bandgap (WBG) devices in power electronics packages has brought significant attention to the reliability and thermal performance of the bonded interfaces. These interfaces, such as die-attach and substrate-attach, need to withstand the severe stress induced on them by the high-temperature (> 200°C) operation of the WBG devices. Sintered silver and transient liquid phase alloys are key bonded interfaces that can enable the high-temperature operation of WBG devices, however it is essential to evaluate their reliability and study the possible failure mechanisms before they can be used in power electronics packages. Sintered silver is already being adopted in commercial packages as a die-attach, but large-area substrate-attach offers additional reliability challenges. In this project, we investigate the reliability of these interface materials under accelerated thermal cycling and correlate these results with finite element simulations to develop lifetime prediction models. The failure mechanisms of these bonded interfaces are also studied.

47 OTHER INSTRUMENTATION↗