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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Permafrost Region Greenhouse Gas Budgets Suggest a Weak CO 2 Sink and CH 4 and N 2 O Sources, But Magnitudes Differ Between Top-Down and Bottom-Up Methods

Large stocks of soil carbon (C) and nitrogen (N) in northern permafrost soils are vulnerable to remobilization under climate change. However, there are large uncertainties in present-day greenhouse gas (GHG) budgets. We compare bottom-up (data-driven upscaling and process-based models) and top-down (atmospheric inversion models) budgets of carbon dioxide (CO 2 ), methane (CH 4 ) and nitrous oxide (N 2 O) as well as lateral fluxes of C and N across the region over 2000–2020. Bottom-up approaches estimate higher land-to-atmosphere fluxes for all GHGs. Both bottom-up and top-down approaches show a sink of CO 2 in natural ecosystems (bottom-up: -29 (-709, 455), top-down: -587 (-862, -312) Tg CO 2 -C yr -1 ) and sources of CH 4 (bottom-up: 38 (22, 53), top-down: 15 (11, 18) Tg CH 4 -C y -1 ) and N 2 O (bottom-up: 0.7 (0.1, 1.3), top-down: 0.09 (-0.19, 0.37) Tg N 2 O-N yr -1 ). The combined global warming potential of all three gases (GWP-100) cannot be distinguished from neutral. Over shorter timescales (GWP-20), the region is a net GHG source because CH 4 dominates the total forcing. The net CO 2 sink in Boreal forests and wetlands is largely offset by fires and inland water CO 2 emissions as well as CH 4 emissions from wetlands and inland waters, with a smaller contribution from N 2 O emissions. Priorities for future research include the representation of inland waters in process-based models and the compilation of process-model ensembles for CH 4 and N 2 O. Discrepancies between bottom-up and top-down methods call for analyses of how prior flux ensembles impact inversion budgets, more and well-distributed in situ GHG measurements and improved resolution in upscaling techniques.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Intercomparison of Deep Learning Model Architectures for Atmospheric River Prediction

With a rapid surge in the application of machine learning (ML) for a diverse range of tasks in climate science, the present study addresses a challenge for climate scientists when selecting the optimal ML or deep learning (DL) architecture for a given application. In particular, a DL intercomparison study was performed with a focus on forecasting the position of atmospheric rivers (ARs) on short-range time scales (up to 5-day lead times). AR predictions from multiple DL architectures, including various types of convolutional autoencoders and a vision transformer (ViT), were compared against ECMWF ERA5 reanalysis and hindcasts from a global climate model. DL models with similar trainable parameters were trained on ERA5 reanalysis data and AR positions derived from a thresholding algorithm to ensure a fair comparison among the DL models. Each model’s performance and accuracy in forecasting AR location and key input fields within a 5-day window were assessed using metrics of root-mean-square error, anomaly correlation, and mean intersection over union. The ViT architecture outperformed other autoencoder models in most of the metrics. Incorporating additional meteorological fields only yielded slight improvements in forecasting certain fields at longer lead times. The results also suggest that a smaller number of input time steps or smaller number of autoregressive steps can achieve better prediction skills, while also improving the overall computational efficiency. This research offers valuable insights into the strengths and weaknesses of different DL techniques for AR forecasting, hopefully guiding the development of improved models for forecasting this phenomenon.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2026

Multidimensional scaling informed by F -statistic: Visualizing grouped microbiome data with inference

Multidimensional scaling (MDS) is a widely used dimensionality reduction technique in microbial ecology data analysis that captures the multivariate structure of the data while preserving pairwise distances between samples. While improvements in MDS have enhanced the ability to reveal group-specific data patterns, these MDS-based methods require prior assumptions for inference, limiting their application in general microbiome analysis. Here, in this study, we introduce a new MDS-based ordination method, “F-informed MDS,” which configures the data distribution based on the F-statistic, the ratio of dispersion between groups sharing common and different characteristics. Using semisynthetic datasets, we demonstrate that the proposed method is robust to hyperparameter selection while maintaining statistical significance throughout the ordination process. Various quality metrics for evaluating dimensionality reduction confirm that F-informed MDS is comparable to state-of-the-art methods in preserving both local and global data structures. Its application to a diatom-associated bacterial community suggests the role of this new method in interpreting the community’s response to the host. Our approach offers a well-founded refinement of MDS that aligns with statistical test results, which can be beneficial for broader multidimensional data analyses in microbiology and ecology. This new visualization tool can be incorporated into standard microbiome data analyses.

Biological and medical sciences↗
DOE OSTI2024

Lattice realizations of topological defects in the critical (1+1)-d three-state Potts model

Topological/perfectly-transmissive defects play a fundamental role in the analysis of the symmetries of two dimensional conformal field theories (CFTs). In the present work, spin chain regularizations for these defects are proposed and analyzed in the case of the three-state Potts CFT. In particular, lattice versions for all the primitive defects are presented, with the remaining defects obtained from the fusion of the primitive ones. The defects are obtained by introducing modified interactions around two given sites of an otherwise homogeneous spin chain with periodic boundary condition. The various primitive defects are topological on the lattice except for one, which is topological only in the scaling limit. The lattice models are analyzed using a combination of exact diagonalization and density matrix renormalization group techniques. Low-lying energy spectra for different defect Hamiltonians as well as entanglement entropy of blocks located symmetrically around the defects are computed. The latter provides a convenient way to compute the g-function which characterizes various defects. Finally, the eigenvalues of the line operators in the “crossed channel” and fusion of different defect lines are also analyzed. The results are all in agreement with expectations from conformal field theory.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Advances in Miscanthus × Giganteus Planting Techniques May Increase Carbon Uptake in the Establishment Year

Agricultural lands hold significant potential for CO 2 sequestration, particularly when utilizing biomass crops and agricultural residues. Among these, Miscanthus × giganteus (mxg) stands out due to its high productivity and carbon sequestration capabilities. Recognizing the importance of such biomass crops, the Intergovernmental Panel on Climate Change (IPCC) has identified Bioenergy with Carbon Capture and Storage (BECCS) as a crucial strategy for achieving net-zero CO 2 emissions by 2050. This study examines the carbon uptake potential of mxg during its establishment year at the Sustainable Advanced Bioeconomy Research (SABR) farm in Iowa, USA, where mxg was planted at a density exceeding previous studies. Using eddy covariance (EC) measurements, we quantified the net ecosystem carbon exchange (NEE), and derived gross primary productivity (GPP), and ecosystem respiration (R eco ). Our findings reveal that SABR's mxg exhibited a significant carbon uptake of –621 g C m –2 , a threefold increase compared to a similar EC site in the “corn-belt” (University of Illinois Energy Research Farm; UIEF), which was established with lower planting density and pre-commercial planting equipment. Favorable growing conditions and advanced planting technologies at SABR likely contributed to this high carbon uptake. Comparisons with other global EC studies indicated a strong correlation between higher planting densities and greater carbon uptake. These results suggest that increasing mxg planting density can enhance carbon uptake, but further studies are necessary to evaluate the impacts under varying environmental conditions and management practices. Additionally, economic analyses are essential to determine the viability of higher planting densities. Our study underscores the potential of optimized mxg management practices to contribute significantly to CO 2 uptake and supports the development of BECCS as a viable climate change mitigation strategy.

09 BIOMASS FUELS↗
DOE OSTI2024

Critical mineral substitutions in IN617: A combined computational and experimental approach to performance evaluation and feasibility

Addressing the escalating demand for critical minerals (CMs) driven by global climate change initiatives, this study explores compositional modifications to Inconel 617 (IN617) by substituting cobalt (Co) with manganese (Mn) across various atomic percentages. Here, we conducted a computational feasibility study employing Molecular Dynamics (MD) simulations to provide strategic guidance for experimental validation. The simulations analyzed tensile strength and corrosion resistance for five modified compositions (M1 to M5) to identify optimal properties. Tensile tests on cubic simulation cells were performed to generate stress-strain curves, revealing the impact of Co replacement with Mn on tensile strength—a metric correlated with hardness. Oxygen penetration simulations were conducted to evaluate corrosion resistance, indicating that reduced oxygen penetration depth corresponds to enhanced resistance. Promising compositions underwent phase diagram calculations for assessing phase stability. The optimal composition (M1), characterized by high tensile strength and minimal oxygen penetration, was chosen for experimental validation using induction melting and friction stir consolidation techniques. The materials were further characterized using SEM-EDS, XRD, and Vickers hardness testing. Our findings suggest that Mn substitution in IN617 can yield mechanical performance at par with high-Co alloys in energy-critical applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

HOD-dependent systematics in Emission Line Galaxies for the DESI 2024 BAO analysis

The Dark Energy Spectroscopic Instrument (DESI) will provide precise measurements of Baryon Acoustic Oscillations (BAO) to constrain the expansion history of the Universe and set stringent constraints on dark energy. Therefore, precise control of the global error budget due to various systematic effects is required for the DESI 2024 BAO analysis. In this work, we estimate the level of systematics induced in the DESI BAO analysis due the assumed Halo Occupation Distribution (HOD) model for the Emission Line Galaxy (ELG) tracer. We make use of mock galaxy catalogs constructed by fitting various HOD models to early DESI data, namely the One-Percent survey data. Our analysis includes typical HOD models for the ELG tracer used in the literature as well as extensions to the baseline models. Among the extensions, we consider various recipes for galactic conformity and assembly bias. We use 25 AbacusSummit simulations under the ΛCDM cosmology for each HOD model and perform independent analyses in Fourier space and in configuration space. To recover the BAO signal from our mocks we perform BAO reconstruction and apply the control variates technique to reduce sample variance noise. Our BAO analyses can recover the isotropic BAO parameter α iso within 0.1% and the Alcock Paczynski parameter α AP within 0.3%. Overall, we find that the systematic error due to the HOD dependence is below 0.17%, with the Fourier space analysis being more robust against the HOD systematics. We conclude that our analysis pipeline is robust enough against the HOD systematics for the ELG tracer in the DESI 2024 BAO analysis, for the assumptions made.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

A critical review of electrochemical heat pump technologies: Status, challenges, and perspectives

The development of advanced heat pump technologies is critical for reducing global energy consumption in the building sector, where space heating and cooling account for nearly 50% of energy use. Electrochemical heat pumps (EHPs) offer a promising alternative to vapor compression systems by enabling direct electrochemical-to-thermal energy conversion, often with environmentally benign working fluids that exhibit low or zero global warming potential (GWP). Prior literature has predominantly focused on chemically reactive heat pumps, while comprehensive assessments of electrochemical mechanisms remain limited. Here, this review addresses this gap by systematically evaluating the underlying principles, architectures, and performance metrics of EHP systems. Compared to conventional vapor compression systems, EHPs can achieve 10%-30% higher energy efficiency, with reported cooling coefficients of performance (COP c ) ranging from 3.5 to 14.3 under standard operating conditions. Despite these advantages, widespread adoption is hindered by challenges including membrane degradation, electrode fouling, sluggish redox kinetics, and elevated system-level capital costs. To address these limitations, the review outlines three research priorities: (i) the development of advanced membranes, catalysts, and electrode materials with enhanced chemical and mechanical stability; (ii) the application of molecular-level simulations for the rational design of high-performance redox-active working fluids; and (iii) the integration of advanced diagnostic techniques for real-time monitoring and sustained operation of EHPs. By consolidating recent advances and explicitly identifying technological and scientific gaps, this work uniquely contributes a comprehensive framework for guiding future electrochemical heat pump research and facilitating the transition to sustainable thermal management technologies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Engineered Nanoporous Frameworks for Adsorption Cooling Applications

The energy demand for traditional vapor-compressed technology for space cooling continues to soar year after year due to global warming and the increasing human population’s need to improve living and working conditions. Thus, there is a growing demand for eco-friendly technologies that use sustainable or waste energy resources. Here this review discusses the properties of various refrigerants used for adsorption cooling applications followed by a brief discussion on the thermodynamic cycle. Next, sorbents traditionally used for cooling are reviewed to emphasize the need for advanced capture materials with superior properties to improve refrigerant sorption. The remainder of the review focus on studies using engineered nanoporous frameworks (ENFs) with various refrigerants for adsorption cooling applications. The effects of the various factors that play a role in ENF–refrigerant pair selection, including pore structure/dimension/shape, morphology, open-metal sites, pore chemistry and possible presence of defects, are reviewed. Next, in-depth insights into the sorbent–refrigerant interaction, and pore filling mechanism gained through a combination of characterization techniques and computational modeling are discussed. Finally, we outline the challenges and opportunities related to using ENFs for adsorption cooling applications and provide our views on the future of this technology.

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

Study on Application of Distributed Network of Sensors with List Mode for NMAC Literature Review

Nuclear material accounting and control (NMAC) for nuclear security detects, deters, and resolves questions related to unauthorized removal (i.e. theft) or misuse of nuclear material. NMAC also serves as a key insider threat mitigation measure and aids in recovery of nuclear material that is missing. Effective nuclear security depends on NMAC for timely and accurate information about nuclear material types, quantities, and locations. Bulk nuclear material processing facilities, however, present unique challenges for effective NMAC due to the presence of large quantities of material in-process and the accumulation of residual material holdup within process equipment. These holdup accumulations can obscure accurate physical inventory taking and complicate efforts to resolve NMAC irregularities at the facility level. Bulk material monitoring systems often rely on material balance calculations and indirect measurement techniques, which may mask protracted theft of smaller amounts of nuclear material. These monitoring limitations have generated increased interest in continuous monitoring technologies, including distributed non-destructive assay (NDA) sensor networks capable of providing real-time or near-real-time measurement of material movement and accumulation within bulk processing environments. Recent advancements in distributed networks of NDA radiation detectors and sensing technologies provide an opportunity to address these limitations. Although such distributed sensor networks have been implemented in select facilities for IAEA Safeguards applications, their potential for supporting NMAC functions specifically tailored to nuclear security objectives remains largely unexplored. Furthermore, emerging list-mode data acquisition technologies have reached high technology readiness levels, enabling time-correlated detection of nuclear events across multiple temporal scales. These capabilities provide enhanced opportunities for accurate holdup measurement, continuous process monitoring, and improved detection of material theft or misuse over time. The increasing global expansion of civil nuclear power and development of related bulk material processing facilities, including those supporting high-assay low-enriched uranium (HALEU) and other advanced reactor fuel fabrication, further increases the need for advanced measurement and monitoring strategies for NMAC.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2025

Global tuning of hadronic interaction models with accelerator-based and astroparticle data

In high-energy and astroparticle physics, event generators play an essential role, even in the simplest data analyses. As analysis techniques become more sophisticated, e.g. based on deep neural networks, their correct description of the observed event characteristics becomes even more important. Physical processes occurring in hadronic collisions are simulated within a Monte Carlo framework. A major challenge is the modeling of hadron dynamics at low momentum transfer, which includes the initial and final phases of every hadronic collision. QCD-inspired phenomenological models used for these phases cannot guarantee completeness or correctness over the full phase space. These models usually include parameters which must be tuned to suitable experimental data. Until now, event generators have been developed and tuned mainly on the basis of data from high-energy physics experiments at accelerators. The wealth of data available from the latest generation of astroparticle experiments has not yet been fully exploited, and in many cases is not satisfactorily described. Both kinds of data sets are complementary as astroparticle experiments provide sensitivity especially to hadrons produced nearly parallel to the collision axis and cover center-of-mass energies up to several hundred TeV, well beyond those reached at colliders so far. In this report, we provide an overview of state-of-the-art event generators and their tuning, including the most relevant inputs from high-energy accelerator and astroparticle experiments. We present a road map that shows, for the first time, how the unified tuning of event generators with accelerator-based and astroparticle data can be performed.

Albrecht, J. [Ruhr U., Bochum, RAPP Ctr.; Ruhr U.,↗
DOE OSTI2025

Understanding Soil Microbial Sources of Nitrous Acid and their Effect on Carbon-Nitrogen Cycle Interactions

Descriptions of soil emissions of reactive nitrogen (NO y ) in climate models are underdeveloped or non-existent, due to the fact that details of the mechanisms leading to nitrous acid (HONO) and nitrogen di-oxide (NO 2 ) formation in soil are lacking. This represents a major gap in our understanding of a significant land-atmosphere interaction that prevents us from scaling these processes from the laboratory scale to the ecosystem and global scales. There is a critical need to include these mechanisms into climate models since NO y controls the oxidative capacity of the atmosphere and the lifetime of greenhouse gases and the rate of secondary aerosol formation that directly and indirectly affect climate. The first objective of this proposal is to conduct laboratory and field measurements of NO y fluxes from diverse soil types and determine the mechanism of biogenic NO y formation. The working hypothesis based on preliminary data is that soil HONO and NO 2 is ultimately derived from ammonia-oxidizing archaea (AOA) and bacteria (AOB) that are widespread, but whose abundance varies across ecosystems. In the case of NO 2 , reactive oxygen species derived from iron-containing minerals and heterotrophic bacteria drive NO-to-NO 2 conversion. The approach is to link soil fluxes of HONO and NO 2 to AOA, AOB, and other heterotrophs using a combination of laboratory and field experiments, isotopic analysis, and molecular techniques to address how variability in land surfaces and edaphic properties impact emissions. In addition, we will determine the effect of HONO and NO 2 on nitrogen immobilization and the photo-oxidative capacity of soil. The working hypothesis is that HONO uptake in soil will be a source of nitrosonium and hydroxyl radical that will lead to thermal- and photodegradation of soil organic matter to CO 2 and CO, and the incorporation of N in soil organic matter. We will use surface-sensitive mass spectrometry techniques and gas phase detection to study N-immobilization in soil and subsequent enhancements in reactivity that lead to decomposition of organic matter. The results will be used to reduce the uncertainty in projections from the Community Earth System Model (CESM) stemming from inaccurate representations of soil NO y emissions. The proposed research is significant because, in addition to demonstrating new mechanisms of NO y formation and loss, it will be a crucial first step towards modeling the land-atmosphere exchange of HONO and NO 2 in the CESM. Improved model treatment of land-air exchange of NO y is key for understanding feedbacks between human activity and climate, and addressing societal concerns about the fate of N and C emitted to the atmosphere.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Deep-learning-based canopy height model generation from sub-meter resolution panchromatic satellite imagery

Canopy height models (CHMs) with sufficient resolution to distinguish individual trees are useful for a variety of applications. However, standard techniques to acquire such data, such as airborne lidar surveying, are often prohibitively expensive. Deep learning techniques for generating CHMs from high-resolution imagery are an attractive option to reduce costs. To date, success with these methods has been demonstrated using multichannel aerial photography and specialized satellite data products derived from multiple sensors, neither of which is commonly available at temporal resolutions finer than one year. Here we demonstrate a method to generate sub-meter resolution CHMs in three forests in California using a more abundant data source: sub-meter resolution, panchromatic satellite imagery from a single sensor. We show that phenology and species composition play important roles in model transferability; when trained using imagery from a single conifer forest in autumn, the model performs well on autumn imagery from a second conifer forest several hundred kilometers distant with no re-training. With modest additions to the training dataset, the same model generates minimally biased estimates of canopy height in both conifer and deciduous forests during multiple seasons. Because the model operates on satellite data with global coverage and a relatively short return interval, we propose its suitability to extrapolate tree-level canopy height data to remote regions and conduct high-temporal resolution monitoring of forest structure. We furthermore demonstrate the workflow’s applicability to fire modeling by conducting simulations in forests populated by trees measured using both this approach and airborne lidar surveying. We find minimal differences in fire behavior relative to a baseline case in which only statistical distributions of tree height and crown area are known. This result underscores the value of forest structural information derived from our workflow for improving the fidelity of wildland fire simulations, among other ecological applications.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

DRDMannTurb: A Python package for scalable, data-driven synthetic turbulence

Synthetic turbulence models (STMs) are used in wind engineering to generate realistic flow fields and are employed as inputs to industrial wind simulations. Examples include prescribing inlet conditions in large eddy simulations that model loads on wind turbines and tall buildings. We are interested in STMs capable of generating fluctuations based on prescribed second-moment statistics since such models can simulate environmental conditions that closely resemble on-site observations. To this end, the widely used Mann model (see Mann, 1994, 1998) is the inspiration for DRDMannTurb. The Mann model is described by three physical parameters: a magnitude parameter influencing the global variance of the wind field and corresponding to the Kolmogorov constant multiplied by the rate of viscous dissipation of the turbulent kinetic energy to the two-thirds, αϵ 2/3 , a turbulence length scale parameter L, and a nondimensional parameter Γ related to the lifetime of the eddies. A number of studies, as well as international standards (e.g., those by the International Electrotechnical Commission (IEC)), include recommended values for these three parameters with the goal of standardizing wind simulations according to observed energy spectra. Yet, having only three parameters, the Mann model faces limitations in accurately representing the diversity of observable spectra. This Python package enables users to extend the Mann model and more accurately fit field measurements through flexible neural network models of the eddy lifetime function. Following Keith et al. (2021), we refer to this class of models as Deep Rapid Distortion (DRD) models. DRDMannTurb also includes a general module implementing an efficient method for synthetic turbulence generation based on a domain decomposition technique. This technique is also described in Keith et al. (2021).

17 WIND ENERGY↗
DOE OSTI2025

Bringing Inorganic Carbon to Life: Developing Model Metalloenzymes for C1 Conversion Reactions

The global carbon cycle is carefully balanced through the use of specialized enzymes in plants, algae, bacteria, and archaea. A primordial metabolic pathway for the conversion of inorganic carbon into cellular biomass uses a large, nickel-containing enzyme called carbon monoxide dehydrogenase (CODH)/acetyl coenzyme A synthase (ACS). This system fixes carbon dioxide (CO 2 ) into carbon monoxide (CO) at the CODH site. The carbon monoxide is then used to generate acetyl coenzyme A, a biological building block, through a key carbon-carbon bond forming step at the nickel site in ACS. Despite the significance of these processes in the context of energy conversion, the fundamental chemistry underlying these transformations has remained elusive, in part due to the complexity of the natural enzyme. To better understand the principles governing these biological processes, which represent one-carbon (C 1 ) activation reactions, this project will develop functional models of CODH and ACS based on modifications to a small metalloprotein scaffold. Comprehensive characterization of these systems using advanced spectroscopic and biophysical techniques will reveal key elements responsible for conferring high levels of activity to the model systems, with implications for gaining insight into the mechanisms of the natural enzymes. Moreover, the principles learned from this research can be used to guide design of robust catalysts for efficient conversion of CO 2 and CO into liquid fuels.

10 SYNTHETIC FUELS↗
DOE OSTI2025

Data-Driven Clustering and Classification of Outage Patterns with Insights into their Links to Extreme Events

At a global level extreme events have increased in both scale and impact. These events have the potential to affect the electrical grid infrastructure and cause a wide range of outages, which can lead to a disruption in daily patterns, cost millions of dollars and also the loss of life. Currently, to track these outage events there have been various approaches developed ranging from regional to national level quantifications for what defines an outage. However, this variation in methods can potentially lead to subjective decision-making and a lack of proper management in relation to the event. While previous work has made strides in determining spatio-temporal patterns, minimal attention has been given to the type and number of outages an area may be exposed to. The differences in incurred cost and the overall severity of an event between a transformer box malfunction and a hurricane are drastic, and by finding historical signals, we can allow for more efficient management, potentially saving lives and millions of dollars. Here, we leverage unsupervised machine learning techniques to delineate outage patterns among 22 counties within the United States and find that there are clear, segregated clusters (0.93 silhouette) of data which are related by event behavior and underlying cause. This finding will allow for energy stakeholders, policy makers, and researchers to gain a deeper understanding of the extent and severity of historic events and to better prepare for electrical grid infrastructure planning and management.

Koob, Benjamin [ORNL]↗
DOE OSTI2024

Upcycling of Mixed Aluminum Alloy Shredder Scrap using Shear Processing

Conservation of critical materials is an increasing area of focus in the Unites States. In 2023, aluminum was added to the US Department of Energy Final Critical Materials List which has spurred public and private research into sustainable management of these resources. Additionally, efficiency in manufacturing and conservation of natural resources are growing concerns with targets to lower global carbon emissions, as primary aluminum alloy production is energy intensive, requiring 14 MWh of electricity plus 0.4 tonnes of CO2 per tonne of Al. Due to these factors, is essential that more sustainable manufacturing methods for aluminum alloys are developed going forward. To this end, much research is ongoing on the topic of more efficient utilization and recovery. However, most of this research still requires primary aluminum in the production process. Here, it will be attempted to bypass the use of primary aluminum and produce useful material recycled from 100% post-consumer scrap. Even considering recent developments in recycling of Al scrap, there is still a large amount of post-consumer scrap that is underutilized due to high impurity content, and that amount will increase significantly as more and more aluminum alloys are utilized in vehicles. This “scrap wave” is expected to cover 80% of the demand for automotive aluminum alloys by 2050 . A challenge to be addressed before the coming scrap wave can be fully utilized is that the tolerance of manufacturing techniques to impurities or off-spec alloy compositions must be increased. Particularly, in 5000-and 6000-series alloys (the most common wrought alloys in durable products), excess iron, copper, and silicon create brittle intermetallics during casting that remain in the extruded microstructure which limit the formability, ductility, and corrosion resistance of the alloy. Concerningly, many of the highest-volume post-consumer aluminum scrap streams such as automotive shredder scrap contain a mix of alloys including both wrought and cast alloys. Their compositions can vary widely depending on geography and the time of year. Because they are mixed, they often contain high content of multiple alloying elements such as Si and Cu in higher concentrations than are found in typical wrought alloys. They may also be contaminated with non-Al alloys from fasteners that get mixed in and often have high content of unwanted elements such as Fe. As a method for utilizing these underused scrap streams that are high in tramp elements, an emerging extrusion technology is being developed at the Pacific Northwest National Laboratory (PNNL) that aims to upcycle 100% post-consumer aluminum scrap directly into extruded components without the addition of primary aluminum . This new technology, called Shear Assisted Processing and Extrusion (ShAPE), is enabling a shift away from today’s recycling paradigm by reaching deeper into lower-value scrap streams, using shredder scrap as the extrusion billet material. Sometimes referred to as Twitch or Tweak, these scrap streams result from shredding and sorting of automobiles, building materials, appliances, and consumer goods. ShAPE combines the linear axis of conventional extrusion with a rotating extrusion die. This rotating die applies large strain to the material during extrusion, which breaks up large impurity-containing intermetallic particles, reducing their deleterious effects. This has been demonstrated for 6063 machining scrap spiked with excess Fe, and Twitch scrap high in Fe, Si and Cu where strength and ductility were retained for both feedstock compositions. Additionally, the extreme plastic deformation during ShAPE enables extrusion of billets with high Si that are too brittle for processing by conventional extrusion. By using 100% post-consumer shedder scrap as feedstock, ShAPE has the potential to slash embodied energy and carbon in extruded components by >80% compared to conventional extrusion of primary aluminum alloys.

Milligan, Brian K.↗
DOE OSTI2024

A Generation-Storage Coordination Dispatch Strategy for Power System Based on Causal Reinforcement Learning

In the backdrop of global energy transformation, power systems integrating high proportions of renewable energy sources are facing unprecedented challenges in operational stability and dispatch efficiency. To address these challenges, this study introduces a generation-storage coordination real-time dispatch strategy based on Causal Power System Dynamic Reinforcement Learning (CPSDRL). Diverging from traditional reinforcement learning approaches, CPSDRL innovatively incorporates causal inference within the state prediction model - the crux of model-based reinforcement learning - thereby establishing the Power Causal Dynamic Model (PCDM). Assisted by the prior knowledge of power systems, the model significantly enhances prediction accuracy and reliability through a two-stage training process. Utilizing PCDM, this study further applies a direct policy search algorithm to optimize the real-time dispatch strategy. Experimental results indicate that the proposed method improves the stability of generation-storage coordination real-time dispatch and exhibits competitive advantages in sample efficiency and computational speed, compared to traditional model-based and model-free reinforcement learning algorithms. This method is expected to enhance the practicality and adaptability of causal reinforcement learning techniques in power system scheduling and control.

causal reinforcement learning↗