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At least 343 records · Page 19

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DOE OSTI2021

In situ neutron diffraction study of fatigue behavior of CrFeCoNiMo 0.2 high entropy alloy

In situ neutron diffraction measurement was applied to study the low-cycle fatigue behavior of CrFeCoNiMo 0.2 high entropy alloy. A two-step stress-controlled fatigue test with a stress range of 100–460 and 20–500 MPa was employed. The as-cast sample was cycled 129,000 and 61,000 times, respectively, before fracture. The evolution of the lattice strain and peak intensity demonstrates that the main deformation mechanism is dislocation slip, while no evidence of stacking fault was found. A three-stage ratcheting was clearly observed. Under the stress-controlled mode, the experimentally determined dislocation density increases linearly with the ratcheting strain. Here, the increase of the dislocation density results in a decay of the ratcheting strain rate, which stabilizes the structure and is beneficial for fatigue resistance.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Advanced high-performance large diameter Cs 2 HfCl 6 (CHC) and mixed halides scintillator

This paper reports on successful growth and performance evaluation of two large diameter Cs 2 HfCl 6 (CHC) and Cs 2 HfCl 4 Br 2 (CHCB), both recently developed scintillator crystals. The discovery of Cs 2 HfCl 6 (CHC) as a scintillator has lately generated much interest in this material and its family, which belongs to the K 2 PtCl 6 cubic crystal structure. CHC is an intrinsic scintillator that is non-hygroscopic (slightly deliquescent, i.e., slightly moisture sensitive but does not deteriorate much when left in air), has no self-radioactivity, provides excellent energy resolution, and has excellent non-proportionality. CHC has a moderate density of 3.9 g/cm 3 and an effective atomic number of 58. Reported in this paper are transparent crack-free single crystal CHC and CHCB boules of one inch in diameter, both grown using the vertical Bridgman method. Samples retrieved from the boules, sized 23 mm × 30 mm and 23 mm × 26 mm, respectively, are characterized for their optical and scintillation properties. Energy resolutions of 3.5% and 3.7% (FWHM) at 662 keV, respectively, are reported. Light yields of 23,000 ph/MeV and 20,000 ph/MeV have been calculated for the large diameter CHC and CHCB crystals, respectively. Results comparable to previously reported results for smaller crystals have been obtained. Studies on decay time, non-proportionality, as well as detector characterization are also reported.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Crystal growth, physical and optical properties of TlSr 2 Cl 5 and TlSr 2 Br 5

Small diameter (Ø 16 mm) TlSr 2 Cl 5 and TlSr 2 Br 5 crystals were grown by the Vertical Bridgman method. X-ray diffraction measurements show that both have the monoclinic crystal structure with space group P21/c. TlSr 2 Cl 5 and TlSr 2 Br 5 have a density of 4.14 g/cm 3 and 5.03 g/cm 3 , respectively. The effective Z of TlSr 2 Cl 5 and TlSr 2 Br 5 is 63.7 and 58.6, respectively. Radioluminescence spectra of TlSr 2 Cl 5 and TlSr 2 Br 5 feature a broad emission band peaking at 440 and 445 nm, respectively. As a result the light yield of TlSr 2 Cl 5 and TlSr 2 Br 5 was estimated to be 17,000 and 45,000 ph/MeV, respectively.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Part II: Predicting performance of $\mathrm{DOWEX 21K}$ resin for remediation of comingled contaminants in groundwater

The selectivity of ion exchange (IX) resins for aqueous contaminant removal can be impacted by changing concentrations of competing natural groundwater ions. In a two-part investigation, the Hanford Site 200 West Area pump-and-treat (P&T) facility in Washington State, USA is used as a case study to evaluate the performance of two IX resins for groundwater treatment: Purolite® A532E for pertechnetate (TcO 4 - ) removal, explored in Part I, and DOWEX 21K (DOWEX) for uranium (U) removal. In Part II, DOWEX selectivity for U, as uranyl carbonate species, and uptake kinetics is quantified in a series of laboratory-scale aqueous batch experiments containing Hanford-relevant concentrations of competing anions nitrate (NO 3 - ), sulfate (SO 4 2- ), chloride (Cl - ), and carbonate (CO 3 2- ), as well as co-mingled contaminant TcO 4 - . Here the results demonstrate that DOWEX trimethylammonium functional groups are highly selective for U carbonate species (85–100 % uptake) under all conditions investigated. Only NO 3 - concentrations of 100 mM were shown to decrease U removal, with the extent (85–99 %) depending on competing anion concentrations present in solution. However, at the highest NO 3 - concentrations reported for groundwaters treated at the P&T facility (25 mM), the effect on U uptake is minimal. The batch sorption results are modeled to obtain chloride normalized equilibrium exchange coefficients (K) for predicting DOWEX performance: K SO4--/Cl- = 2.0, K NO3-/Cl- = 5.0, K HCO3-/Cl- = 1.5, K TcO4-/Cl- = 2,000, and K U/Cl- = 50,000. These K values predict little effect of current and future influent chemistries on U removal by DOWEX, where both uranyl carbonate species and TcO 4 - are removed such that effluent concentrations meet groundwater treatment requirements.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Risk assessment of wellbore leakage during underground hydrogen storage

The expansion of renewable energy sources would require large-scale energy storage options to overcome the intermittent nature of these sources. Underground hydrogen storage (UHS) in depleted hydrocarbon reservoirs offers a scalable and practical energy storage solution. These reservoirs are chosen for their availability and large capacity, but the unique properties of hydrogen raise concerns about potential leakage pathways, particularly through wellbores. In this study, we develop and apply, for the first time, reduced-order models (ROMs) specifically designed for efficient leakage risk prediction in UHS systems operating in depleted hydrocarbon reservoirs. Using 3,000 high-fidelity simulation scenarios, we examine the influence of 11 key parameters, including reservoir and aquifer depths, wellbore permeability and porosity, initial saturations of water, oil and gas fractions (hydrogen, light, intermediate, and heavy hydrocarbons), reservoir pressure multiplier, and the aquifer-to-reservoir volume ratio, to simulate leakage behavior over a 1,000-year timescale. We train ROMs using a two-step classification-regression approach, achieving R 2 values exceeding 99 % across all targets. These ROMs effectively capture the leakage evolution and identify critical controls of leakage, guiding the design of mitigation strategies. Results indicate that gas leakage occurs in about 27 % of scenarios as early as five years post-operation, reaching volumes of up to 106 ft3. Oil leakage is less frequent (~17 %) and typically begins decades later. Our findings also show that hydrogen often migrates first, owing to its smaller molecular size and higher buoyancy, followed by heavier hydrocarbons. Over time, these heavier components contribute significantly to the total leaked volume, reinforcing the need for targeted monitoring and remediation strategies. Our analysis highlights that deeper storage reservoirs, shallower aquifers, and low-permeability wellbores significantly reduce leakage risks. In conclusion, this work offers a robust framework for risk-informed UHS deployment, supporting energy security through reliable large-scale hydrogen storage while safeguarding environmental integrity.

08 HYDROGEN↗

DOE OSTI2021

Oxide evolution on the SiC layer of TRISO particles during extended air oxidation

Tristructural isotropic (TRISO) fuel particles have been primarily developed for high-temperature gas-cooled nuclear reactors and can be subjected to oxidizing environments for extended periods in an off-normal accident scenario. Surrogate TRISO fuel particles were oxidized in air at 1,000 or 1,100 °C for up to 120 h. Here, the oxide scale morphology and thickness were studied via scanning electron microscopy, focused ion beam, and atomic force microscopy. TRISO particles oxidized at 1,100 °C exhibited a highly crystalline oxide scale, which led to significant cracking and irregularly shaped closed porosity, whereas those oxidized at 1,000 °C possessed a primarily amorphous oxide scale, which contained small, rounded internal pores and no larger defects. The observed phenomena deviated from the expected behavior based on models for oxide growth on flat-plate and fiber SiC. The oxidation kinetics of TRISO fuel particles in high-temperature air were investigated without mechanically deforming the surface and were analyzed with respect to oxide morphology.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Intense cyclic heating effects on thermo-fracture and thermal shock of solid tungsten and open-cell tungsten foam

Here we investigate here the effects of transient (cyclic) arc-jet plasma and laser heating on fracture behavior of W-foam and solid tungsten. The two key parameters that control the foam thermomechanical response are its density and mean cell size expressed in Pores Per Inch (PPI). Tungsten foam samples were fabricated with Chemical Vapor Deposition (CVD) with variety of PPI and relative density. These were tested under two types of qualitatively different conditions: (1) high-enthalpy arc-jet, and (2) high-power cyclic laser heating. None of the foam samples showed macroscopic through-thickness cracks. However, distributed micro-cracks were observed on ligaments and their triple junctions. Under the same loading conditions, W-foam and solid tungsten showed similar crack network pattern and characteristic length-scale. However, Crack Opening Displacement (COD) was twice as large in solid W as compared to W-foam. Foam samples that have been previously exposed to a low-pressure helium plasma showed significant changes in their surface forming nano-texture fuzz which was removed by subsequent testing in the arc-jet. Extensive fracture and re-crystallization were observed in the thin solid W disk that was fully-constrained from expansion. Thicker and fully-constrained solid W disks did not display recrystallization, grain growth, and extensive cracking. However, thicker disks that were free to expand showed some recrystallization and extensive through-thickness cracks due to less effective cooling and thus higher temperatures. Laser beam testing showed no visible damage formation at 0.19 GW/m 2 and 0.38 GW/m 2 for both low-density (23%) and high-density (43%) foams at low pulses (100-1000). Micro-cracks were observed after 10,000 pulses at 0.19 GW/m 2 in both foams, and in low-density foam after 100,000 at 0.38 GW/m 2 . The nature of thermomechanical damage in W-foam exposed to extreme power (GW/m 2 ) short-duration laser pulses was found to be qualitatively similar to that of high power (MW/m 2 ) long-duration arc-jet.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Highly reversible Zn anode with a practical areal capacity enabled by a sustainable electrolyte and superacid interfacial chemistry

Aqueous zinc-metal batteries are plagued by poor Zn reversibility owing to zinc dendrite and layered double hydroxide (LDH) formation. Here, we introduce a novel additive—N,N-dimethylformamidium trifluoromethanesulfonate (DOTf)—in a low-cost aqueous electrolyte that can very effectively address these issues. The initial water-assisted dissociation of DOTf into triflic superacid creates a robust nanostructured solid-electrolyte interface (SEI)—revealed by operando spectroscopy and cryomicroscopy—which excludes water and enables dense Zn deposition. We demonstrate excellent Zn plating/stripping in a Zn||Cu asymmetric cell for more than 3,500 cycles. Furthermore, near 100% CE is realized at a combined high current density of 4 mA cm -2 and an areal capacity of 4 mAh cm -2 over long-term cycling. Zn||Zn 0.25 V 2 O 5 ·nH 2 O full cells retain ~83% of their capacity after 1,000 cycles with mass-limited Zn anodes. By restricting the depth of discharge, the cathodes exhibit less proton intercalation and LDH formation with an extended lifetime of 2,000 cycles.

25 ENERGY STORAGE↗

DOE OSTI2024

Nanochannel electrodes facilitating interfacial transport for PEM water electrolysis

Proton-exchange membrane water electrolyzers (PEMWEs) are a promising technology for green hydrogen production; however, interfacial transport behaviors are poorly understood, hindering device performance and longevity. Here, we first utilized finite-gap electrolyzer to demonstrate the possibility of proton transfer through water in PEMWEs. The measured high-frequency resistances (HFRs) exhibit a linear trend with increasing gap distance, where extrapolation shows a lower value compared with HFRs in regular zero-gap electrolyzers, indicating that ohmic resistance could be further reduced. We introduce nanochannels to facilitate mass transport, as evidenced by both liquid-fed and vapor-fed electrolysis. Nanochannel electrodes achieve a voltage reduction of 190 mV at 9 A·cm –2 compared with the Ir-PTEs without nanochannels. Furthermore, nanochannel electrodes show negligible degradation through 100,000 accelerated-stress tests and over 2,000 h of operation at 1.8 A·cm –2 with a decay rate of 11.66 μV·h –1 . These results provide new insights into localized transport dynamics for PEMWEs and highlight the significance of interfacial engineering for electrochemical devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

The dual role of iron in alkaline water electrolysis: A friend or a foe?

Trace iron (Fe) impurities pose a challenge in alkaline water electrolysis (AWE) and can significantly impact long-term performance, yet their comprehensive system-level effects remain poorly understood. Here, we present the mechanistic roles of Fe in AWE, using combined rotation disk electrode studies, zero-gap cell measurements, and durability tests up to 1,000 h. Fundamental electrochemistry shows that Fe deposition proceeds through a solution-mediated pathway, with dendritic growth triggered under specific mass-transport and potential conditions. In single-cell operation, Fe incorporation substantially enhances nickel (Ni)-based anode activity by forming highly active Ni-Fe oxyhydroxides, while cathodic Fe forms either thin films or dendrites, depending on potential, surface morphology, and electrolyte distribution. Although dendrites do not degrade hydrogen evolution performance up to 1,000 h, they reveal partial intrusion into the separator, indicating a potential durability risk. We identify five governing factors controlling Fe dendrite formation and provide design principles for impurity-resilient AWE systems.

Lyu, Xiang [ORNL] (ORCID:0000000208673248)↗

DOE OSTI2021

Comprehensive review of photophysical parameters (ε, Φ f , τ s ) of tetraphenylporphyrin (H 2 TPP) and zinc tetraphenylporphyrin (ZnTPP) – Critical benchmark molecules in photochemistry and photosynthesis

Tetraphenylporphyrin (H 2 TPP) and zinc tetraphenylporphyrin (ZnTPP) are widely used benchmark molecules in diverse photochemical studies given facile synthetic access, rich visible-region spectra, and broad structural analogy to chlorophylls. Yet the literature values for each key photophysical parameter – the molar absorption coefficient (ε), fluorescence quantum yield (Φ f ), and also singlet excited-state lifetime (τ S ) – vary over an astonishing range. Here, a comprehensive literature review (~1940–September 2020) encompassing 871 publications is reported for these essential parameters. Each parameter is determined by measurement with distinct instrumentation and suffers idiosyncratic sources of error. The best values for H 2 TPP are ε = 460,000 cm -1 ·M -1 , Φ f = 0.090, and τ S = 12.8 ns in Ar- purged toluene (Φf = 0.070, τS = 9.9 ns in toluene in air); the best values for ZnTPP are ε = 560,000 cm -1 ·M -1 , Φf = 0.030, and τ S = 2.1 ns in Ar-purged toluene (Φ f = 0.029, τ S = 2.0 ns in toluene in air). The choice of values for such parameters has far-reaching consequences in photochemistry ranging from fluorescence (or Förster) resonance energy transfer (FRET) processes to assessments of molecular brightness.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Mesoporous Textured Fe-N-C Electrocatalysts as Highly Efficient Cathodes for Proton Exchange Membrane Fuel Cells

A new platinum group metal (PGM)-free proton exchange membrane fuel cell (PEMFC) cathode catalyst materials, synthesized using the VariPore™ method by Pajarito Powder, LLC, are characterized for their structure and activity. The physico-chemical analysis of the iron-nitrogen-carbon (Fe-N-C) electrocatalysts show mesoporous carbon material effectively doped with iron and nitrogen. The materials have an average pore size of 7-8 nm and high specific surface area. The Fe-N-C catalysts exhibit good oxygen reduction reaction (ORR) activity in 0.5 M H2SO4 electrolyte with high half-wave potential and sustainable electrochemical stability over 10,000 repeated potential cycles with insignificant losses in their activities. As cathode catalysts in a PEMFC, the Fe-N-C materials deliver remarkably good fuel cell performance at low overpotential approaching that of the commercial Pt catalyst. The high ORR electrocatalytic activity of these Fe-N-C catalysts is credited to the synergy between nitrogen-moieties, specifically pyrrolic-N, pyridinic-N, and graphitic-N, and iron in addition to the high mesoporosity that facilitate an effective reaction path in boosting the electrocatalytic activity and stability.

DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Experimental review of the performances of protective coatings for interconnects in solid oxide fuel cells

Ferritic stainless-steel interconnects are used in solid oxide fuel cells; however, coatings are required to improve their performance. Although several types of coatings have been proposed, they have been scarcely investigated under similar conditions. This study compares the characteristics of uncoated Crofer 22 APU and eight different coatings on Crofer 22 APU for up to 3,000 hours at 800°C. The coatings were deposited at various research laboratories around the world, and the experiments were performed at Chalmers University of Technology, Sweden. Cross-sections of the samples were analysed using scanning electron microscopy and energy-dispersive x-ray spectroscopy. The (Co,Mn)-based coated steels showed more than 50-fold lower chromium evaporation and at least 3 times thinner Cr 2 O 3 scale thickness compared to uncoated steel. The coated steel samples showed lower area-specific resistance (ASR) values than the uncoated steel after 3,000 hours of exposure, irrespective of the coating thickness, composition and deposition method.

25 ENERGY STORAGE↗

DOE OSTI2025

Modeling gas, hydrates, and slope stability on the U.S. Atlantic margin during Pleistocene glacial cycles

Changes in temperature and sea level can cause dissociation of methane hydrates in shallow marine sediments, leading to seafloor destabilization. Along the U.S. Atlantic margin, there exists a well-documented history of slope failure and numerous recorded occurrences of gas seeps. Several studies have linked slope failure in the region to gas seepage and hydrate dissociation driven by glacial-interglacial transitions, but this linkage has not been quantitatively demonstrated. Along the shelf edge, in an area where shallow methane gas seeps have been identified, we modeled methane gas and hydrate formation using a one-dimensional fluid flow model. Methane gas formation was modeled over the last 120,000 years to simulate a glacial-interglacial cycle. Here, we ran this model at 16,044 individual locations in the region between 29° N – 45° N and 82° W – 66° W at a resolution of 1 x 1 arcminutes, focusing specifically on water depths between 200 and 1000 m that bracket the seafloor outcrop of the base of the hydrate stability zone. Using historic temperature and pressure records from the last 120,000 years, sediment properties in the area, and factor of safety calculations, we found that hydrate dissociation alone is unlikely to cause sediment failure in the region, implying that an additional driving force would be necessary for failure to occur.

Hydrate dissociation↗

DOE OSTI2023

Experimental and numerical study of the shielding effect of two tandem rough cylinders in flow-induce oscillation

The shielding effect of the downstream cylinder in flow induced oscillation (FIO) of two cylinders arranged in tandem is studied experimentally and numerically at Reynolds number 30,000 to 120,000. Both cylinders are in one degree-of-freedom, transverse-oscillations, and have turbulence stimulation in the form of selective surface roughness to expand FIO beyond vortex-induced vibration (VIV) into galloping. Shielding of the downstream cylinder has a negative effect on harnessing hydrokinetic energy. Further, to study its effect and mechanics, selective cases are studied both numerically and experimentally and discussed to demonstrate the shielding effect on the downstream cylinder and understand its cause. The main conclusions are: (1) The shielding effect for the downstream cylinder shows a strong relation to the damping ratio. As the damping ratio increases, the shielding effect is mitigated. Additionally, the oscillation of the rear cylinder becomes stable and shows stable frequency. (2) In the VIV region, as the stiffness and natural frequency increase, the shielding effect decreases substantially. (3) In the VIV region, the vorticity of the vortices shedding from both the upper and the lower sides of the downstream cylinder does not accumulate enough due to the attraction by the vortices shed from the upstream cylinder, thus resulting in partial suppression of the oscillation on the downstream cylinder. (4) In the galloping region, the shielding effect for the downstream cylinder depends on whether the vorticity near the downstream cylinder is strengthened by the vortices generated by the shear layers of the upstream cylinder or weakened.

42 ENGINEERING↗

DOE OSTI2023

A database of ultrastable MOFs reassembled from stable fragments with machine learning models

High-throughput screening of hypothetical metal-organic framework (MOF) databases can uncover new materials, but their stability in real-world applications is often unknown. We leverage community knowledge and machine learning (ML) models to identify MOFs that are thermally stable and stable upon activation. We separate these MOFs into their building blocks and recombine them to make a new hypothetical MOF database of over 50,000 structures with orders of magnitude more (1) connectivity nets and (2) inorganic building blocks than were present in prior databases. Further, this database shows a 10-fold enrichment of ultrastable MOF structures that are stable upon activation and more than 1 standard deviation more thermally stable than the average experimentally characterized MOF. For nearly 10,000 ultrastable MOFs, we compute elastic moduli to confirm that these materials have good mechanical stability, and we report methane deliverable capacities. We identify privileged metal nodes in ultrastable MOFs that optimize gas storage and mechanical stability simultaneously.

36 MATERIALS SCIENCE↗

DOE OSTI2026

A foundation model for non-destructive defect identification from vibrational spectra

Defects are ubiquitous in solids and strongly influence materials’ functional properties. However, non-destructive characterization and quantification of defects, especially when multiple types coexist, remain a long-standing challenge. Here, we introduce DefectNet, a foundation machine learning model that predicts the chemical identity and concentration of substitutional point defects with multiple coexisting elements directly from vibrational spectra, specifically phonon density-of-states (PDoS). Trained on over 16,000 simulated spectra from 2,000 semiconductors, DefectNet employs a tailored attention mechanism to identify up to six distinct defect elements at concentrations ranging from 0.2% to 25%. The model generalizes well to unseen crystals across 56 elements and can be fine-tuned on experimental data. Validation using inelastic scattering measurements of SiGe alloys and MgB 2 superconductor demonstrates its accuracy and transferability. Furthermore, our work establishes vibrational spectroscopy as a viable, non-destructive probe for bulk point defect quantification, and highlights the promise of foundation models in data-driven defect engineering.

artificial intelligence↗

DOE OSTI2020

Microstructure-based prediction of thermal aging strength reduction factors for grade 91 ferritic-martensitic steel

This study aimed to develop a microstructure-based mechanistic approach to address the long-term thermal aging effect on yield stress and ultimate tensile strength and to provide a physical basis for developing thermal aging factors for G91 for a design life of 60 years. Several heats of G91 steel were examined. Controlled aging experiments were conducted on two heats at temperatures of 550, 600, and 650 °C for times up to ~64,000 h. Specimens were also taken from archived creep-tested specimens of G91 and from a tube removed from the Kingston coal-fired power plant to obtain data that cover a wide range of temperatures and for aging times up to 155,000 h. Thermal aging caused significant subgrain recovery, coarsening of M 23 C 6 carbides at subgrain boundaries and MX carbonitrides within subgrains. The intermetallic Laves phase forms during aging and grows rapidly. The growth rate of the subgrain width and MX mean size during thermal aging were described by kinetic models. Thermal aging results in the reductions in the yield stress and the ultimate tensile strength of G91. The effects of thermal aging on the reductions in yield stress and ultimate tensile strength were well described by the microstructure-strength model that considers three superimposed strengthening mechanisms, namely, sub-boundary strengthening, MX precipitation hardening, and Mo solid solution strengthening. Furthermore, the model was independently validated by the ASME Code values and is being used by the ASME to develop the aging-induced strength reduction factors for G91 steel for a design life of 60 years.

36 MATERIALS SCIENCE↗