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DOE OSTI2026

Hierarchical Epoxy Structures via Tunable Polymerization-Induced Phase Separation Combined with Additive Manufacturing

Polymerization-induced phase separation (PIPS) allows for the control of thermoset morphologies and properties, enabling the tuning of domain sizes and thermomechanical response. However, its use in generating substructural features in additively manufactured materials has been limited. In this work, we combine epoxy PIPS with UV curable acrylate and rheological modifiers to print nano- to macro-phase separating materials via a two-step, dual-cure approach. This method enables direct ink write printing of hierarchical structures with both controlled morphologies through phase separation and macroscale architecture through print design. We find that formulations for phase-separating materials require judicious incorporation of additives to enable printability and to provide sufficient green strength. Atomic force microscopy-nano infrared mapping reveals tunable, reticulated nano- to micron-scale domains of the resultant multiphase materials and their morphology changes due to additives, resulting in alterations to thermomechanical and tensile properties. Shape memory behavior is also demonstrated through multimaterial additive manufacturing of epoxies with functionally graded internal morphology using active mixing techniques, highlighting this method’s ability to fabricate complex architectures with controlled morphologies and thermomechanical response.

Van Meter, Kylie E [Organic Materials Science, San↗

DOE OSTI2024

Facets control charge separation during photoelectrochemical water oxidation with strontium titanate (SrTiO 3 ) single crystals

The photocatalytic overall water splitting reaction provides a pathway to hydrogen fuel from sunlight. Photocatalysts must achieve the reaction without the application of an external bias, which requires an effective charge separation mechanism. Photolabeling studies and electrostatic simulations for the well-known CoOOH/Al:SrTiO 3 /Rh/Cr 2 O 3 photocatalyst suggest that charge separation is driven by work function differences at the (100) and (110) facets of SrTiO 3 , which are electron and hole selective, respectively. Here we use hydrogen annealed SrTiO 3–x single crystals to obtain the first quantitative assessment of the charge separation ability of the (100), or (110), or (111) facets during oxygen evolution. Under UV illumination (60 mW cm –2 ), the crystals exhibit variable water oxidation photocurrents (0.34, 0.82, 1.36 mA cm –2 at 1.23 V versus RHE) and photovoltage values of 1.40, 1.52 and 1.52 V for (100), (110), and (111) SrTiO 3–x , respectively. A surface photovoltage increase in that same order (0.31 V < 0.57 V < 0.67 V) is confirmed independently with vibrating Kelvin probe surface photovoltage spectroscopy (VKP-SPV) under 375 nm (1.91 mW cm –2 ) illumination. Mott Schottky measurements in aqueous K 3/4 [Fe(CN) 6 ] reveal facet-dependent flatband positions of –0.58, –0.71, and –0.74 V RHE for the (100), (110), and (111) crystals respectively. This confirms that the photoelectrochemical water oxidation performance of SrTiO 3–x crystals is controlled by the work function of each facet, which determines the electron transfer barrier height of the respective solid–liquid junctions. After correcting for differences in electron donor concentrations, barriers are found to increase in the order (100) < (111) < (110) and differ by as much as 0.16 eV, similar to an earlier prediction. Altogehter, these results explain the charge separation mechanism in SrTiO 3 photocatalysts and highlight the need for faceted semiconductor crystals as light absorbers in particle-based photocatalysts.

08 HYDROGEN↗

DOE OSTI2026

Transition Metals Separation with Commercial Neutral Extractants – A Review

The increasing use of extraction chromatography resins across fields such as hydrometallurgy, nuclear medicine, and environmental analysis has created a need for a deeper understanding of their interactions with transition metals. Despite extensive research on f-element separations, the behavior of transition metals in these systems remains relatively understudied. This review provides a comprehensive overview of the current state of knowledge on the extraction behavior of transition metals with neutral extractants, including TODGA, TEHDGA, TBP, and CMPO, and their corresponding resins, such as DGA, BDGA, UTEVA, TBP, and TRU. The review summarizes extraction data, extracted complex coordination environments, separation reaction stoichiometries, and associated thermodynamics, highlighting inconsistencies and knowledge gaps in the literature. The study emphasizes the need for further research using spectroscopy and computational methods to elucidate extraction mechanisms and to improve the efficiency and selectivity of transition metal separations. By identifying areas for future research and development, this review aims to stimulate advancements in the field and promote the development of innovative separation technologies. The implications of this research are far-reaching, with potential applications in nuclear waste management, nuclear forensics, metal recovery, and environmental remediation. Overall, this review provides a foundation for future studies on the extraction of transition metals using neutral extractants and resins.

Wall, Nathalie A.↗

DOE OSTI2024

The Chalkboard: An Introduction to Electrochemical Separations

Chemical separations are a cornerstone of industrial manufacturing processes that generate products and services that have improved the standard of living for humans across the globe. To give some context as to how ubiquitous separations are in the modern world, they are involved in the production of fuels, medicines, clean water, fertilizers, materials used in semiconductor chip manufacturing, and other goods. A 2019 report by the National Academies of Sciences, Engineering, and Medicine highlights that chemical separations account for about 10 to 15% of energy use in the United States. Of the four broad sectors (residential, transportation, industry, and commerce) that use energy in the United States, industry has the largest use at 32% and about half of the energy use in industry hails from separations. It is likely that the transportation and residential sectors will experience significant decarbonization in the next 25 years with the proliferation of wind and solar energy sources coupled with electrochemical energy storage and electrification of vehicles. Finally, industrial decarbonization, on the other hand, is far more complex and challenging and it is imperative that future engineers and scientists work hard to devise alternative processes that can be powered on renewable electrons while generating little waste to produce the goods and services that make up our modern lives.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Development of Mixed Matrix Membranes by Using NH 2 ‐Functionalized UiO‐66 and [APTMS][AC] Ionic Liquid for the Separation of CO 2

The ever‐escalating CO 2 concentration in the atmosphere calls for accelerated development and deployment of carbon capture processes to reduce emissions. Mixed matrix membranes (MMMs), which are fabricated by incorporating the beneficial properties of highly selective inorganic fillers into a polymer matrix, have exhibited significant progress and the ability to enhance the performance of a membrane for gas separation. In this research, an amine‐based ionic liquid (IL) [APTMS][AC] was prepared, which has greater CO 2 affinity and greater solubility due to its amine moiety. The metal–organic framework (MOF) UiO‐66 with a multidimensional crystalline structure was used as a filler due to its appropriate porosity and tunable properties, and it was functionalized with NH 2 . MOFs were further modified with an IL to prepare UiO‐66@IL and UiO‐66‐NH 2 @IL, and MMMs incorporating each MOF were fabricated with the polymer Pebax‐1657. All the prepared membranes and MOFs were characterized to predict their separation efficiency. Several characterization techniques, namely, FTIR spectroscopy, XRD, and SEM, were used to successfully synthesize UiO‐66@IL and UiO‐66‐NH 2 @IL composites and confirmed proper dispersion and excellent polymer‒filler compatibility at filler loadings ranging from 0 to 30 wt.%. The separation performances were investigated, and the results showed that the incorporation of RTIL with the highly crystalline structure and large surface area of UiO‐66 enhanced the separation efficiency of the membrane. The permeability of CO 2 for all fabricated membranes continuously increased with increasing filler concentration, wherein the permeability was comparatively high for the UiO‐66‐NH 2 MMMs. The CO 2 /CH 4 selectivity improved by 35%, 54%, and 60%, respectively, for UiO‐66@IL, UiO‐66‐NH 2 , and UiO‐66‐NH 2 @IL MMMs compared to simple UiO‐66 for CO 2 /CH 4 and by 28%, 36%, and 63%, respectively, for CO 2 /N 2 , with an increase in filler loading in the MMMs.

Khalid, Hafiza Mamoona (ORCID:0009000135165855)↗

DOE OSTI2024

Nanoconfined Interfaces for Highly Selective Separation of Critical Rare Earth Elements

Industrial demand for rare earth elements (REEs) has surged over the past three decades due to their unique properties that support sustainable energy and new technologies. Separating individual REEs is challenging and hazardous, typically done through liquid-liquid extraction. There is an urgent need for environmentally friendly and efficient separation technologies for REEs. Porous materials offer promising advances for sustainable REE separation via ion-selective capture. We hypothesize that REE separation can be efficiently achieved in reactive nanopores, such as Zr(IV) and Cr(III) metal-organic frameworks (MOFs), through surface functionalization. By integrating material synthesis, interfacial chemistry experiments, theory, computation, and machine learning, we gained insights into the chemical factors controlling REE speciation and their competitive adsorption on MOFs. Our findings show that these materials’ selectivity can be tuned by surface functionalization. The machine learning component addressed ion-specific diffusion based on MOF topology and chemistry.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Leveraging Macrocyclic Chelators for Rare Earth Element Separations

The long-term objective of this project is to develop new, more energy-efficient and environmentally benign separations of the rare earth elements. The current approaches to separate the rare earth elements employ liquid-liquid extraction methods, using a biphasic mixture of aqueous and organic solvents containing different metal-binding agents. Although a significant amount of work has been carried out to develop new organic-phase extractants, significantly less has been executed for the design of aqueous complexants. Our approach to achieve better rare earth separations is to modify and optimize these aqueous complexants for achieving different rare earth-binding properties. Once synthesized, these new complexants were evaluated for more environmentally friendly and energy-efficient separations of the rare earth elements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Operation of Argonne's Liquid Salt-Liquid Metal Separation Testbed for U/TRU Product Processing

Argonne National Laboratory has constructed a liquid salt-liquid metal separation testbed for use in the development and advancement of cathode processing of U/TRU co‑deposits generated by pyroprocessing of used nuclear fuel. The U/TRU product recovered from the electrorefiner contains adhered and entrained salt that must be removed prior to consolidation of the U/TRU alloy for use in advanced reactor fuel fabrication. The bottom pour operation utilizes the low melting points of U/TRU co‑deposits and higher densities of molten metals compared to molten salts to separate and consolidate the U/TRU product. Argonne’s testbed is designed to support the development and optimization of bottom-pouring configurations for batch and semi-continuous operations, integration of process monitoring and control technologies, and determination of operational requirements for implementing in an industrial setting. Scoping tests were performed to demonstrate operational aspects of the testbed, including operation using single-pour spout and dual-pour spout configurations, effectiveness of salt containment and extent of salt vaporization, and the use of sensor probes to detect the location of the interface between the metal and salt phases during pouring. Recommendations for process optimization testing for further development of bottom pour processing to separate U/TRU alloys from adhered salt were made based on the results of scoping tests. Completing the recommended activities will increase the technical readiness level (TRL) of the liquid salt-liquid metal separation operation and consolidation of U/TRU alloys to support industrialization of pyroprocessing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

BOTTLE: Hybrid Chemical-Mechanical Separation and Upcycling of Mixed Plastic Waste

The main objective of this project is to develop a hybrid mechanical-chemical recycling technology for multilayered and laminated plastics. We aimed to separate and upcycle up to more than 80% of the two main constituents of such structures, polyolefins and polyesters, for a significantly lower cost and at higher energetic efficiency and much larger throughputs than chemical recycling. At the end of the project, the team was able to: a) Develop an extrusion-based separation technology that resorts to polyester depolymerizaton and extraction and allows for more than 90% of the polyester to be separated in the melt from the main polyolefin stream. b) Depolymerize the separated PET to more than 90%, which facilitates its posterior repolymerization and guarantees its retention in the polymer value-chain. c) Develop a zeolite-induced extrusion-based technology able to conduct continuous catalytic cracking of polyolefins, including highly contaminated PCR streams, at temperatures as low as 350 OC. d) Show, using LCA/TEA analysis that the two technologies are much more advantageous techno-economically and over the material’s life cycle than existing recycling technologies.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Holography vs. Scale Separation

In this work, we point out a contradiction between holography and scale-separated AdS (i.e. parametrically large mass gap) in string theory, making the standard assumption that the holographic CFT describes the IR degrees of freedom on a brane that decouple from gravity. We show that the CFT can only decouple from gravity if the scalar potential in the dual AdS satisfies a certain criterion. Namely, there must exist a scalar field trajectory that follows the gradient of the scalar potential to the asymptotic region of the scalar field space in which limit $\partial_ϕ\ln(V)\partial_ϕ\ln(Λ_s)\leq2/(d-2)$, where $Λ_s$ is the quantum gravity cut-off. This condition, which generically implies lack of scale-separation, is satisfied in the standard examples of AdS/CFT. However, proposed attempts at achieving scale separation, such as DGKT, employ scalar potentials that violate this condition. We therefore conclude that the CFT duals of DGKT vacua cannot exist in string theory. Barring fine-tuning, our conclusions apply to other Ricci-flat flux compactifications including the KKLT scenario which relies on scale separation to obtain a metastable de Sitter uplift.

FOS: Physical sciences↗

NASA NTRS1972

Lifetime estimates for sterilizable silver-zinc battery separators

The lifetime of separator membranes currently employed in the electrolyte environment of silver-zinc batteries was estimated at 3 to 5 years. The separator membranes are crosslinked polyethylene film containing grafted poly (potassium acrylate)(PKA), the latter being the hydrophilic agent which promotes electrolyte ion transport. The lifetime was estimated by monitoring the rate of loss of PKA from the separators, caused by chemical attack of the electrolyte, and relating this loss rate to a known relationship between battery performance and PKA concentration in the separators.

Cuddihy, E. F.↗

NASA NTRS1973

Separation over a flat plate-wedge configuration at oceanic Reynolds numbers

An experimental study of flow over a two-dimensional flat plate-wedge configuration is presented. The investigation encompasses a range of Reynolds numbers characteristics of conditions encountered by deep submersible oceanic vehicles. Flow separation, similar to that found on high speed aircraft control surfaces, is reported and discussed in light of the laminar or transitional nature of the separated shear layer. As discovered in previous high Mach number studies of plate-wedge or ramp configurations, the dependency of the size of the separated region on free stream Reynolds number is reversed for laminar and transitional types of flow separation.

Campbell, D. R.↗

NASA NTRS1973

Inorganic separator technology program

Testing and failure analyses of silver zinc cells with largely inorganic separators were performed. The results showed that the wet stand and cycle life objective of the silver-zinc cell development program were essentially accomplished and led to recommendations for cell composition, design, and operation that should yield further improvement in wet and cycle life. A series of advanced inorganic materials was successfully developed and formulated into rigid and semiflexible separator samples. Suitable screening tests for evaluation of largely inorganic separators were selected and modified for application to the separator materials. The results showed that many of these formulations are potentially superior to previously used materials and permitted selection of three promising materials for further evaluation in silver-zinc cells.

Smatko, J. S.↗

NASA NTRS1973

Dynamic effects of shock-induced flow separation.

Shock-induced flow separation is the flow mechanism usually responsible for what the structural dynamicist terms 'buffet.' The shock-induced flow separation affects the aeroelastic response via two different mechanisms: (1) the flow separation generates fluctuating pressures, i.e., a forcing function that is independent of the motion of the aerodynamic surface, e.g., an aircraft wing, and (2) the flow separation affects the motion-dependent forces and can in some cases generate negative aerodynamic damping. A simple analysis is presented which, using static experimental data as an input, can predict these two buffet-components for a wing in high Mach number subsonic flow.

Ericsson, L. E.↗

NASA NTRS1973

The rate of separation of magnetic lines of force in a random magnetic field.

The mixing of magnetic lines of force, as represented by their rate of separation, as a function of distance along the magnetic field, is considered with emphasis on neighboring lines of force. This effect is particularly important in understanding the transport of charged particles perpendicular to the average magnetic field. The calculation is carried out in the approximation that the separation changes by an amount small compared with the correlation scale normal to the field, in a distance along the field of a few correlation scales. It is found that the rate of separation is very sensitive to the precise form of the power spectrum. Application to the interplanetary and interstellar magnetic fields is discussed, and it is shown that in some cases field lines, much closer together than the correlation scale, separate at a rate which is effectively as rapid as if they were many correlation lengths apart.

Jokipii, J. R.↗

NASA NTRS1973

Analysis of the Flow About Delta Wings with Leading Edge Separation at Supersonic Speeds

A research program was conducted to develop an improved theoretical flow model for the flow about sharp edge delta wings with leading-edge separation at supersonic speeds. The flow model incorporates a representation of the secondary separation region which occurs just inboard of the leading edge on such wings and is based on a slender-wing theory whereby the full three-dimensional problem is reduced to a quasi two-dimensional problem in the cross-flow plane. The secondary separation region was modeled by a surface distribution of singularities or a linearized type of cavity representation. The primary vortex and separation were modeled by a concentrated vortex and cut in the cross-flow potential which represents its feeding sheet. The cross-flow solutions for the cavity model were obtained, but these solutions have physical significance only in a very restricted range of angle of attack. The reasons for the failure of the flow model are discussed. The analysis is presented so that other interested researchers may critically review the work.

Nenni, J. P.↗

NASA NTRS1974

Separated flow over bodies of revolution using an unsteady discrete-vorticity cross wake. Part 2: Computer program description

A method is developed to determine the flow field of a body of revolution in separated flow. The computer was used to integrate various solutions and solution properties of the sub-flow fields which made up the entire flow field without resorting to a finite difference solution to the complete Navier-Stokes equations. The technique entails the use of the unsteady cross flow analogy and a new solution to the two-dimensional unsteady separated flow problem based upon an unsteady, discrete-vorticity wake. Data for the forces and moments on aerodynamic bodies at low speeds and high angle of attack (outside the range of linear inviscid theories) such that the flow is substantially separated are produced which compare well with experimental data. In addition, three dimensional steady separated regions and wake vortex patterns are determined. The computer program developed to perform the numerical calculations is described.

Marshall, F. J.↗

NASA NTRS1974

The numerical calculation of laminar boundary-layer separation

Iterative finite-difference techniques are developed for integrating the boundary-layer equations, without approximation, through a region of reversed flow. The numerical procedures are used to calculate incompressible laminar separated flows and to investigate the conditions for regular behavior at the point of separation. Regular flows are shown to be characterized by an integrable saddle-type singularity that makes it difficult to obtain numerical solutions which pass continuously into the separated region. The singularity is removed and continuous solutions ensured by specifying the wall shear distribution and computing the pressure gradient as part of the solution. Calculated results are presented for several separated flows and the accuracy of the method is verified. A computer program listing and complete solution case are included.

Klineberg, J. M.↗