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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 469 records · Page 26

Data‐Driven Insights into Rare Earth Mineralization: Machine Learning Applications Using Functional Material Synthesis Data

Understanding rare‐earth element (REE) mineralization mechanisms is essential for developing efficient separation strategies. Although the geochemical pathways that generate REE deposits are qualitatively known, quantitative links between specific conditions and mineralization outcomes remain limited. Herein, the repurpose laboratory REE hydrothermal synthesis data—originally collected for functional‐materials fabrication—as a surrogate for studying mineralization with data‐driven methods. The compiled 1,200+ hydrothermal reaction records and trained three machine‐learning models—K‐nearest neighbors (KNN), random forest (RF), and extreme gradient boosting (XGB)—to predict product elements and phases from precursors, additives, reaction conditions, and engineered features. Validation shows XGB achieves the highest accuracy. Feature importance indicates thermodynamic properties of cations and anions dominate model decisions. Correlations reveal positive relationships among precursor concentration, reaction time, pH, and temperature, consistent with classical crystallization behavior. XGB‐based regressors are built to predict crystallization temperature and pH from precursor/product attributes. Performance is strongest when similar training examples exist, while accuracy declines for underrepresented reactions, notably REE carbonates and heavy‐REE systems. Overall, the study shows that functional‐materials datasets can illuminate REE mineralization and provide priors for exploration and processing. Expanding datasets with less‐studied chemistries and conditions will improve generality and support deposit discovery and more efficient REE recovery.

feature importance analysis↗

Report on the Assessment of Ion Irradiations on High Entropy Alloys

Idaho National Laboratory (INL) initiated a joint international effort with the Czech Republic to explore the feasibility of manufacturing High Entropy Alloys for high-temperature nuclear applications using Additive Manufacturing. This effort was funded at INL by the United States Department of Energy’s Office of Nuclear Energy under the Advanced Reactor Technologies and Advanced Materials and Manufacturing Technologies (AMMT) Program. The High Entropy Alloys were specifically designed for the corrosive and irradiation environments as experienced in gas fast reactors, molten salt reactors, and fusion power. These alloys were manufactured by multiple processes to determine the impact of manufacturing processes on the performance of the alloys in corrosive and irradiation environments. Preliminary results show that MoNbTiV and MoNbTi alloys exhibit no degradation after multiple corrosion tests. These MoNbTiV and MoNbTi alloys were also evaluated after irradiation experiments were conducted at the Michigan Ion Beam Laboratory at the University of Michigan, which is the focus of this milestone report. For these irradiation experiments, the MoNbTiV and MoNbTi alloys manufactured by arc melting and Electric Field Assisted Sintering (EFAS) were tested at 500 C at a dose of 30 dpa to evaluate the microstructural stability and decomposition.

36 - MATERIALS SCIENCE↗

Development of Casting Techniques for d-phase Uranium-Zirconium Alloys: CRADA 524 [Abstract only]

Casting of d-phase HALEU UZr2 alloy is an early milestone in the fabrication process for Lightbridge Fuel™. The Radiochemical Processing Laboratory at PNNL has been identified as having both the capability and expertise to perform the necessary high temperature casting of samples of Lightbridge’s alloy. The necessary equipment, facility licensing, and shipping capabilities for special nuclear material coupled with its expertise in uranium casting techniques makes PNNL uniquely suited to this project.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Summer Student Internship: Experimental and modeling experiences

My internship at the Los Alamos National Laboratory has been an information-filled summer. Loren Espada-Castillo brought me into her project and helped mentor and guide me through the summer. The project that I was brought into was the process of shooting materials with electrons. The electron beam we used conducts a series of shots in which electrons are generated and then fired towards a target, the sample holder. The sample holder holds either a single sample or three samples. The sample holder also consists of multiple calorimeters surrounding the sample/s. The goal is to shoot certain materials and then analyze how they react to the exposure of the electrons. We shot titanium, which was meant to serve as a containment vessel window.

36 MATERIALS SCIENCE↗

Cadmium Telluride Photovoltaics Accelerator Consortium Solicitation: Request for Proposals Information

Cadmium telluride photovoltaics (CdTe PV) is a leading PV technology built on U.S. innovations that currently holds significant market share within domestic utility scale PV systems. In order to keep pace with a highly competitive and innovative global PV module market, CdTe manufacturing needs readily adaptable advances at the cell and module levels that simultaneously enable higher conversion efficiencies and manufacturing cost reductions without risking long-term module durability. In pursuit of this goal, the Department of Energy (DOE) Solar Energy Technologies Office (SETO) has asked the National Renewable Energy Laboratory (NREL) to launch and support a Consortium to accelerate domestic CdTe technology development through a competitive solicitation process. NREL will competitively select a CdTe Consortium with the goals of enhancing U.S. competitiveness and expanding domestic CdTe PV material and module production through 2030. NREL will provide coordination and oversight through development of technical scopes, review of technical proposals, subcontract support, and review of deliverables along with research support to the Consortium. The new Consortium is expected to include major U.S. companies and universities that possess strong technology development, transfer, and validation capabilities. The research and analysis output of the CdTe Consortium will inform purchasing, design, deployment, and operations decisions of companies in the domestic CdTe PV supply chain, leading to increased material and module production in the U.S.

41 EE - Solar Energy Technologies Office (EE-4S)↗

Final Technical Report for DoE award DE‐SC0023367 “Energetic Electron Transport in Magnetized Plasma with Magnetic Islands”

This project investigated how plasmas interact with energetic particles and solid materials under extreme conditions relevant to fusion energy, space plasmas, and planetary environments. Using experiments on the DIII-D National Fusion Facility, the research first examined how high-energy electrons move, become trapped, and are released in plasmas containing magnetic islands—structures commonly found in fusion reactors and Earth’s magnetosphere—providing new insight into particle transport and acceleration processes. The project also explored plasma-driven chemical reactions that can occur during meteoroid entry into planetary atmospheres, demonstrating that simple molecules such as ammonia can be produced and survive in high-temperature plasma conditions. Together, these results improve understanding of plasma behavior across laboratory, space, and planetary systems while informing fusion plasma control and plasma–material interaction studies. The project additionally contributed to workforce development by training graduate students, undergraduates, and early-career researchers and by disseminating results through peer-reviewed publications and international scientific conferences.

Orlov, Dmitri Mikhailovich [UC San Diego] (ORCID:0↗

Benchmarking the AirSquared All-Metal Scroll Pump Against the Normetex 15 - Preliminary report

Tritium operations require specialized equipment for material compatibility, safety, and waste considerations. Non-metallic pump materials (polymer, oil, or grease) on a tritium-wetted surface can absorb tritium and/or undergo isotope exchange between tritium and more common protium, creating tritiated compounds that can result in material property modification via beta-radiolysis, inventory loss, reduced performance and special waste considerations, all of which increase the operating cost for a facility. Vacuum pumps move gas via a pressure differential between volumes of an operation. Several types of all-metal vacuum pumps exist for this application including metal bellows, diaphragm and scroll pumps. A metal bellows pump incorporates only metal components at the wetted surfaces. The common metal bellows pump employed in tritium facilities, the MB601 (Senior Metal Bellows, Sharon, PA, USA) creates a gas-motive force with a vacuum pressure between 30-40 torr. These pumps can efficiently move gas from one process step to another, as long as sub-30 torr pressures are not required. However, for higher vacuum demand, an all-metal scroll pump can be used with the bellows pump serving as a “backing” pump. This configuration typically provides an achievable vacuum of less than 20 mTorr. All-metal scroll pumps are a technology uniquely applicable to tritium gas handling. The industry standard all-metal scroll pump for glovebox-scale tritium operations is the Normetex 15 m 3 /hr, typically referred to as the Normetex 15 (Normetex Pompes, Pont Audemer, France). However, the final Normetex pumps were manufactured in 2012, rendering them no longer available. Eumeca SaRL (formerly Normetex) has developed and is marketing a scroll pump based on the design of the Normetex 15. A US company, AirSquared (Broomfield, Colorado), has developed and is marketing a potential alternative to the Normetex 15. The Gas Transfer Systems group (Q-7) of the Los Alamos National Laboratory (LANL) procured serial number 0001 of the AirSquared All Metal Vacuum Scroll pump model number V16H034A-C01 in 2019. The LANL Hydrogen Processing Laboratory (HPL) has been evaluating the performance of the pump compared to a Normetex pump as a potential replacement in tritium and fusion facilities requiring this type of pump.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Solar Thermochemical Carbon Dioxide Splitting Using Ceria and Iron Aluminate Foam Devices and Simulation of a Plant System for Demonstration

An international research project has been undertaken to integrate a unique solar thermal processing reactor system with ceria and iron aluminate as active redox materials for CO2 splitting. Experimental investigations for CO2 splitting were conducted using a solar simulator and tube furnace at Niigata University, followed by demonstrations using a high-flux solar furnace (HFSF) at the National Renewable Energy Laboratory (NREL) in Golden, CO. Each experimental setup consisted of foam devices composed of reticulated porous ceramic (RPC). The RPC has a full ceria or iron aluminate body. It fabricated using the replica method and subjected to a two-step redox reaction, which iteratively separated a stream of CO2 into O2 and CO. Reactivity was evaluated using CO production per mass of the reactive material. The tubular furnace yielded a CO production of 6.41 mL/g at a reduction temperature of 1600degrees C, showcasing a higher CO production rate and total amount than those obtained from experiments conducted with solar simulators and solar furnace setups. For iron aluminate RPC, the productivity was measured as 3.57 mL/g using HFSF at a reduction temperature of 1450degrees C. These results are somewhat higher than those of the previous experiment at lower reduction temperatures of 1400degrees C-1500degrees C. Additionally, the production of CO in the case of ceria RPC was compared with the steady flow model simulation, which assumed chemical equilibrium at various levels of oxygen partial pressure during the reduction process. On the basis of these results, this study proposes a solar fuel system with an open receiver that uses a high-temperature heat transfer fluid.

carbon dioxide thermochemical splitting↗

Paths to circularity for plastics in the United States

In 2019, the United States consumed over 57 million metric tons (MMT) of plastic with less than 7% recovered for reuse. This study provides an updated material flow analysis at national and regional scales for all durable and single-use plastics in the United States. From this material flow analysis, we develop a series of alternative future national plastic flow scenarios that envision a scale-up of recycling technologies, incorporating technical limitations and sorting infrastructure constraints. The results suggest that a maximum of 68% (24 MMT) of plastic waste could be diverted from landfills by scaling up existing commercial recycling technologies. Based on the current technological landscape, reaching near-zero waste is only possible if processes that are operating at pilot and laboratory scales can be effectively scaled and coupled with improved sorting infrastructure. Through these scenarios with increased recycling, the availability of postconsumer resin stocks could increase by 22–43 MMT.

36 MATERIALS SCIENCE↗

Mesoscale Magnetostructural Phase Separation in Fe‐deficient Fe 5 GeTe 2

Two-dimensional van der Waals ferromagnet Fe 5-x GeTe 2 (F5GT) is promising for spintronic applications due to its high Curie temperature, layered structure, and ability to host complex magnetic textures. However, the origin of its sample-dependent magnetic anisotropy remains unclear, hindering control of its magnetic behavior. Here, we use spatially resolved cryogenic scanning transmission electron microscopy (STEM) to correlatively map magnetism, lattice structure, and chemistry across atomic-to-micron scales. We reveal that only mesoscale, not nanoscale, inclusions of a Fe-deficient secondary phase significantly modify magnetic behavior, establishing a previously unrecognized critical length scale. This phase separation, induced by quenching, leads to in-plane magnetic anisotropy, while slow cooling confines separation to a few nanometers and preserves out-of-plane anisotropy. These findings reconcile prior inconsistencies and establish a predictive framework for tuning magnetism in F5GT through thermal processing, with broader implications for controlling anisotropy in other two-dimensional magnetic materials.

2D ferromagnets↗

Mechanical Characteristics of Additively Manufactured ODS 316L and 316H Alloys with and Without Post-build Processing

This research aims to explore an accelerated development path for oxide dispersion-strengthened (ODS) alloys by integrating additive manufacturing (AM) technologies with recent advances in ODS materials and traditional manufacturing methods. Novel AM and post-build processing routes have been developed for ODS austenitic alloys, specifically Fe-Cr-Ni alloys like 316L and 316H. Electron microscopy and mechanical characterizations were conducted to evaluate the effects of process variables on microstructure and properties, aiming for an economically feasible route property optimization. Traditionally, ODS alloy production involves multi-day high-energy mechanical milling of alloy powder with yttria (Y 2 O 3 ) followed by powder consolidation via extrusion or other methods and additional thermomechanical processing (TMP) for property control. Here, to address these challenges associated with this complex and costly approach, we propose exploring alternative, cost-effective processing routes focusing on AM and traditional TMP methods. The new ODS alloy processing routes have achieved up to a 400% increase in yield strength and a 60% increase in ultimate tensile strength compared to wrought stainless steels while still maintaining significant ductility and fracture toughness. This paper details the novel and economical AM-based processing routes for ODS austenitic alloys, combined with post-build TMPs, and discusses the mechanical and microstructural characteristics of the developed materials.

Byun, Thak Sang [Oak Ridge National Laboratory (OR↗

ExaCA v2.0: A versatile, scalable, and performance portable cellular automata application for additive manufacturing solidification

The previously established ExaCA software for performance portable alloy grain structure simulation has been updated to better represent the solidification behavior during complex alloy processing conditions, such as those encountered during metal additive manufacturing (AM), and for improved performance and scalability. Here, an extension to the time–temperature history input data format and the core ExaCA algorithm to include an arbitrary number of melting and solidification events yielded improved prediction of texture for various melt pool geometries, expanding the range of AM-relevant conditions that can be accurately simulated. Improved heat transport process simulation coupling, including the creation of large raster datasets from single track time–temperature history data and in-memory coupling with the new, performance portable finite difference code Finch, were also demonstrated in example studies on the effect of multilayer AM microstructure predictions on hatch spacing and cell size, respectively. Additional new features are detailed and demonstrated, including the ability to perform simulations using various interfacial response function forms, execute simulations on state-of-the-art hardware, improved usability through post-processing versatility, and improved strong and weak scaling performance. The performance, physics, and versatility improvements demonstrated here will further enable large-scale studies on AM process–microstructure relationships that were not previously possible. Furthermore, the usability improvements and ability to run coupled AM process–microstructure simulations using the Finch-ExaCA workflow will facilitate broader use of this open-source software by the computational materials community.

36 MATERIALS SCIENCE↗

Machine learning approaches for intentional materials engineering

In this article, the development of nanoporous metals and metallic composites through dealloying processes presents significant opportunities in materials engineering. However, designing multicomponent precursor alloys and establishing corresponding processing methods that yield predictable compositions and nanostructures remain a complex challenge. This article explores how machine learning (ML)-augmented computational and experimental methodologies can tackle these challenges by predicting precursor alloy compositions, final nanoporous structures, and mechanical properties, while integrating ML-enabled autonomous experimentation for material design and quantification. We highlight recent advancements in applying ML to nanostructured materials design via dealloying and discuss how techniques from other nanomaterial designs can be adapted for improved control over morphological and compositional outcomes in nanoporous and nanocomposite materials. Furthermore, we explore the role of ML in autonomous synchrotron x-ray experimentation, enabling real-time feedback between modeling and experimental setups. ML-driven approaches to microstructure characterization and mechanical property prediction are also examined, with a focus on modeling and advanced imaging techniques such as three-dimensional nanotomography. Finally, this article outlines future directions for ML-enhanced materials science, emphasizing the exploration of high-dimensional parameter spaces and the incorporation of materials kinetics into processing and property evaluation, ultimately advancing the design of nanoporous structures and materials science.

36 MATERIALS SCIENCE↗

Exploration of signal processing methods for superconducting magnet and quench data

Quenching is the phenomenon of a superconducting magnetic material carrying current transitioning into a regular conducting material. This may cause severe and irreparable damage to the superconductor due to Joule heating. The Magnet Department at Fermi National Accelerator Laboratory (FNAL) has acquired experimental data through quench antenna arrays that are recorded when the quench is detected. These data are in terms of voltage signals that are sampled at 100kHz for several minutes. There are multiple channels and each channel provides a data set of more than 20 million observations, while there is one channel, called the trigger channel which shows the time when quench is detected. Despite some advancements that were made including machine learning, data complexity still shadows the progress. In this work, we studied a multi-resolution analysis of the quench antenna data through the Haar wavelet transform. In particular, we applied the maximally overlapped discrete w avelet transform (MODWT) of a suitable level L to the given data and then projected it onto the wavelet basis. This decomposes a given signal (Original data) $x ϵ \mathbb{R}^N$ into $L + 1$ subspaces of $\mathbb{R}^N$. One of the subspaces called the approximation, captures the trend of the signal, and the others, called the details, capture the fluctuations at different frequency bands. This decomposition provides a clear trend of the data at a suitable level and also various activities (spikes) are seen in the details of the decomposition at every level. These spikes might reveal some information about the quench under investigation but in any case, give information about magnet behavior. Also, this decomposition is seen to be very useful in removing noise present in the data due to the source or mechanism of the experiment.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Decision-Model Supported Algal Cultivation Process Enhancement (DMSACPE) (Final Technical Report)

This project was proposed in response to the FY19 Bioenergy Technologies Office Multi-Topic Funding Opportunity Announcement DE-FOA-0002029, Area of Interest Subtopic 1 (AOI1): Cultivation Intensification Processes for Algae. The main challenge identified by the FOA was “in translating results between laboratory research systems and larger-scale outdoor (or mass culture) systems. These difficulties limit reliable experimental durations, adequate and representative experimental volumes of material, and results that can be reproduced reliably. By overcoming the challenge in translating results between laboratory and mass cultures, the objective of AOI 1 is to increase the harvest yield, robustness, and quality of algae cultivation for biofuels and bioproducts”. This report marks the final technical deliverable of this project and reviews all the major findings of the research program.

09 BIOMASS FUELS↗

NREL's Biochemical Conversion Pilot Plant Capabilities

NREL's biochemical conversion plant is a flexible pilot plant for testing a wide range of bio-based technologies for producing renewable fuels and byproducts. The biochemical conversion pilot plant is housed in the Integrated Biorefinery Research Facility located on the National Renewable Energy Laboratory's (NREL's) main campus. The facility provides industry partners the opportunity to test and develop their own biorefining technology using NREL equipment or rental equipment that can be brought into the plant. The pilot plant can process materials up to one dry ton per day in an integrated fashion using a variety of operating modes including batch, fed-batch, and continuous processing.

biochemical↗

Production of National Nuclear Material Archive Subsamples for High Precision Chemical Analysis

With its historical mission as the focal point for production of uranium components for the NNSA nuclear weapons program, the National Nuclear Materials Archive (NNMA) makes use of Y-12's wide range of uranium materials processing knowledge and onsite materials to identify, collect, and preserve sample materials for nuclear forensics purposes. In 2019, Y-12 took on the responsibility for identifying, subsampling, and shipping a total of 24 NNMA samples to the Lawrence Livermore National Laboratory (LLNL) for further forensics analysis. These were highly enriched uranium metal pieces representative of different weapon systems components produced by Y-12 from approximately 1963 to 1993. The purpose was to provide the NNMA program with higher precision analyses of these materials than what is currently available from historical Y-12 production stream data.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗

Transforming Energy Through Computational Excellence: High-Performance Computing for Energy Innovation

The challenges associated with energy efficiency of manufacturing and advanced materials often cannot be addressed through experimentation alone, whether because of scale, complexity, or practicality. High-performance computing (HPC) enables fast tackling of these challenges in the manufacturing sector - vital to achieving net-zero carbon emissions by 2050. The National Renewable Energy Laboratory (NREL) and industry partners leverage HPC to apply advanced modeling, simulation, and data analysis to improve manufacturing efficiency, explore new materials for energy applications, and develop technologies to manage carbon across the life cycle. From improving additive manufacturing processes to increasing the energy efficiency of jet-engine components, advanced computing can help manage emissions produced by manufacturing in a wide variety of ways.

advanced materials↗