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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Rapid Analytical Methodology for Chloride Molten Salt Reactor Safeguards and Process Monitoring

Technologies that enable near real-time isotopic analysis of advanced molten salt reactor (MSR) fuels are critically needed to safeguard these reactors, increase their operational efficiency, and enable their widespread deployment with confidence. We present a systematic approach to developing near real-time dissolution and chemical isolation of U, Pu, and major fission products from highly radioactive chloride molten salt samples. Chemical yields greater than 95% were observed for both uranium and the lanthanides. Interference reduction enabled the detection and quantification of key diagnostic isotopes (including 112Ag, 147Nd, and 153Sm) that were previously undetectable in the original sample. The results from this initial scoping study lay the foundation for the development of future automated systems that can enable cost-efficient, near-real time chemical separation and analysis of extremely highly radioactive molten salt samples.

38 - RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCL↗
DOE OSTI2024

First Measurements of Differential Cross Sections In Kinematic Imbalance Variables With The MicroBooNE Detector

Making high-precision measurements of neutrino oscillation parameters requires an unprecedented understanding of neutrino-nucleus scattering. In this presentation, we present the first muon neutrino charged current double-differential cross sections in kinematic imbalance variables. These variables characterize the imbalance in the plane transverse to an incoming neutrino. We use events with a single muon above 100 MeV/c, a single final state proton above 300 MeV/c, and no recorded final state pions. Thus, these variables act as a direct probe of nuclear effects such as final state interactions, Fermi motion, and multi-nucleon processes. We also present a complementary ongoing analysis using electron neutrinos. This channel is of the utmost importance for the extraction of neutrino oscillation parameters by making high-precision measurements. Our measurements allow us to constrain systematic uncertainties associated with neutrino oscillation results performed by near-future experiments of the Short Baseline Neutrino (SBN) program, as well as by future large-scale experiments like DUNE.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2025

Market Driven Residential Energy Codes: Comparing Performance in a Changing Technological Environment

The research project is undertaken to better understand the changing relationship between the two basic methods of building energy code compliance – prescriptive and performance – and how those methods relate to each other with respect to advancements in building energy computer simulation standards and capabilities. The International Energy Efficiency Code (IECC) is a model code adopted by many jurisdictions across the United States. Historically, the prescriptive compliance methodology has been preferred in most jurisdictions. The prescriptive methodology requires meeting or exceeding specific efficiency minimums for each envelope component. This tends to be a simple method to teach and verify. A more involved prescriptive alternative called the Total UA alternative is sometimes used. This method requires some multiplication, summing, and comparison to compute, so it is done with a fairly simple computer program. However, advances in computer and building energy simulation technology have resulted in increased use of more detailed performance compliance methods. The performance compliance method establishes the annual energy cost threshold via hourly simulation models. The compliance threshold is determined with a comparison building model simulation with geometry similar to the proposed home and with energy feature parameters and efficiencies as specified in the IECC. This project examines relationships between the two methods of building energy code compliance, including: • Overall annual energy use based on utility bill analysis by compliance method • Code official work processes with respect to compliance methods • Gaps and issues associated with building code compliance methods • Simulated energy use difference between compliance methods • Code compliance cost as a function of compliance method • Code compliance labeling effectiveness for high performance residences • Getting to net zero energy use and net zero greenhouse gas emissions through high performance code alternatives • Electronic code permitting and compliance alternatives

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Ammonium Looping with Membrane Absorber and Distributed Stripper for Enhanced Algae Growth

The objective of this project is to conduct a comprehensive investigation to develop and demonstrate a practical, reliable, and cost-effective integrated carbon dioxide (CO 2 ) capture and biofixation process for algae production. This process utilizes a chemical hindered ammonium solution (NH 4 OH) as both a capture reagent and an algae nutrient. The membrane absorber employed in the system ensured minimal ammonia (NH 3 ) emissions in the treated flue gas. Additionally, distributed solar-energy powered strippers located near the bioreactor modules facilitate solvent regeneration and enable just-in-time delivery of CO 2 and NH 3 to the algae, thereby minimizing the pH swing for enhanced productivity. The proposed membrane CO 2 absorber and solar-powered stripper is designed and seamlessly integrated with the existing 0.1 MWth bench-scale CO 2 capture system (CCS) and open raceway ponds (ORPs) at the University of Kentucky Center for Applied Energy (UK CAER) campus. The entire integrated process has undergone construction, operation, testing, and analysis. Furthermore, technology has been evaluated with a techno-economic analysis (TEA), technology gap analysis (TGA), life-cycle analysis (LCA), and a technology maturation plan (TMP). This project was performed within two budget periods, 54 months in duration. There are fourteen Project Tasks, twelve Milestones and four Success Criteria.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Reinventing wastewater treatment plants: energy neutral treatment and enhanced fertilizer production through a novel resource recovery center

Wastewater treatment plants (WWTPs) are typically energy intensive, mainly due to the secondary treatment processes such as activated sludge (AS) for treatment of organics as well as nutrients like nitrogen. Nitrogen removal presents a big problem for WWTPs. The main form of nitrogen in wastewater is ammonium, and an AS process uses oxygen to convert ammonium into nitrite and nitrate which is then converted to nitrogen through denitrification process. During anaerobic digestion (AD), organic nitrogen gets degraded, resulting in an effluent stream (centrate) with a high nitrogen content, mostly in the form of ammonium. This contributes 15-30% of total nitrogen to the wastewater influent which further increases energy consumption for aeration. The project aims to transform this conventional municipal WWTPs into energy-neutral, resource-recovering facilities by integrating three core technologies: • Cloth Media Filtration (CMF) to replace conventional primary sedimentation (CPS) and increase the diversion of organics from the energy intensive secondary treatment to AD. This results in reduced energy demand for aeration in the secondary process while simultaneously increasing the biogas production in the anaerobic digesters. • Anerobic Digester to increase biogas and ammonia production. • Membrane Evaporation (ME) to recover ammonia from AD centrate and produce marketable fertilizer. The benefits of proposed WWTP process modifications were evaluated using techno economic analysis (TEA) and life cycle assessment (LCA). For CMF portion of the research a statistical analysis was employed to develop data-driven tools that could be used to enhance and optimize its performance in terms of energy savings and effluent quality. The main objective of this project is to reduce the energy demand for secondary treatment at municipal WWTPs by at least 50%, increase anaerobic digester (AD) biogas and ammonia production by 100% and 120%, respectively, and recover 90% of ammonia from the AD. Integrated CMF, AD, and ME was shown to work synergistically toward achieving these decarbonization targets through energy-positive treatment and fertilizer recovery techniques.

42 ENGINEERING↗
DOE OSTI2025

Block Island Noise Modeling Data

Noise propagation near Block Island was simulated to assess environmental impacts of impact pile driving during wind turbine construction. Computational models complement field-recorded acoustic data, providing insights into sound attenuation, spectral variability, and propagation dynamics. The dataset includes: 1. Propagation Models: Simulated underwater sound fields documenting sound pressure and directional variability across frequency bands and distances. 2. Spectral Analysis (LTSA): Long-term averages and processed outputs calculating acoustic intensity over time. 3. Visualization Files: Graphs, 2D/3D simulation results, and reference calculations used in sound modeling.

17 WIND ENERGY↗
DOE OSTI2026

Human Lung Cellular Response to HCoV-229E Infection, Post-Translational Modification Proteomics Time Course (ACS-TZ-DP6)

The purpose of this experiment was to evaluate the human lung cellular response to wild type human coronavirus strain 229E (HCoV-229E) infection. Sample data was obtained for mock-infected and HCoV-229E infected immortalized human lung epithelial cells (A549) (MOI 3) and immortalized human lung fibroblasts (MRC-5) (MOI 3). Whole cell lysates were collected at 8, 16, and 24 hours post infection and were processed for post translational modification (PTM) proteomics analysis to determine the HCoV-229E phosphoproteome, redox proteome, and acetylation proteome.

Sims, Amy C [Pacific Northwest National Laboratory↗
DOE OSTI2024

Comparative Life Cycle Assessment of Bacterial and Thermochemical Retting of Hemp

The processes of hemp bast fiber retting, forming, and drying offer the opportunity for value-added products such as natural fiber-reinforced composites. A new process for the retting of raw bast fibers through enzyme-triggered self-cultured bacterial retting was developed in the lab-scale setup. This study focused on comparing the energy consumption and environmental impacts of this bacterial retting process with the thermochemical retting process currently widely used to obtain lignocellulosic fibers for composites. The gate-to-gate life cycle assessment (LCA) models of the two retting processes were constructed to run a comparison analysis using the TRACI (the tool for the reduction and assessment of chemical and other environmental impacts) method for environmental impacts and the cumulative energy demand (CED) method for energy consumptions. This work has demonstrated the advantages of the bacterial retting method from an environmental standpoint. The result of our research shows about a 24% gate-to-gate reduction in CED for bacterial retting and 20–25% lower environmental impacts relating to global warming, smog formation, acidification, carcinogenics, non-carcinogenics, respiratory effects, ecotoxicity, and fossil fuel depletion when compared to that of thermochemical retting.

Chemistry↗
DOE OSTI2024

Systematic and objective evaluation of Earth system models: PCMDI Metrics Package (PMP) version 3

Systematic, routine, and comprehensive evaluation of Earth system models (ESMs) facilitates benchmarking improvement across model generations and identifying the strengths and weaknesses of different model configurations. By gauging the consistency between models and observations, this endeavor is becoming increasingly necessary to objectively synthesize the thousands of simulations contributed to the Coupled Model Intercomparison Project (CMIP) to date. The Program for Climate Model Diagnosis and Intercomparison (PCMDI) Metrics Package (PMP) is an open-source Python software package that provides quick-look objective comparisons of ESMs with one another and with observations. The comparisons include metrics of large- to global-scale climatologies, tropical inter-annual and intra-seasonal variability modes such as the El Niño–Southern Oscillation (ENSO) and Madden–Julian Oscillation (MJO), extratropical modes of variability, regional monsoons, cloud radiative feedbacks, and high-frequency characteristics of simulated precipitation, including its extremes. The PMP comparison results are produced using all model simulations contributed to CMIP6 and earlier CMIP phases. An important objective of the PMP is to document the performance of ESMs participating in the recent phases of CMIP, together with providing version-controlled information for all datasets, software packages, and analysis codes being used in the evaluation process. Among other purposes, this also enables modeling groups to assess performance changes during the ESM development cycle in the context of the error distribution of the multi-model ensemble. Quantitative model evaluation provided by the PMP can assist modelers in their development priorities. In this paper, we provide an overview of the PMP, including its latest capabilities, and discuss its future direction.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

First Measurements of Differential Cross Sections In Kinematic Imbalance Variables With The MicroBooNE Detector

Making high-precision measurements of neutrino oscillation parameters requires an unprecedented understanding of neutrino-nucleus scattering. In this presentation, we present the first muon neutrino charged current double-differential cross sections in kinematic imbalance variables. These variables characterize the imbalance in the plane transverse to an incoming neutrino. We use events with a single muon above 100 MeV/c, a single final state proton above 300 MeV/c, and no recorded final state pions. Thus, these variables act as a direct probe of nuclear effects such as final state interactions, Fermi motion, and multi-nucleon processes. We also present a complementary ongoing analysis using electron neutrinos. This channel is of the utmost importance for the extraction of neutrino oscillation parameters by making high-precision measurements. Our measurements allow us to constrain systematic uncertainties associated with neutrino oscillation results performed by near-future experiments of the Short Baseline Neutrino (SBN) program, as well as by future large-scale experiments like DUNE.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

First Measurements of Differential Cross Sections In Kinematic Imbalance Variables With The MicroBooNE Detector

Making high-precision measurements of neutrino oscillation parameters requires an unprecedented understanding of neutrino-nucleus scattering. In this presentation, we present the first muon neutrino charged current double-differential cross sections in kinematic imbalance variables. These variables characterize the imbalance in the plane transverse to an incoming neutrino. We use events with a single muon above 100 MeV/c, a single final state proton above 300 MeV/c, and no recorded final state pions. Thus, these variables act as a direct probe of nuclear effects such as final state interactions, Fermi motion, and multi-nucleon processes. We also present a complementary ongoing analysis using electron neutrinos. This channel is of the utmost importance for the extraction of neutrino oscillation parameters by making high-precision measurements. Our measurements allow us to constrain systematic uncertainties associated with neutrino oscillation results performed by near-future experiments of the Short Baseline Neutrino (SBN) program, as well as by future large-scale experiments like DUNE.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Machine Learning Driven Sensitivity Analysis of E3SM Land Model Parameters for Wetland Methane Emissions

Methane (CH 4 ) is globally the second most critical greenhouse gas after carbon dioxide, contributing to 16%–25% of the observed atmospheric warming. Wetlands are the primary natural source of methane emissions globally. However, wetland methane emission estimates from biogeochemistry models contain considerable uncertainty. One of the main sources of this uncertainty arises from the numerous uncertain model parameters within various physical, biological, and chemical processes that influence methane production, oxidation, and transport. Sensitivity Analysis (SA) can help identify critical parameters for methane emission and achieve reduced biases and uncertainties in future projections. This study performs SA for 19 selected parameters responsible for critical biogeochemical processes in the methane module of the Energy Exascale Earth System Model (E3SM) land model (ELM). The impact of these parameters on various CH 4 fluxes is examined at 14 FLUXNET- CH 4 sites with diverse vegetation types. Given the extensive number of model simulations needed for global variance-based SA, we employ a machine learning (ML) algorithm to emulate the complex behavior of ELM methane biogeochemistry. We found that parameters linked to CH 4 production and diffusion generally present the highest sensitivities despite apparent seasonal variation. Comparing simulated emissions from perturbed parameter sets against FLUXNET-CH 4 observations revealed that better performances can be achieved at each site compared to the default parameter values. This presents a scope for further improving simulated emissions using parameter calibration with advanced optimization techniques.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Sensitivity analysis of a parameterization of coagulation in an aqueous transport model

A three-dimensional aqueous transport model, ALGE, was developed at the Savannah River National Laboratory (SRNL) as a tool for emergency response. Recently, coagulation and break-up of sediment and particulate (contaminant adhered to sediment) matter has been added as a new model capability, representing both processes as functions of salinity and turbulence. A sensitivity analysis was performed by comparing time series of sediment and particulate concentrations at various locations when the model’s parameters (particle size and density) are altered. The results show significant differences between experiments in both freshwater and saltwater systems parameters vary (P-values < 0.05). From this sensitivity study, we have concluded the importance of incorporating both salinity and turbulent effects, as they have a large role in the physical process of coagulation and breakup of sediment. By accounting for these physical processes, we have made the ALGE model a more robust tool for emergency response.

Aqueous fate and transport↗
DOE OSTI2024

Co-synthesis of Hydrogen and High-Value Carbon Products from Methane Pyrolysis

The ARPA-E Methane Pyrolysis Project successfully developed a scalable technology for hydrogen production with low-CO x emission through methane pyrolysis, co-producing high-value carbon nanotubes (CNTs). The project focused on optimizing reactor design, enhancing catalyst performance, and assessing techno-economic feasibility to create a commercially viable and environmentally sustainable process. The fluidized bed reactor achieved over 90% methane (CH 4 ) conversion by using a 5% CO 2 co-feed, which stabilizes carbon yields and minimizes catalyst deactivation. This setup allowed for continuous operation across ten cycles, each consisting of a 14-minute pyrolysis phase followed by a 10-minute dislodging phase to remove a fraction of the accumulated carbon, resulting in stable performance and high-quality CNT production. In parallel, monolith reactors coated with Fe demonstrated a sustained methane conversion of 73% while producing CNTs with high crystallinity. Although promising for continuous operation, monolith reactors face challenges in coating durability and scalability, highlighting areas for further optimization in commercial applications. Catalyst formulation played a key role in enhancing process efficiency. The core catalyst used was 5%Fe/Al 2 O 3 (wt%), optimized through wet impregnation, which improved CNT morphology, yielding longer and more uniform CNTs. The catalyst's performance was further enhanced by adding promoters: 2.5 wt% Ni increased methane conversion close to the thermodynamic limit, while 2.5 wt% Mn improved CNT alignment and crystallinity, and 1.5 wt% NaCl boosted CNT morphology but slightly lowered methane conversion. These adjustments allowed the reactor to maintain high methane conversion while producing high-quality CNTs, enabling stable performance over multiple cycles. To address carbon buildup and ensure uninterrupted operation, a pneumatic conveying tube was implemented for effective carbon dislodging in the fluidized bed configuration. CO 2 and H 2 O co-feeds were also introduced to enhance carbon removal, with CO 2 boosting CNT yield by approximately 15%. This setup enabled stable reactor operation across multiple cycles, preventing clogging and minimizing catalyst wear, making the process suitable for industrial scaling. Techno-economic analysis (TEA) projected hydrogen production costs between $\$$1.00 and $\$$1.64 per kilogram, with CNT values assumed at $\$$375/ton and $\$$100/ton. The life cycle assessment showed that CO 2 emissions could be as low as 0.64 kg CO 2 e/kg H 2 at 95% methane conversion assuming an electricity input of 50 kg CO 2 e/MWh. Even at 50% methane conversion, emissions remained below 1 kg CO 2 e/kg H 2 , demonstrating the process's low-emission potential and making it a viable alternative to traditional steam methane reforming. Overall, the results from this project demonstrate the feasibility of a pyrolysis process where carbon is continuously removed from the catalyst surface and hydrogen is continuously produced until a catalyst regeneration step is required to fully clean the catalyst surface and renew catalyst performance. Major open challenges are related to avoiding the loss of catalyst material in the dislodged carbon during fluidized bed conditions, since our best result demonstrated a carbon purity of ~70 wt. % (rest being iron and alumina). A monolith reactor was used to favor dislodgement of carbon compared to fluidized bed conditions but our results do not demonstrate an advantage of the monolith configuration. Catalyst performance was similar to fluidized bed conditions with slower deactivation rates overall, but we could not observe carbon dislodging in any of the tens of experiments that were run at Stanford. Our results show that the most relevant areas of improvement are related to the fundamental understanding of the iron-carbon interface for dislodging, and the development of catalyst that can produce CNTs via a base-growth mechanism such that catalyst is not lost in the dislodgement steps. The final report documents all findings and methodologies in detail, providing a valuable resource for the scientific community. By building on these results, researchers can further advance methane pyrolysis technology, moving toward a more sustainable, scalable pathway for hydrogen production. This work lays the foundation for future research and commercial efforts to reduce emissions in hydrogen production while generating valuable carbon products.

08 HYDROGEN↗
DOE OSTI2026

Policy Reforms to Unleash Domestic Critical Minerals Mining and Processing

The United States faces growing strategic and economic risks due to its limited ability to mine, process, and refine the minerals required for national defense, energy systems, advanced manufacturing, and emerging technologies. Although the country possesses significant geological resources, development has been slowed by long and unpredictable permitting timelines, fragmented regulatory responsibilities, limited midstream processing capacity, and a shrinking technical workforce. These structural barriers have created supply chain vulnerabilities that constrain industrial growth and reduce national resilience. This report presents a comprehensive set of reforms intended to modernize the nation’s approach to critical minerals. The recommendations address federal permitting, environmental review processes, the legal framework governing mining activities, interagency coordination, domestic processing and refining capacity, and the education and workforce systems needed to support long term industry development. The analysis emphasizes practical steps to shorten project timelines, improve regulatory clarity, expand processing infrastructure, enable recovery from both conventional and nontraditional sources, and update outdated requirements that hinder the development of essential materials. Taken together, the recommended reforms would strengthen domestic supply chains, improve investment certainty, and reduce dependence on external minerals and processing infrastructure. By aligning policy, regulatory frameworks, and workforce capabilities with national needs, the United States can build a more resilient and secure critical minerals ecosystem that supports long term economic competitiveness and technological leadership.

29 - ENERGY PLANNING, POLICY AND ECONOMY↗
DOE OSTI2026

Data and Code for: Observation-constrained agroecosystem model inversion reveals continental-scale variation of winter wheat traits

This repository contains the simulation outputs and processing scripts associated with the study of winter wheat traits across the United States, utilizing the Ecosys agroecosystem model. The dataset includes model results for both rainfed and irrigated winter wheat systems, supporting the findings presented in the manuscript titled "Observation-constrained agroecosystem model inversion reveals continental-scale variation of winter wheat traits." Data includes the original Ecosys simulation outputs (archived in .db format within the compressed .zip files) and extracted analysis data (stored in .pkl files for efficient processing). Python code for data processing and figure generation is provided in a Jupyter notebook. External Observational Datasets should refer to the following official repositories for the input and validation data used in this study. The eddy covariance data from the AmeriFlux network (https://ameriflux.lbl.gov/). Climate-forcing data of NLDAS-2 from NASA LDAS (https://ldas.gsfc.nasa.gov/nldas/nldas-2-forcing-data). Soil data from the Gridded Soil Survey Geographic Database (gSSURGO), available at (https://www.nrcs.usda.gov/resources/data-and-reports/gridded-soil-survey-geographic-gssurgo-database). Crop yields, planting and harvest dates from the USDA public databases (https://quickstats.nass.usda.gov/; https://webapp.rma.usda.gov/apps/actuarialinformationbrowser/CropCriteria.aspx). Satellite-derived SLOPE GPP data from ORNL DAAC (https://daac.ornl.gov/cgi-bin/dsviewer.pl?ds_id=1786). Land use and crop progress information from the USDA Crop Data Layer and Crop Progress and Condition Gridded Layers (https://www.nass.usda.gov/Research_and_Science/). The Ecosys model code is available online at https://github.com/jinyun1tang/ECOSYS.

Wheat↗
DOE OSTI2025

Multiscale Characterization of Additive Manufacturing Components with Computed Tomography, 3D X-ray Microscopy, and Deep Learning

Additive manufacturing (AM) facilitates the creation of complex-geometry parts, driving advancements in lightweight aerospace components, high-efficiency engine cooling channels, and customized medical implants. However, ensuring the quality and reliability of AM parts remains challenging due to internal defects, surface irregularities, porosity, and residual trapped powder, which are often inaccessible to traditional inspection methods. Recent developments in X-ray computed tomography (XCT) and 3D X-ray microscopy (XRM), particularly systems equipped with resolution-at-a-distance (RaaD™) capabilities, enable high-resolution, non-destructive evaluation of AM components across multiple scales, from sub-micrometer to macroscopic levels. This paper explores modern XCT and XRM techniques for multiscale characterization of AM parts, focusing on their ability to detect and analyze defects such as porosity, cracks, inclusions, and surface roughness, while offering insights into defect formation mechanisms, material properties, and process-induced variations. The integration of deep learning (DL) frameworks, including Simurgh, DeepRecon, and DeepScout, enhances XCT/XRM workflows by reducing scan times, improving resolution recovery, and enabling accurate defect detection even with limited projection data. These DL-based methods overcome limitations of traditional reconstruction techniques, enabling faster, more reliable characterization of dense materials like Inconel 718 and novel alloys such as AlCe. Applications include process parameter optimization, high-throughput quality control, and multistage AM process evaluation, with DL-enhanced workflows accelerating analysis times from weeks to days. Correlative imaging approaches further validate XCT and XRM data against scanning electron microscopy (SEM) images of physically sectioned samples, confirming the accuracy of DL-based reconstructions and enabling comprehensive defect analysis. While challenges remain in generalizing DL models to diverse materials and imaging conditions, improvements in resolution, noise reduction, and defect detection highlight the transformative potential of these methods. This multiscale and correlative approach enables precise identification and correlation of microstructural features with the overall performance of AM components. By integrating advanced XCT, XRM, and DL techniques, this paper demonstrates a significant leap forward in AM characterization, offering valuable insights into the relationships between processing parameters, microstructure, and part performance, and driving innovations that enhance the quality and reliability of AM products for demanding industrial applications.

Additive manufacturing↗
DOE OSTI2024

Experimental and statistical study on the effect of process parameters on the quality of continuous fiber composites made via additive manufacturing

Ongoing research in additive manufacturing towards structural and industrial application has led to the use of commingled roving as a manufacturing feedstock for printing high fiber volume fraction composites. The prospects of using this technology for high performance applications necessitates the need for a comprehensive experimental investigation into the effects of processing parameters on the quality of an additively manufactured composite printed from commingled roving feedstock. Here, in this work, transverse flexure and void fraction matrix pyrolysis testing are both performed to evaluate composite quality. The transverse flexure test is a testing approach that evaluates the quality of the interfacial fiber-matrix bond while the void fraction test estimates the void content in the printed composite. A full observational study consisting of 27 different test combinations is done to investigate the effects of three different process parameters namely, temperature, pressure, and print speed across three different levels. Composite samples were made from commingled roving of E-glass and amorphous PET using an in-house built continuous fiber composite digital manufacturing system. Least squares regression analysis is performed to study the main, interaction and quadratic effects of process parameters. A statistical regression model having an R2 adjusted value of 80.1% is generated from the transverse flexure study, which is used to explain main and interaction effects and also predict performance. Response surface plots are also generated and are used to optimize process parameters which can subsequently be of help in scaling up composite manufacturing. Results show that all three process parameters are highly statistically significant at the 0.01 level of significance. Pressure * Temperature and Pressure * Printspeed are significant interaction terms. Pressure plays a weightier role when print speed is increased or temperature is decreased as it closes more voids that would ordinarily have been introduced because of drop in polymer melt viscosity. Micrographic analysis is also performed.

36 MATERIALS SCIENCE↗