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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

A User-Friendly GUI Tool for Automated Microstructural Analysis of Fiber-Reinforced Composites and Porous Structures

Understanding and quantifying microstructural features such as fiber orientation and porosity is critical for predicting the mechanical behavior and performance of fiber-reinforced polymer composites. Traditional manual analysis is time-consuming, subjective, and unsuitable for high-throughput datasets. We present a graphical user interface (GUI) application that automates the analysis of microscopy images to extract key microstructural metrics, including fiber orientation tensors, fiber orientation distribution, porosity and pore size distribution. The app integrates multiple image segmentation techniques including global and local thresholding, clustering, and region-based approaches, offering flexibility for different types of image qualities and features. Users can load microstructural images, select regions of interest and segmentation techniques tailored to their image dataset. It also addresses a critical challenge in fiber orientation analysis: the ambiguities caused by touching, overlapping, or partially cut fibers. It supports autorun examples for standardized workflows, enabling reproducible analysis and facilitating training and benchmarking. This tool significantly reduces manual intervention, enhances consistency, and accelerates data generation for structure–property modeling, process optimization, and digital materials research. The tool is intended for use by materials scientists, engineers, and researchers engaged in composite characterization, quality control, and machine learning-based microstructural studies.

Chawla, Komal [ORNL] (ORCID:0000000190327565)↗
DOE OSTI2018

Stress Relaxation Related to Spontaneous Thin Film Buckling: Correlation between Finite Element Calculations and Micro Diffraction Analysis

Compressive residual stresses generated during thin film deposition may lead to undesirable film damage, such as delamination, buckling, and flaking, ultimately leading to the failure of the device employing the film. Understanding the residual stress generation and role in these damage mechanisms is necessary to preserve thin film integrity and optimize its functional properties. Thin shell theory has been used for decades to predict buckling but the results have not yet been correlated with experimental data since the techniques used to measure stress in metallic films were not able to do so at the required micron scale until recently. Micro scanning X-ray diffraction now enables the direct mapping of the local stress of metallic films. In this paper, finite element method based on thin shell theory and synchrotron X-ray micro diffraction have been used to determine stress maps of thin film buckling patterns. Calculations of the stress distribution in the metallic films have been performed taking into account the buckling geometry determined from optical measurements. Stress distributions over gold blisters and tungsten wrinkles obtained with the two techniques are in fair agreement and allow for the accurate determination of the stress relaxation profile from the bottom to the top of the buckling, validating the thin shell theory model.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Implementing marine organic aerosols into the GEOS-Chem model

Marine-sourced organic aerosols (MOAs) have been shown to play an important role in tropospheric chemistry by impacting surface mass, cloud condensation nuclei, and ice nuclei concentrations over remote marine and coastal regions. In this work, an online marine primary organic aerosol emission parameterization, designed to be used for both global and regional models, was implemented into the GEOS-Chem (Global Earth Observing System Chemistry) model. The implemented emission scheme improved the large underprediction of organic aerosol concentrations in clean marine regions (normalized mean bias decreases from -79% when using the default settings to -12% when marine organic aerosols are added). Model predictions were also in good agreement (correlation coefficient of 0.62 and normalized mean bias of -36%) with hourly surface concentrations of MOAs observed during the summertime at an inland site near Paris, France. Our study shows that MOAs have weaker coastal-to-inland concentration gradients than sea-salt aerosols, leading to several inland European cities having >10% of their surface submicron organic aerosol mass concentration with a marine source. The addition of MOA tracers to GEOS-Chem enabled us to identify the regions with large contributions of freshly emitted or aged aerosol having distinct physicochemical properties, potentially indicating optimal locations for future field studies.

Gantt, B.↗
DOE OSTI2014

Process Simulation Role in the Development of New Alloys Based on Integrated Computational Material Science and Engineering

To accelerate the introduction of new materials and components, the development of metal casting processes requires the teaming between different disciplines, as multi-physical phenomena have to be considered simultaneously for the process design and optimization of mechanical properties. The required models for physical phenomena as well as their validation status for metal casting are reviewed. The data on materials properties, model validation, and relevant microstructure for materials properties are highlighted. One vehicle to accelerate the development of new materials is through combined experimental-computational efforts. Integrated computational/experimental practices are reviewed; strengths and weaknesses are identified with respect to metal casting processes. Specifically, the examples are given for the knowledge base established at Oak Ridge National Laboratory and computer models for predicting casting defects and microstructure distribution in aluminum alloy components.

Sabau, Adrian S↗
DOE OSTI2015

CASTING DEFECT MODELING IN AN INTEGRATED COMPUTATIONAL MATERIALS ENGINEERING APPROACH

To accelerate the introduction of new cast alloys, the simultaneous modeling and simulation of multiphysical phenomena needs to be considered in the design and optimization of mechanical properties of cast components. The required models related to casting defects, such as microporosity and hot tears, are reviewed. Three aluminum alloys are considered A356, 356 and 319. The data on calculated solidification shrinkage is presented and its effects on microporosity levels discussed. Examples are given for predicting microporosity defects and microstructure distribution for a plate casting. Models to predict fatigue life and yield stress are briefly highlighted here for the sake of completion and to illustrate how the length scales of the microstructure features as well as porosity defects are taken into account for modeling the mechanical properties. Thus, the data on casting defects, including microstructure features, is crucial for evaluating the final performance-related properties of the component. ACKNOWLEDGEMENTS This work was performed under a Cooperative Research and Development Agreement (CRADA) with the Nemak Inc., and Chrysler Co. for the project "High Performance Cast Aluminum Alloys for Next Generation Passenger Vehicle Engines. The author would also like to thank Amit Shyam for reviewing the paper and Andres Rodriguez of Nemak Inc. Research sponsored by the U. S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Office, as part of the Propulsion Materials Program under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Part of this research was conducted through the Oak Ridge National Laboratory's High Temperature Materials Laboratory User Program, which is sponsored by the U. S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Program.

Sabau, Adrian S↗
DOE OSTI2014

Hyperion

The Hyperion system was designed to "look inside" an executable program and determine software's function or "behavior" without the use of the software's source code. Hyperion accomplishes this by generating associated program behaviors and the complete set of conditions under which they occur. These behaviors can be automatically checked for known malicious signatures and inspected by domain experts to assure correct operation and the absence of malicious content. Hyperion can also be used to check a program's security properties and to optimize a program.

Prowell, Stacy↗
DOE OSTI2014

Fermilab 4.3-MeV Electron Cooler

The Recycler Electron Cooler (REC) was the first cooler working at a relativistic energy (gamma = 9.5). It was successfully developed in 1995-2004 and was in operation at Fermilab in 2005-2011, providing cooling of antiprotons in the Recycler ring. After introducing the physics of electron cooling and the REC system, this paper describes measurements carried out to tune the electron beam and optimize its cooling properties. In particular, we discuss the cooling strategy adopted for maximizing the collider integrated luminosity.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

MRP: Qualification of Powder Metallurgy Hot Isostatic Pressed (PM HIP) Materials for Elevated-Temperature Nuclear Construction

PM HIP is a mature technology that offers many advantages that are attractive to the microreactor industry. The elevated-temperature creep-fatigue properties of the PM HIP 316H SS bar that has been characterized are reduced compared to the wrought material. Work will be carried out in fiscal year 2022 to identify the mechanisms responsible for the reduced creep-fatigue properties. Confirmatory testing of optimized material will be conducted to demonstrate long-term PM HIP properties comparable to the wrought-product form. The lessons learned for PM HIP 316H SS will be applied to the procurement and confirmatory testing of PM HIP Alloy 800H.

316H stainless steel↗
DOE OSTI2025

Characterization and Damping Control of Mechanical Connections to Improve Performance of Horn Stripline

Magnetic focusing horns are critical components for creating a stable beam of neutrinos for neutrino facilities, such as the Long Baseline Neutrino Facility (LBNF) and the Neutrinos and Main Injector (NuMI) beam lines at Fermilab. The pulsed magnetic horns are powered by high current electricity through long striplines. In addition to requirements for low inductance and voltage standoff, the striplines must survive in a harsh radiation environment for the operational life of the component, specified as the 100 million pulses requirement for LBNF. Each stripline assembly consists of four (eight layers that splits off to 2 pairs of four layers at the horn interface) layers of Al 6101-T6. As an electromechanical system, the stripline layers are bolted together with ceramic isolators for electrical insulation and connections must facilitate passive cooling and mechanical stability. The striplines experience vibrational force in addition to clamping force, repetitive thermal and electro-magnetic loading. The holes of stripline plates for ceramic joints represent one of the weak links for potential failure [1,2]. By characterizing the contact behavior of these joints and optimizing their damping properties through finite element analysis and experimental modal analysis, stripline performance and longevity can be improved. This study not only helps predict the behavior of the striplines but also improves their performance to meet the required operational lifetime.

Liu, Zunping [Fermilab]↗
DOE OSTI2025

Enhancing Post-Irradiation Examination (PIE) Efficiency with High-Throughput Experiments

Nuclear materials testing is essential for understanding changes in reactor environments, but traditional methods are costly and time-consuming. High-Throughput Experimentation (HTE) enables rapid screening and optimization of material properties by significantly increasing the number of specimens in the experiment. In this work, HTE methods were employed to irradiate novel materials at the Advanced Test Reactor (ATR) at Idaho National Laboratory. A total of 367 sub-sized tensile specimens were irradiated using the standard capsule design. To facilitate HTE, automated systems such as the Automated Mechanical Testing System were implemented for mechanical testing within hot cell environments, thereby reducing the need for manual interaction with hot cell manipulators and significantly lowering both the cost and duration of experiments. Digital image correlation (DIC) was used to measure displacement during mechanical testing, providing precise, non-contact measurement capabilities. The methodologies developed in this research will support the advancement of HTE techniques for future nuclear materials testing experiments at ATR. This approach allows for more efficient and cost-effective evaluation of new materials, ultimately leading to improved reactor performance, enhanced safety, and extended longevity within the nuclear industry.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Efficient Discovery of Optimal N -Layered TMDC Hetero-Structures

ABSTRACT Vertical hetero-structures made from stacked monolayers of transition metal dichalcogenides (TMDC) are promising candidates for next-generation optoelectronic and thermoelectric devices. Identification of optimal layered materials for these applications requires the calculation of several physical properties, including electronic band structure and thermal transport coefficients. However, exhaustive screening of the material structure space using ab initio calculations is currently outside the bounds of existing computational resources. Furthermore, the functional form of how the physical properties relate to the structure is unknown, making gradient-based optimization unsuitable. Here, we present a model based on the Bayesian optimization technique to optimize layered TMDC hetero-structures, performing a minimal number of structure calculations. We use the electronic band gap and thermoelectric figure of merit as representative physical properties for optimization. The electronic band structure calculations were performed within the Materials Project framework, while thermoelectric properties were computed with BoltzTraP. With high probability, the Bayesian optimization process is able to discover the optimal hetero-structure after evaluation of only ~20% of all possible 3-layered structures. In addition, we have used a Gaussian regression model to predict not only the band gap but also the valence band maximum and conduction band minimum energies as a function of the momentum.

Bassman Oftelie, Lindsay↗
DOE OSTI2016

Designing networks: A mixed-integer linear optimization approach

Designing networks with specified collective properties is useful in a variety of application areas, enabling the study of how given properties affect the behavior of network models, the downscaling of empirical networks to workable sizes, and the analysis of network temporal evolution. Despite the importance of the task, there currently exists a gap in our ability to systematically generate networks that adhere to theoretical guarantees for the given property specifications. In this work, we propose the use of Mixed-Integer Linear Optimization modeling and solution methodologies to address this Network Generation Problem. We present useful modeling techniques and apply them to mathematically express and constrain a broad class of network properties in the context of an optimization formulation. We derive complete formulations for the generation of networks that attain specified levels of connectivity, spread, assortativity and robustness, and we illustrate these via a number of computational case studies.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2025

The Path towards Plasma Facing Components: A Review of State-of-the-art in W-Based Refractory High-Entropy Alloys

Developing advanced materials for plasma-facing components (PFCs) in fusion reactors is a crucial aspect for achieving sustained energy production. Tungsten (W) - based refractory high-entropy alloys (RHEAs) have emerged as promising candidates due to their superior radiation tolerance and high-temperature strength. This review paper will focus on recent advancements in W-based RHEA research, particularly emphasizing the key role of modelling using machine learning (ML) in the stage of discovery by predicting properties for each composition and expediting the identification of optimal RHEA compositions with desired properties. Additionally, the application of additive manufacturing (AM) techniques for fabricating W-based RHEAs is explored, highlighting their advantages for rapid prototyping and multi-compositional sample production in a high throughput manner. The review critically evaluates the current understanding of mechanical properties relevant to PFC applications, including high-temperature strength and ductility. Furthermore, the radiation tolerance of W-based RHEAs under irradiated conditions is discussed. Finally, the validity of current AM-manufactured W-based RHEAs as PFC materials is assessed, and key challenges and opportunities for future research are identified. This review aims to provide a comprehensive overview of W-based RHEAs for fusion applications and their potential to guide the development and validation of advanced refractory high entropy alloys.

Hatler, Caleb [University of Wisconsin-Madison]↗
DOE OSTI2018

Enhancement of Thermoelectric Performance in CuSbSe 2 Nanoplate–Based Pellets by Texture Engineering and Carrier Concentration Optimization

This work reports the thermoelectric properties of the CuSbSe 2 -x mol% PtTe2 (x = 0, 0.5, 1.0, 1.5, and 2.0) pellets composed of highly oriented single crystalline nanoplates. CuSbSe 2 -PtTe 2 single crystalline nanoplates are prepared by a wet-chemical process, and the pellets are prepared through a bottom-up self-assembly of the CuSbSe 2 -PtTe 2 nanoplates and spark plasma sintering (SPS) process. X-ray diffraction and field emission scanning electron microscopic analyses show a highly textured nature with an orientation factor of ≈0.8 for (00l) facets along the primary surface of the pellets (in-plane, perpendicular to the SPS pressure). By this way, bulk-single-crystal-like electrical and thermal transport properties with a strong anisotropy are obtained, which results in an effective optimization on thermoelectric performance. The maximum in-plane thermoelectric figure-of-merit ZT value reaches 0.50 at 673 K for CuSbSe 2 -2.0 mol% PtTe 2 pellet, which is about five times higher than the in-plane ZT (0.10) for pure CuSbSe 2 .

36 MATERIALS SCIENCE↗
DOE OSTI2015

Comparative study of structure formation and mechanical behavior of age-hardened Ti–Nb–Zr and Ti–Nb–Ta shape memory alloys

This work sets out to study the peculiar effects of aging treatment on the structure and mechanical behavior of cold-rolled and annealed biomedical Ti–21.8Nb–6.0Zr (TNZ) and Ti–19.7Nb–5.8Ta (TNT) (at.%) shape memory alloys by means of transmission electron microscopy, X-ray diffractometry, functional fatigue and thermomechanical testing techniques. Dissimilar effects of aging treatment on the mechanical behavior of Zr- and Ta-doped alloys are explained by the differences in the ω-phase formation rate, precipitate size, fraction and distribution, and by their effect on the alloys' critical stresses and transformation temperatures. Even short-time aging of the TNZ alloy leads to its drastic embrittlement caused by “overaging”. On the contrary, during aging of the TNT alloy, formation of finely dispersed ω-phase precipitates is gradual and controllable, which makes it possible to finely adjust the TNT alloy functional properties using precipitation hardening mechanisms. To create in this alloy nanosubgrained dislocation substructure containing highly-dispersed coherent nanosized ω-phase precipitates, the following optimum thermomechanical treatment is recommended: cold rolling (true strain 0.37), followed by post-deformation annealing (600 °C, 15–30 min) and age-hardening (300 °C, 30 min) thermal treatments. It is shown that in TNT alloy, pre-transition diffraction effects (diffuse reflections) can “mask” the β-phase substructure and morphology of secondary phases. - Highlights: • TNZ alloy is characterized by much higher ω-phase precipitation rate than TNT alloy. • Difference in precipitation rates is linked to the difference in Zr and Ta diffusion mobility. • Aging of nanosubgrained TNZ alloy worsens its properties irrespective of the aging time. • Aging time of nanosubgrained TNT alloy can be optimized to improve its properties.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Ferroelectric, piezoelectric, and dielectric properties of BiScO{sub 3}-PbTiO{sub 3}-Pb(Cd{sub 1/3}Nb{sub 2/3})O{sub 3} ternary high temperature piezoelectric ceramics

(0.95-x)BiScO{sub 3}-xPbTiO{sub 3}-0.05Pb(Cd{sub 1/3}Nb{sub 2/3})O{sub 3} (BS-xPT-PCN) high temperature piezoelectric ceramics near the morphotropic phase boundary (MPB) have been synthesized by traditional solid-state reaction methods. The microstructural morphology, phase structure, and electrical properties of BS-xPT-PCN ceramics were investigated in detail. X-ray diffraction analysis indicated BS-xPT-PCN ceramics have a pure perovskite structure. The coexistence of rhombohedral and tetragonal phases at MPB composition enhanced the polarizability by the coupling between two dynamically equivalent energy states, resulting in the improved piezoelectric and ferroelectric properties at MPB vicinity. The BS-xPT-PCN (x = 0.60) ceramics possess the optimal piezoelectric and ferroelectric properties with d{sub 33} = 505pC/N, k{sub p} = 55.9%, k{sub t} = 36.5%, strain = 0.23% (under the electric field 37.5 kV/cm), and P{sub r} = 39.7 {mu}C/cm{sup 2}. High temperature dielectric behaviors showed diffuse phase transition in BS-xPT-PCN ceramics. The Curie temperature T{sub c} was found to increase from 371 Degree-Sign C to 414 Degree-Sign C with x increasing from 0.58 to 0.62. All these results together with the good thermal stabilities make the BS-xPT-PCN ceramics promising candidates for high temperature piezoelectric applications.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Electrical and optical properties of NdAlO{sub 3} synthesized by an optimized combustion process

Nanocrystals of neodymium aluminate (NdAlO{sub 3}) are synthesized using an optimized single step auto-ignition citrate complex combustion process. The combustion product was characterized by X-ray diffraction, transmission electron microscopy, Fourier transform infrared spectroscopy, Raman spectroscopy and Ultraviolet–visible reflection spectroscopy. The combustion product is single phase and composed of aggregates of nanocrystals of sizes in the range 20–40 nm. The NdAlO{sub 3} crystallized in rhombohedral perovskite structure with lattice parameters a = 5.3223 Å and c = 12.9292 Å. The absorption spectrum of the NdAlO{sub 3} nanocrystals shows characteristic absorption bands of the Nd atom. The polycrystalline fluffy combustion product is sintered to high density (∼ 97%) at ∼ 1450 °C for 4 h and the microstructure was characterized by scanning electron microscopy. The electrical properties of the sintered product were studied using dielectric measurements. The sintered NdAlO{sub 3} has a dielectric constant (ε{sub r}) and a dielectric loss (tan δ) of 21.9 and ∼ 10{sup −3} at 5 MHz, respectively. - Highlights: • NdAlO{sub 3} nanocrystals were synthesized through a citrate combustion process. • The nanocrystals were sintered to ∼ 97% of theoretical density. • The materials were characterized using a number of analytical techniques. • Nanostructured NdAlO{sub 3} showed crystal field splitting of Nd ions. • Dielectric properties of the sintered NdAlO{sub 3} ceramics were studied.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Stress transfer during different deformation stages in a nano-precipitate-strengthened Ni-Ti shape memory alloy

Understanding the role of fine coherent precipitates in the micromechanical behavior of precipitate-strengthened shape memory alloys (SMAs), which still remains a mystery heretofore, is of crucial importance to the design of advanced SMAs with optimal functional and mechanical properties. Here, we investigate the lattice strain evolution of, and the stress partition between the nanoscale Ni{sub 4}Ti{sub 3} precipitates and the matrix in a precipitate-strengthened Ni-Ti SMA during different deformation stages by in-situ synchrotron high-energy X-ray diffraction technique. We found that, during R-phase reorientation and stress-induced martensitic transformation, which both involve the shear deformation process, the lattice strain of the nanoscale precipitates drastically increases by a magnitude of 0.5%, which corresponds to an abrupt increase of ∼520 MPa in internal stress. This indicates that stress repartition occurs and most of the stress is transferred to the precipitates during the shear deformation of the matrix. It is further revealed that the nanoscale precipitates which only have a low volume fraction bear a considerable amount of applied stress during all deformation stages investigated, implying that the nanoscale precipitates play an important role in the deformation behavior of the precipitate-strengthened Ni-Ti SMAs.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗