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At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

BETO 2021 Peer Review - Biological Upgrading of Sugars (BUS) 2.3.2.105

The Biological Upgrading of Sugars (BUS) project directly targets the anaerobic conversion of lignocellulosic feedstocks into intermediate molecules readily upgradeable to fuel precursors. Recent efforts on the BUS project have a particular emphasis on the biological production of butyric acid, an intermediate that can be readily upgraded to sustainable aviation fuel, diesel blend-stocks, and high value chemicals. The BUS project approaches this direction through a combination of strain engineering, fermentation process engineering, development of novel separations technologies, and the design and build of pilot scale systems. Our ultimate project goal is to develop an integrated cost-effective process at pilot scale to achieve DOE's MYPP targets of $2.50/GGE. The major thrust of the BUS project over the last project cycle was on the development of integrated processes surrounding the anaerobic production of carboxylic acids using diverse Clostridium species. We developed and expanded genetic tools for several Clostridium species and rewired microbial metabolism in an attempt to maximize substrate utilization and flux towards butyric acid. We designed and built novel bioreactors with an in situ product recovery system enabling the biological production and recovery of highly purified acids. We leveraged this system to generate 100s of grams of acid from corn stover hydrolysate. In this presentation we highlight data surrounding our proposed process and accompanying results from technoeconomic and life-cycle analyses of our integrated process. Finally, we detail plans of our pilot scale reactor system that is in process and discuss our future routes towards achieving economically viable and sustainable diesel and jet blendstocks.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Greenhouse gas mitigation strategies and opportunities for agriculture

To cope with increasing demands for food, feed, and energy along with environmental challenges due to climate change, the agricultural sector has a unique opportunity to meet sustainable development goals set by the United Nations through innovative and regenerative agriculture practices that enhance agricultural productivity, ecosystem services, and human well-being simultaneously. Among many sustainability metrics to measure agriculture's impacts on sustainability and contribution to its improvements, we focus on the greenhouse gas (GHG) emissions from the agricultural sector as a key environmental indicator to assess several GHG mitigation practices from the perspective of life-cycle analysis applied to agriculture. In this work, we first analyze the key factors contributing to farming GHG emissions and then identify a range of GHG mitigation strategies, such as optimizing farm fertilizer/chemical inputs, manufacturing low-carbon fertilizer/chemical, reducing on-farm energy/fuel consumption, and increasing soil carbon stocks. Furthermore, we elaborate on how these strategies can be successfully implemented to different scales of farming through policies and incentives and better quantification and verification schemes for effective policies and incentives. Finally, we present the holistic evaluation of agricultural GHG emissions in terms of landscape management approaches and provide ecosystem services to address social and economic issues.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Carbon cycling across ecosystem succession in a north temperate forest: Controls and management implications

Despite decades of progress, much remains unknown about successional trajectories of carbon (C) cycling in north temperate forests. Drivers and mechanisms of these changes, including the role of different types of disturbances, are particularly elusive. To address this gap, we synthesized decades of data from experimental chronosequences and long-term monitoring at a well-studied, regionally representative field site in northern Michigan, USA. Our study provides a comprehensive assessment of changes in above- and belowground ecosystem components over two centuries of succession, links temporal dynamics in C pools and fluxes with underlying drivers, and offers several conceptual insights to the field of forest ecology. Our first advance shows how temporal dynamics in some ecosystem components are consistent across severe disturbances that reset succession and partial disturbances that slightly modify it: both of these disturbance types increase soil N availability, alter fungal community composition, and alter growth and competitive interactions between short-lived pioneer and longer-lived tree taxa. Further, these changes in turn affect soil C stocks, respiratory emissions, and other belowground processes. Second, we show that some other ecosystem components have effects on C cycling that are not consistent over the course of succession. For example, canopy structure does not influence C uptake early in succession but becomes important as stands develop, and the importance of individual structural properties changes over the course of two centuries of stand development. Third, we show that in recent decades, climate change is masking or overriding the influence of community composition on C uptake, while respiratory emissions are sensitive to both climatic and compositional change. In synthesis, we emphasize that time is not a driver of C cycling; it is a dimension within which ecosystem drivers such as canopy structure, tree and microbial community composition change. Changes in those drivers, not in forest age, are what control forest C trajectories, and those changes can happen quickly or slowly, through natural processes or deliberate intervention. Stemming from this view and a whole-ecosystem perspective on forest succession, we offer management applications from this work and assess its broader relevance to understanding long-term change in other north temperate forest ecosystems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Increasing temperature weakens the positive effect of genetic diversity on population growth

Abstract Genetic diversity and temperature increases associated with global climate change are known to independently influence population growth and extinction risk. Whether increasing temperature may influence the effect of genetic diversity on population growth, however, is not known. We address this issue in the model protist system Tetrahymena thermophila . We test the hypothesis that at temperatures closer to the species’ thermal optimum (i.e., the temperature at which population growth is maximal, or T opt ), genetic diversity should have a weaker effect on population growth compared to temperatures away from the thermal optimum. To do so, we grew populations of T . thermophila with varying levels of genetic diversity at increasingly warmer temperatures and quantified their intrinsic population growth rate, r . We found that genetic diversity increases population growth at cooler temperatures, but that as temperature increases, this effect weakens. We also show that a combination of changes in the amount of expressed genetic diversity (G) in r , plastic changes in population growth across temperatures (E), and strong G × E interactions underlie this temperature effect. Our results uncover important but largely overlooked temperature effects that have implications for the management of small populations with depauperate genetic stocks in an increasingly warming world.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Carbon budget of the Harvard Forest Long-Term Ecological Research site: pattern, process, and response to global change

How, where, and why carbon (C) moves into and out of an ecosystem through time are long-standing questions in biogeochemistry. Here, we bring together hundreds of thousands of C-cycle observations at the Harvard Forest in central Massachusetts, USA, a mid-latitude landscape dominated by 80–120-yr-old closed-canopy forests. These data answered four questions: (1) where and how much C is presently stored in dominant forest types; (2) what are current rates of C accrual and loss; (3) what biotic and abiotic factors contribute to variability in these rates; and (4) how has climate change affected the forest’s C cycle? Harvard Forest is an active C sink resulting from forest regrowth following land abandonment. Soil and tree biomass comprise nearly equal portions of existing C stocks. Net primary production (NPP) averaged 680–750 g C·m –2 ·yr –1 ; belowground NPP contributed 38–47% of the total, but with large uncertainty. Mineral soil C measured in the same inventory plots in 1992 and 2013 was too heterogeneous to detect change in soil-C pools; however, radiocarbon data suggest a small but persistent sink of 10–30 g C·m –2 ·yr –1 . Net ecosystem production (NEP) in hardwood stands averaged ~300 g C·m –2 ·yr –1 . NEP in hemlock-dominated forests averaged ~450 g C·m –2 ·yr –1 until infestation by the hemlock woolly adelgid turned these stands into a net C source. Since 2000, NPP has increased by 26%. For the period 1992–2015, NEP increased 93%. The increase in mean annual temperature and growing season length alone accounted for ~30% of the increase in productivity. Interannual variations in GPP and NEP were also correlated with increases in red oak biomass, forest leaf area, and canopy-scale light-use efficiency. Compared to long-term global change experiments at the Harvard Forest, the C sink in regrowing biomass equaled or exceeded C cycle modifications imposed by soil warming, N saturation, and hemlock removal. Furthermore, the results of this synthesis and comparison to simulation models suggest that forests across the region are likely to accrue C for decades to come but may be disrupted if the frequency or severity of biotic and abiotic disturbances increases.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Estimating carrying capacity for juvenile salmon using quantile random forest models

Abstract Establishing robust methods and metrics to evaluate habitat quality is critical for the recovery of endangered Pacific salmonids ( Oncorhynchus spp.). A variety of modeling approaches are used for status and trend monitoring of anadromous species throughout the Pacific Northwest, USA, but current methods may fail to capture the complex relationship between fish and habitat and are often limited in predictive power beyond specific watersheds. Further, the focus on species distribution and abundance is not easily manipulated to predict carrying capacity and traditional stock‐recruitment analyses are reliant on long‐term data which are not always available. In this study, we developed a quantile random forest model to provide estimates of habitat carrying capacity for Chinook salmon ( O. tshawytscha ) parr during the summer months, at both the site and watershed scale. Quantile random forest models allow for the consideration of noisy data, correlated variables, and non‐linear relationships: common features in fish–habitat datasets. We leveraged Columbia Habitat Monitoring Program data to select habitat co‐variates and predict capacity at those sites. We also identified a set of globally available attributes to extrapolate capacity estimate predictions throughout wadeable streams within the Columbia River basin. Total capacity estimates for watersheds closely matched estimates from alternative fish productivity models. Carrying capacity estimates based on quantile random forest models, like those presented here, provide managers a framework to guide the identification, prioritization, and development of habitat rehabilitation actions to recover salmon populations.

See, Kevin E.↗
DOE OSTI2026

Long‐term growth and persistence of granitic inselbergs in a semi‐arid cratonic landscape

Granitic inselbergs are enduring landforms that punctuate planation surfaces in tectonically stable settings, yet the mechanisms and timescales of their persistence remain debated. Here, in this study, we present a multinuclide cosmogenic dataset ( 10 Be, 26 Al and 21 Ne) from bedrock, fluvial sediments and planation surfaces in the semi-arid Central Ceará Domain, north-eastern Brazil, to quantify denudation rates and reconstruct the long-term dynamics of residual relief formation. This triple-nuclide approach enables independent validation of denudation contrasts and long-term exposure histories, providing quantitative constraints on inselberg evolution that a single-nuclide approach could not resolve. Bedrock denudation rates (1–4 m Myr −1 ) are systematically lower than basin-wide rates (8–14 m Myr −1 ), revealing a regional pattern of vertical differential denudation. When combined with summit elevations and surface exposure ages of up to 5 Myr, these contrasts suggest that cumulative relief growth has been operating over timescales of tens of millions of years (1–57 Myr). Morphological and structural observations further indicate localized mass wasting and heterogeneous erosion styles, modulated by rock fabric and joint density. Cosmogenic nuclide inventories in detrital sediments reveal partial reworking from older sediment stocks, including surface pebbles with exposure ages up to 5 Myr, which record multistage of burial and re-exposure histories and reflect episodic remobilization in low-connectivity, semi-arid catchments. Rather than static relicts of ancient surfaces, inselbergs in this cratonic setting emerge as dynamic landforms actively sustained by slow but persistent differential denudation. These results provide new constraints on long-term cratonic landscape evolution and underscore the interplay between lithological resistance, structural inheritance and sediment transfer processes in sustaining topographic relief. They also call for a critical reassessment of classical inselberg models, suggesting that hybrid mechanisms, rather than single-process paradigms, more accurately capture the complexity of residual landform development in cratonic interiors.

Cosmogenic nuclides↗
DOE OSTI2021

Modeling interval trendlines: Symbolic singular spectrum analysis for interval time series

Abstract In this article we propose an extension of singular spectrum analysis for interval‐valued time series. The proposed methods can be used to decompose and forecast the dynamics governing a set‐valued stochastic process. The resulting components on which the interval time series is decomposed can be understood as interval trendlines, cycles, or noise. Forecasting can be conducted through a linear recurrent method, and we devised generalizations of the decomposition method for the multivariate setting. The performance of the proposed methods is showcased in a simulation study. We apply the proposed methods so to track the dynamics governing the Argentina Stock Market (MERVAL) in real time, in a case study over a period of turbulence that led to discussions of the government of Argentina with the International Monetary Fund.

de Carvalho, Miguel↗
DOE OSTI2026

Modelling the Sensitivity of Yukon River Biogeochemical Dynamics to Environmental and Chemical Drivers: Implications for Dissolved Organic Carbon

Riverine dissolved organic carbon (DOC) is a critical biogeochemical component that transmits information from Arctic soils to the Arctic Ocean, significantly influencing carbon dynamics in this unique ecosystem. As DOC travels downstream, it undergoes transformations that alter its composition and fate. The Yukon River serves as an effective testbed for modelling these dynamics, offering sufficient scale to capture key biogeochemical processes while having a simpler hydrology than other major Arctic rivers, as well as long-term DOC observational data for model validation. To investigate DOC transformations during transit in the Yukon River, we adapted our Arctic Riverine Organic Macromolecular Model by applying regional-specific parameterisations. Our model simulates the transport and transformation of 15 organic macromolecules, including CDOM (coloured dissolved organic matter), proteins, polysaccharides, lipids, lignin phenols, and humic substances. Initial DOC concentrations were derived from observed soil organic carbon stocks in the surrounding watershed, while chemical transformations and hydrological dynamics were modelled along the river's course. Sensitivity and uncertainty analyses were conducted using a Monte Carlo approach under two experimental setups. Results revealed that variability in DOC and CDOM concentrations at the river mouth were predominantly driven by initial DOC concentration (~70% of variability explained) and dilution at confluence points (~10%). The refractory fraction of DOC explained 21%–88% of the variability in 14 macromolecular concentrations and ranked in the top five sensitive parameters for all outputs when a uniform parameter distribution was assumed. However, when a more likely variability was applied to this parameter, its influence on DOC and CDOM decreased. Given that refractory DOC accounts for ~80% of total DOC in Arctic Rivers, this suggests that most DOC resists degradation and retains its chemical composition during transport to the coastal environment. River velocity, which determines residence time, explained 8%–47% of the variability in protein, polysaccharide, lipid, pigments, and lignin phenols at the river mouth. In contrast, chemical turnover times contributed only 1%–5% to output variability. Our findings underscore the need for improved land-specific headwater observations, including seasonal soil moisture and lateral transport dynamics that control the initial tributary-specific DOC inputs. With accelerated permafrost thaw and increasing river discharge, extending our model to other Arctic River systems and seasons will enhance understanding of Arctic riverine carbon fluxes and their contributions to the Arctic Ocean.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

A Fish Out of Basin: Increased Stress Physiology and Reduced Performance of Salmon River Hatchery Chinook Salmon

Abstract Variation in rearing conditions across hatcheries and basins can affect the performance of hatchery salmonids in the wild. In 2008, the Shoshone-Bannock Tribes began planning an out-of-basin hatchery facility on the eastern Snake River Plain for rearing threatened Chinook Salmon Oncorhynchus tshawytscha for release in tributaries of the upper Salmon River, Idaho, USA. To help determine the viability of the planned out-of-basin hatchery, we reared 100,000 juvenile Chinook Salmon from the same genetic stock at one in-basin (Sawtooth Fish Hatchery on the Salmon River) and one out-of-basin (Springfield Fish Hatchery on the Snake River Plain) site in Idaho that are characterized by significant differences in water hardness and temperature regime. In October 2018 and April 2019, we tested whether fish condition, stress physiology, acute mortality, and downstream survival differed between the two groups at the parr and smolt life stages upon release in the Yankee Fork Salmon River, which is characterized by low water hardness. For both release groups, parr experienced low acute mortality during the 48 h after release; however, the out-of-basin group had a downstream survival rate through an unimpounded portion of the migration corridor that was an order of magnitude lower than that for the in-basin group. During the smolt release, the out-of-basin group showed signs of extreme physiological stress, acute mortality rates of 40–80%, and low survival in the unimpounded portion of the migratory corridor. The in-basin group recovered from the stress of transport and release, had no acute mortality, and survived through the unimpounded migratory corridor at a rate comparable to that of previous years’ releases. Based on the results of this comparative study, comanagers are evaluating alternatives to the proposed out-of-basin hatchery program. This case study highlights the effects of differences between rearing and release conditions on salmon physiology and survival as well as the value of conducting preliminary evaluations prior to implementing large-scale hatchery supplementation programs.

Ebel, Jonathan D.↗
DOE OSTI2023

Genetic monitoring of steelhead in the Klickitat River to estimate productivity, straying, and migration timing

Abstract Objective Salmonids with a complex life history variation present challenges for conservation management, but genetic approaches alongside fisheries monitoring can address questions regarding the viability of the natural populations. Methods We genotyped adult (n = 3108) and juvenile (n = 2624) samples of steelhead Oncorhynchus mykiss that were collected in the Klickitat River, Washington, USA at traps in the lower drainage to examine tributary level productivity, straying from outside sources, and variation in adult migration timing. Result Genetic assignment of steelhead from this system indicated that the majority were produced within or near tributaries of the middle Klickitat River (juvenile mean = 72.8%; adult mean = 87.3%). Analyses with parentage-based tagging identified that most hatchery-origin adults were assigned to the Skamania Hatchery (80.8%), as expected, since this has been the release stock for decades within the Klickitat River drainage. Hatchery-origin adults were also identified from programs operating outside the Klickitat River, which were primarily strays from Snake River hatcheries. Most natural-origin steelhead were assigned to the Klickitat River, but there were also natural-origin fish identified as strays from other regions of the Columbia River (22.3% of natural returns). We also examined genes known to be associated with migration timing in adult steelhead observed at the trap and observed a strong relationship between migration date and alleles for early and late migration, but individual outliers were detected across seasons. Conclusion Our results indicate that genetic variation of steelhead in the Klickitat River has been influenced by hatchery programs as well as natural-origin straying from other subbasins, but genetic diversity remains high throughout the subbasin, and both early and late migration alleles are maintained. The genetic diversity present in Klickitat River steelhead may enable this Endangered Species Act listed (threatened) species to better adapt to stochastic environmental conditions compared to less diverse populations.

Collins, Erin E. (ORCID:0000000260978479)↗
DOE OSTI2022

Dynamic Material Flow Analysis of Silicon Photovoltaic Modules to Support a Circular Economy Transition

Solar photovoltaics (PV) are the fastest growing renewable energy technologies for clean, cheap, and sustainable electricity generation. To prepare for rapid scale-up, the PV industry needs to project material requirements to build out all aspects of the supply chain appropriately and plan to handle large volumes of module waste. Impacts of deploying different material circularity strategies to reduce waste and conserve primary resources need to be quantified to inform sustainable material management. Here, we introduce the photovoltaic dynamic material flow analysis (PV DMFA) model based on PV electricity generation. The model quantifies material flows and stocks in the cradle-to-cradle life cycles of utility-scale c-Si PV systems in the United States through 2100. We present case studies for solar flat glass and aluminum frame materials under various scenarios to project the impacts of PV performance, reliability, and processing parameters, material circularity strategies, and module design shifts. In the absence of circularity measures, ~100 million MT of flat glass and ~12 million MT of aluminum would be needed for PV installations by 2100 to meet projected growth in domestic utility PV demand to nearly 1000 TWh in 2100. With optimistic but feasible improvements in efficiency, reliability, and circularity, material intensity and waste could be reduced by nearly 50%. Efficient module collection, minimally intrusive recycling, and careful scrap handling and cleaning could improve material circularity in the PV value chain. This model serves as a sustainability data support tool that may aid in the circular economy transition for PV systems.

circular economy↗
DOE OSTI2024

Informing forest carbon inventories under the Paris Agreement using ground-based forest monitoring data

Human interactions with forests have shaped Earth's climate for millennia and will continue to do so as we target net-zero emission goals. Accurately characterizing these climate impacts requires making reliable forest carbon data available for forest monitoring and planning. Here, we develop a semi-automated process for submitting forest carbon measurements from the largest relevant scientific database to the International Panel on Climate Change's Emission Factor Database, which currently has sparse forest carbon data. Building this bridge from scientific research to international policy is an important step towards managing forests in a net-zero motivated future. Humans have been influencing Earth's climate via transformative impacts on forests for millennia, and forests are now recognized as critical to climate change mitigation under the Paris Agreement. The efficacy of climate change mitigation planning and reporting depends on quality data on forest carbon (C) stocks and changes. The Emission Factor Database (EFDB) of the International Panel on Climate Change (IPCC) is intended to be a definitive source for such data, but needs comprehensive and well-documented data to be so. To facilitate submission of forest C estimates from scientific studies to EFDB, we develop and document a process for semi-automated data submission from the Global Forest C database (ForC v4.0), which is the largest compilation of ground-based forest C estimates. We then assess the data currently available through ForC and provide recommendations for improving forest data collection, analysis, and reporting. As of September 2024, ForC contained ~19,286 records potentially relevant to EFDB, 1068 of which had been submitted and posted to EFDB. These represented 19% of the total EFDB records for forest land. Records were unevenly distributed across variables and geographic regions. ForC records (37%) reviewed could not be submitted because the original publication lacked required information. In the future, ground-based forest C estimates should target gaps in the record, and studies should ensure that they report all information necessary for inclusion in EFDB. Given that climate change is rapidly impacting the world's forests, timely reporting of recent estimates will be critical to accurate forest C inventories.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

The Role of Pentaerythritol Tetranitrate (PETN) Aging in Determining Detonator Firing Characteristics

Pentaerythritol tetranitrate (PETN) is one of the most commonly used explosives for both military and mining applications. PETN is used in EBW (exploding bridge wire) and EFI (exploding foil initiator) detonator devices. Due the widespread usage of PETN, studies focusing on how the explosive changes with age, primarily its function in detonators has received particular interest. Aging studies have identified several factors that affect PETN detonator function over time, most notably the specific surface area of the explosive powder. Though small-scale studies have been performed on specific detonator systems with isolated batches of material, what is missing is a large statistically-significant study focusing on PETN aging characteristics - such as powder coarsening - and their influence on detonator performance. Herein we report the first large statistically viable PETN aging study focusing on four batches of PETN powder from the same stock of PETN using two stabilizers, polysaccharide and TriPEON. PETN was aged both as a free-flowing powder as well as in modified EBW RP-2 detonators, for one month at 75 °C. The PETN powder has been analyzed chemically using Fisher specific surface area analysis, SEM imaging and light scattering particle size analysis. Additionally the detonators were tested for performance through voltage-sweep threshold testing and function time measurements. Findings from the study indicate that aging at 75 °C for one month significantly changes the specific surface area and particle size of unstabilized PETN, leading to increases in detonator function time, but not detonator threshold values. Powders stabilized with TriPEON displayed less significant increases in function time, while powder stabilized with polysaccharide exhibited no aging effects, despite the high temperature aging.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2024

History of the Beer Game

This article describes the history of the Beer Game. By triangulating information from literature, archival analysis, and interviews with experts in the field, the main changes in the game over its almost 70-year history are identified. The article discusses three aspects of the game: 1) its structure (phases of its history, stocks and flows, parameters, etc.); 2) the process for playing the game; and 3) the game debrief. The structure of the Beer Game, and the process for running it, have stabilized over the years into what is now a de facto standard approach. Additional work is needed in the game debrief, specifically in the clarification of key insights and messages (depending on the context of the use of the game), in how to communicate such messages to different audiences, and in the development of support materials for its delivery. © 2024 UChicago Argonne, LLC. System Dynamics Review published by John Wiley & Sons Ltd on behalf of System Dynamics Society.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Wind power costs driven by innovation and experience with further reductions on the horizon

The costs of wind power have declined to levels on par with or below those of conventional sources in many parts of the world. Wind power has become one of the fastest-growing sources of new electricity generation. We take stock of wind power cost evolution over the past 20 years, review methodologies commonly used for cost assessment, discuss the potential for continued cost reduction, and identify anticipated cost and value drivers. Our scope includes both onshore and offshore wind technologies. We draw from a vast body of literature on these topics to highlight key trends, approaches, and limitations. Furthermore, we discuss strategies for wind power assets to enhance their marginal economic value to the broader power system and consumers. We identify a myriad of factors that are expected to influence the future cost and value of wind power, including siting, project scale, turbine size, operational synergies, commodity prices, advancements in turbine technologies, enhanced management of the wind resource, and novel control technologies that provide value for the electricity grid. Because the common methods for forecasting future costs each have their own strengths and weaknesses, we find the best insights are elicited from a combination of methods. Overall, researchers and analysts anticipate further sizable cost reductions for onshore and offshore wind. Midrange forecasts for levelized cost of energy in 2050 are generally between $20 and $30/MWh for onshore wind and $40 and $60/MWh for offshore wind, a reduction to approximately half of today's levels. Optimistic forecasts anticipate these levels as early as 2030.

17 WIND ENERGY↗
DOE OSTI2025

Control of machining-induced residual stress via tool geometry and process parameter modification

Distortion generated in machined, monolithic, thin-walled aerospace components due to residual stresses leads to significant material and economic waste in the manufacturing industry. Inherent residual stress (IRS) present in stock materials combines with machining-induced residual stress (MIRS) to influence the final machined part distortion. It is hypothesized that MIRS can be controlled, based on the part geometry, through deliberate cutting tool geometry and process parameter modifications to negate the effect of IRS on distortion, consequently resulting in distortion-free parts. A finite element (FE) orthogonal cutting model is developed to study how tool geometry and process parameters influence machining-induced residual stress (MIRS). Orthogonal cutting experiments are performed on Al 7075-T651 samples to measure cutting forces and MIRS. A cutting force dynamometer is used to measure forces during cutting and a novel digital image correlation (DIC) based hole drilling technique is employed to measure the near-surface residual stress (RS) in the cut samples. These data are subsequently utilized to validate the FE prediction model. Various cases of cutting simulations involving different depths of cut, tool tip radii, and rake angles are performed to study their effects on RS. Similar to prior literature, increasing the depth of cut, tool tip radius, or rake angle is found to promote the formation of near-surface tensile stresses. The competing effects of material plowing and temperature are shown to determine the type of RS at the end of the cut. Moreover, a window of variation of RS (up to ± 400 MPa) is estimated within the given range of conditions, allowing for the control of MIRS through tool and process modification.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗