Understanding Microstructure Evolution during Processing in Additively Manufactured Functionally Graded Materials
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Materials science↗
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Development of a Multi-Sensor Data Science System Used for Signature Development on Solvent Extraction Processes in support of safeguards- an overview
A new nuclear fuel cycle test bed is being built at Idaho National Laboratory to support the purification of special nuclear material recovered from used fuel. The test bed provides an opportunity to research process flow and the application of computational tools in solvent extraction processes. A deeper understanding of process and equipment behavior coupled with real time data collection can indicate whether a process failure is accidental or purposeful. The goal of this project is to develop a system that utilizes non-traditional measurement sources such as vibration, acoustics, current, light, flow, and temperature in conjunction with data-based, machine learning techniques that will allow for signal discovery. This multi-sensor data can support the development of safeguards by design and security by design measures for such a facility. Additionally, it can aid in early detection and identification of removed materials indicating diversion, which is essential for initiating material recovery and actor identification. This overview encompasses the current research and testing of sensors to develop a spectrum of process signatures. To be followed by planned experiments aimed to characterize said signatures and study potential feature extraction techniques to identify a fault in the system (i.e. flow diversion).
98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
In vitro investigation of protein assembly by combined microscopy and infrared spectroscopy at the nanometer scale
The nanoscale structure and dynamics of proteins on surfaces has been extensively studied using various imaging techniques, such as transmission electron microscopy and atomic force microscopy (AFM) in liquid environments. These powerful imaging techniques, however, can potentially damage or perturb delicate biological material and do not provide chemical information, which prevents a fundamental understanding of the dynamic processes underlying their evolution under physiological conditions. Here, we use a platform developed in our laboratory that enables acquisition of infrared (IR) spectroscopy and AFM images of biological material in physiological liquids with nanometer resolution in a cell closed by atomically thin graphene membranes transparent to IR photons. In this work, we studied the self-assembly process of S-layer proteins at the graphene-aqueous solution interface. The graphene acts also as the membrane separating the solution containing the proteins and Ca 2+ ions from the AFM tip, thus eliminating sample damage and contamination effects. The formation of S-layer protein lattices and their structural evolution was monitored by AFM and by recording the amide I and II IR absorption bands, which reveal the noncovalent interaction between proteins and their response to the environment, including ionic strength and solvation. Our measurement platform opens unique opportunities to study biological material and soft materials in general.
59 BASIC BIOLOGICAL SCIENCES↗
Community Dynamics Drive Calcium Carbonate Production in an Enriched Consortium of Soil Microbes
Recently, there has been a focus on using soil microbes as a means to store carbon in the soil in the form of calcium carbonate, outcomes of which include soil stabilization and biocementation. The molecular processes involved in microbially induced calcium carbonate formation are known, but there is still a significant knowledge gap regarding how community interactions, emergent processes that are distinct from the roles of individual members, may drive the formation of carbonate. To answer these questions, we describe the development and application of a consortium of soil microbes consisting of one species each of the Rhodococcus , Microbacterium , and Curtobacterium genera and two species from the Bacillus genus. We term these five species cultivated together carbon storing consortium A (CSC-A). Growth assays show that only a subset of CSC-A members produces CaCO 3 with Rhodococcus producing the most CaCO 3 but the complete CSC-A produces significantly higher amounts of CaCO 3 compared to the sum total carbonate produced by all member species. The development of CSC-A shows that CaCO 3 production may be as much a community process as it is the contribution of individual species, requiring us to move beyond single species analysis to fully understand carbonate formation by microbial communities in nature. CSC-A will allow the scientific community to ask and answer key questions about the molecular interactions surrounding inorganic carbon formation in soil, an important knowledge gap that must be filled if we wish to stabilize soils and harness microbial processes for materials production.
calcium carbonate↗
Data-driven nonlocal model for fragmentation in the crushing of solids
A technique is proposed for reproducing particle size distributions in three-dimensional simulations of the crushing and comminution of solid materials. The method is designed to produce realistic distributions over a wide range of loading conditions, especially for small fragments. In contrast to most existing methods, the new model does not explicitly treat the small-scale process of fracture. Instead, it uses measured fragment distributions from laboratory tests as the basic material property that is incorporated into the algorithm, providing a data-driven approach. The algorithm is implemented within a nonlocal peridynamic solver, which simulates the underlying continuum mechanics and contact interactions between fragments after they are formed. Finally, the technique is illustrated in reproducing fragmentation data from drop weight testing on sandstone samples.
58 GEOSCIENCES↗
Ultra-fast and Thick Boriding of Geothermal Casing to Enhance Reliability
Harnessing the heat that is continuously generated underneath the Earth’s crust (geothermal) is a clean and renewable source of energy. Geothermal energy can be used to heat and cool buildings, including greenhouses, and to generate electrical power. Compared to other renewable energy sources such as solar and wind, geothermal energy is more reliable because it is available all the time and versatile in its many forms of application and deployment. Nonetheless, the deployment and extensive use of geothermal energy still lags behind other renewable sources due to some technical, but mainly economic challenges. Upfront costs of geothermal power well development are relatively high. Some of this high cost is attributed to the use of expensive construction materials to ensure adequate performance during operation. For example, Inconel 625, super duplex 2507, and titanium alloy materials are used in downhole casings, piping, and other components exposed to brine solution to withstand harsh operating environments (high temperature and corrosive environments). Relatively low-cost carbon steel can be used in many of these components in geothermal power plants; however, they are susceptible to excessive corrosion, thereby limiting their useful lifespan. Ultra-fast boriding (UFB) surface treatment of carbon steel may drastically increase its corrosion resistance thereby providing a cost-effective material solution in geothermal applications. Scientists at Argonne National Laboratory (ANL) recently developed a technique to accelerate the boriding process using a high-temperature electrochemical process to produce relatively thick boride layers on various metal and alloy materials in minutes rather than the several hours it takes through the typical pack boriding process; hence, the process is designated UFB. The process uses molten borax salt at 900– 1000°C in an electrochemical cell in which the material to be borided is the cathode and a graphite plate is the anode. Continuous and durable boride layers with thicknesses of 100–300 µm have been produced on a variety of metals and alloys in one hour. Such a surface layer can indeed be a cost-effective pathway to prevent corrosion of casing materials in contact with the chemically aggressive and corrosive geothermal brine fluids.
15 GEOTHERMAL ENERGY↗
Automation of Laser Plasma Focused Ion Beam Microscopy for Next-Gen Energy Materials
Automation can revolutionize the use of ultrafast laser ablation and plasma-focused ion beam (PFIB) techniques for high-throughput, reproducible cross-sectioning and various sample preparation in materials characterization. As these methods become essential for analyzing complex energy materials and next-generation devices, efficient, standardized workflows are needed to minimize variability and enhance precision. This work highlights our advancements in developing automated processes for sample preparation that integrates machine learning, workflow optimization, and large-scale data acquisition to improve efficiency and scalability in applications such as electrolyzers, photovoltaic cells, and microelectronics. To streamline cross-sectioning and lamella fabrication, we have implemented fully automated workflows that standardize laser ablation and PFIB milling sequences. These workflows incorporate pre-programmed protocols for material removal, alignment, and thinning, reducing user intervention and ensuring consistency across different sample types. Machine learning algorithms further enhance automation by predicting optimal milling strategies and adapting parameters based on material properties and sectioning requirements. This approach significantly improves throughput while maintaining the structural integrity of prepared samples for high-resolution imaging and analysis, including transmission electron microscopy. Beyond sample preparation, our automation platform enables the acquisition of large, high-resolution datasets through serial sectioning, image alignment, and 3D reconstruction. These automated routines facilitate multi-scale characterization, capturing structural and compositional details from the nanoscale to the device level. By reducing variability and increasing efficiency, our automated approach enhances defect analysis, failure diagnostics, and process optimization, accelerating advancements in materials research and device engineering.
36 MATERIALS SCIENCE↗
Electrochemical hydrogen isotope fractionation - fundamental insights leading to process scale up
Vanderbilt University’s role in this collaborative multi-PI project with Savannah River National Laboratory (lead) and Clemson University was to synthesize 2D materials and characterize them for applications specific to Electrochemical hydrogen isotope fractionation - fundamental insights leading to process scale up.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
A Review of Online Monitoring within Used Nuclear Fuel Recycling Processes
The processing of used nuclear fuels and related materials is often complex and variable. The ability to quickly optimize conditions to the material being processed can aid in increasing efficiency and safety, but requires very quick determination of the conditions present in the feedstock, the process, and the product. Furthermore, accurate quantification of materials such as enriched uranium and plutonium aids in maintaining material accountancy and avoiding nuclear proliferation risks. Traditional analytical methods require process samples to be collected and analyzed in a laboratory, which often takes days to weeks. Online monitoring is suitable for collecting this information nearly instantaneously, enabling much faster optimization of the process or detection of material diversion. Online monitoring is also beneficial as it is typically based on robust and nondestructive analytical methods, so no material is removed as samples. This review examines online monitoring relevant to used nuclear fuel processing for the determination of both chemical and physical parameters. The chemical parameters include quantities such as concentration, isotopic composition, and speciation. These values are often well suited to spectroscopic or spectrometric measurements as they are fast, nondestructive, and easily implemented in an online manner. Physical quantities are often more varied and include temperature, pressure, tank fill levels, and others. Due to the specificity of these quantities, specialized instrumentation is often used. However, this instrumentation is often amendable to online monitoring.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Editorial for the Virtual Special Issue of Journal of Power Sources “Low temperature fuel cells and electrolysers” - Science and engineering: Let's play this game hand in hand!
Electrochemistry is already and will increasingly be amongst the major drivers of our energetic mix decarbonization, so to fight anthropogenic global warming. The hydrogen economy vector (ideally produced in water electrolysers using renewable electricity and transformed back into electricity in fuel cells), in parallel with the conversion of carbon dioxide and nitrogen gas into value-added products are seen as pillars of the so-called green and sustainable Energy Revolution. The hydrogen technologies presently attract increasing interest, their momentum growing irremediably in Europe, Asia and Americas. Here, this Virtual Special Issue (VSI) gathers the latest scientific results of major research laboratories worldwide, all addressing various aspects of electrochemical energy and material conversion processes.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Materials Characterization, Prediction, and Control Project: Summary Report on Material Characterization, Part 1
The Pacific Northwest National Laboratory (PNNL) undertook the Materials Characterization, Prediction, and Control (MCPC) Laboratory Directed Research and Development Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems in national security and advanced energy applications (Smith 2021). The MCPC Project executed research across three scientific vertices—material characterization, predictive modeling, and data analytics—with extensive support by a data curation and management team. The central technical objective in the MCPC Project was to improve the prediction and characterization of the process-structure-property relationships within the microstructurally refined region of stainless-steel samples prepared utilizing friction stir processing (FSP). Application of the FSP technique is well established at PNNL within the Solid Phase Processing capability through many years of investment across a range of materials and applications (PNNL 2024). Three distinct rounds of FSP experiments were performed by the experimental team, producing replicate samples utilizing across different nominal processing conditions (Condition IDs) listed in Table 1. The starting material on which FSP was applied was commercially available unprocessed stainless-steel type 316L material. Chosen processing conditions were very diverse, and some were intentionally chosen to produce defects. Several samples experienced tool breakage during experimentation, so a full set of three replicates was not produced for every nominal processing condition.
36 MATERIALS SCIENCE↗
Materials Characterization, Prediction, and Control Project: Summary Report on Material Characterization, Part 2
The Pacific Northwest National Laboratory (PNNL) undertook the Materials Characterization, Prediction, and Control (MCPC) Laboratory Directed Research and Development Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems in national security and advanced energy applications (Smith 2021). The MCPC Project executed research across three scientific vertices—material characterization, predictive modeling, and data analytics—with extensive support by a data curation and management team. The central technical objective in the MCPC Project was to improve the prediction and characterization of the process-structure-property relationships within the microstructurally refined region of stainless-steel samples prepared utilizing friction stir processing (FSP). Application of the FSP technique is well established at PNNL within the Solid Phase Processing capability through many years of investment across a range of materials and applications (PNNL 2024).
36 MATERIALS SCIENCE↗
Materials Characterization, Prediction, and Control Project: Summary Report on Material Characterization, Part 3
The Pacific Northwest National Laboratory (PNNL) undertook the Materials Characterization, Prediction, and Control (MCPC) Laboratory Directed Research and Development Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems in national security and advanced energy applications (Smith 2021). The MCPC Project executed research across three scientific vertices—material characterization, predictive modeling, and data analytics—with extensive support by a data curation and management team. The central technical objective in the MCPC Project was to improve the prediction and characterization of the process-structure-property relationships within the microstructurally refined region of stainless-steel samples prepared utilizing friction stir processing (FSP). Application of the FSP technique is well established at PNNL within the Solid Phase Processing capability through many years of investment across a range of materials and applications (PNNL 2024).
36 MATERIALS SCIENCE↗
Materials Characterization, Prediction, and Control Project: Summary Report on Material Characterization, Part 4
The Pacific Northwest National Laboratory (PNNL) undertook the Materials Characterization, Prediction, and Control (MCPC) Laboratory Directed Research and Development Project to advance understanding of nuclear material processing and enable multifold acceleration in the development and qualification of new material systems in national security and advanced energy applications (Smith 2021). The MCPC Project executed research across three scientific vertices—material characterization, predictive modeling, and data analytics—with extensive support by a data curation and management team. The central technical objective in the MCPC Project was to improve the prediction and characterization of the process-structure-property relationships within the microstructurally refined region of stainless-steel samples prepared utilizing friction stir processing (FSP). Application of the FSP technique is well established at PNNL within the Solid Phase Processing capability through many years of investment across a range of materials and applications (PNNL 2024).
36 MATERIALS SCIENCE↗
Lifetime Energy Savings Via Advanced Manufacturing of Low Density Steels for Transportation Applications
The purpose of this “Low Density Steels for Transportation Applications” project was to develop an alloy composition and processing parameters that would result in a material suitable for use in automotive structural components at a reduced density over the current advanced high strength steel (AHSS) materials used. The project work successfully developed a robust alloy capable of exceeding project mechanical property targets at each stage of development, with an 8% density reduction over benchmark AHSS materials (7.8 g/cm3). The developed alloy has the potential to offer significant vehicle lightweighting and improved fuel economy, without sacrificing the increased passenger safety of more traditional AHSS. Through the three tasks of the project, (1) Alloy design and small-scale laboratory evaluation, (2) Laboratory development of hot rolled material and (3) Laboratory development of a cold rolled material, the laboratory work utilized advanced characterization and analytical methods on novel alloy compositions subjected to both conventional and non-conventional processing operations.
36 MATERIALS SCIENCE↗
Trends in Field and Laboratory Performance of Photovoltaic Modules and Materials
This DuraMAT project intends to identify bill of materials (BOM) and/or process control measures for photovoltaic modules with representative failure modes as informed by accelerated and field tests to guide next steps in module and material design. We have begun work to identify correlation between module field performance and accelerated testing results by cross-comparing a module database of accelerated test results with a module database of fielded systems. We have identified fielded systems with degraded performance, and intend to compare this to the results observed in certification and qualification testing. We also intend to apply lessons and observations from accelerated tests to the field, where it may be possible to mitigate or avoid degradation in the field.
DuraMAT↗
Gallium Nitride and Related Materials - Device Processing and Materials Characterization for Power Electronics Applications
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Armstrong, Andrew Michael [Sandia National Laborat↗
Development of low-loss minimal exposure technique for thallium foil fabrication
Despite its availability as a solid bead or ingot, non-isotopic thallium metal is no longer commercially produced as a foil because of its high toxicity. To conduct fundamental studies on the material, the Stable Isotope Materials and Chemistry Group (SIMC) at Oak Ridge National Laboratory (ORNL) was approached to develop a safe method to process thallium and produce 40 non-isotopic thallium foils. The commercially sourced metal was consolidated into an ingot by melting the material in a special tube furnace under a reducing atmosphere. The resulting ingot was cold rolled using a work-hardened, stainless-steel pack and oil lubricant before cutting the final foils to 2.5 × 2.5 cm2 area and thickness of 50–75 mg/cm2. The appropriate safeguards used at each step are outlined to ensure the safe and consistent production of high-quality foils. The low-loss process enables future requests for isotopic thallium and other hazardous and rare materials.
Conner, Jenny↗