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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Failure Analysis for Molten Salt Thermal Energy Storage Tanks for In-Service CSP Plants

Thermal Energy Storage (TES) is a fundamental component in concentrating solar power (CSP) plants to increase the plant's dispatchability, capacity factor, while reducing the levelized cost of electricity. In central receivers CSP plants, nitrate molten salts have been used for several years for operation temperatures of up to 565 degrees C. Despite many efforts to advance nitrate salt to higher operation temperatures (even considering a replacement with molten chloride salts) to achieve higher energy conversion efficiencies, the 565 degrees C temperature is currently considered the state-of-the art. Although molten salt tanks have been broadly deployed in commercial CSP plants worldwide, several failures have been reported in these tanks after a few months or years of operation, causing significant economic loss and mistrust in CSP technologies. Most of these failures are associated with the infancy of the technology and multiple issues related to tank design, fabrication, commissioning, and aggressive operation. A technical standard dedicated to the design and fabrication of molten nitrate TES tanks does not exist today. Current in-service molten salt tanks have been generally designed based on the American Petroleum Institute's (API) 650 and ASME Section II standards. The API 650 code provides guidelines for dimensions and fabrication for oil storage tanks up to 260 degrees C. The ASME standard provides allowable stress values for various materials at a range of temperatures and conditions. Both standards seem to be limited for molten salt TES tanks where high temperatures, thermal cycling, and transient conditions are expected. In 2020, NREL released the Concentrating Solar Power Best Practices Study (NREL/TP-5500-75763) that summarized multiple issues in CSP plants, along with potential alternatives and recommendations to address those issues based on information collected from participants representing about 80% of operating CSP plants in the world. One of the recommendations from this study was the development of accurate and validated models to evaluate the plant's transient operation, capable of capturing the effect of short-term clouds and operator response, while being flexible in being adapted to various spatial and temporal resource data. The "Failure Analysis for Molten Salt Thermal Energy Tanks for In-Service CSP Plants" project was inspired on this recommendation and was focused on (1) the development and validation of a physics-based model for a representative, commercial-scale molten salt tank, (2) performing simulations to evaluate the behavior of the tank as a function of typical plant operation conditions, (3) understanding tank failures mechanisms, (4) determining the residual stress and distortion in the tank floor after welding fabrication and evaluating their impact in the stresses developed in the tank during operation, (5) assessing the impact of key operation parameters on the temperature and stress distribution, (6) conduct a preliminary evaluation of design features to reduce stress and improve tank's reliability, and (7) estimate the tank's service life based on the stress developed under diverse operation scenarios. From the analysis conducted in the project and presented in this report, it was found that maximum stresses surpassing the yield strength point of the stainless steel (SS) 347H are developed on the tank floor near the perimeter. These large stresses are strongly influenced by the initial residual stresses and distortion of the tank floor after welding fabrication. During operation, large stresses are developed in the tank floor at high operation temperatures with large salt inventory levels during transient operation. High stresses are also related to elevated temperature gradients in the tank floor that could be attributed to insufficient mixing within the salt inflow and the salt inventory. Based on the analysis, creep is the predominant failure mechanism. However, the large stress levels could favor the plastic deformation into buckles, and crack formation due to stress relaxation cracking during cycle operation. A lifetime below 3 years was estimated for the typical plant operation conditions and a specific initial residual stress and deformation distribution of the tank floor. The estimated life agrees with the service time to failure reported in several commercial molten salt tanks. Desing and operation guidelines can be extracted from the analysis presented in this report, which could be adopted by tank manufacturers and CSP operators to advance toward an ultimate solution for tank failures by reducing residual and operational stresses to achieve a tank service life of more than 30 years. Addressing failures in molten salt TES tanks is fundamental for the CSP industry's survivability, but it is also important for other industrial and power generation applications using this technology, including nuclear and concentrating solar thermal.

14 SOLAR ENERGY↗
DOE OSTI2023

Caribbean deepwater snappers: Application of the bomb radiocarbon age estimation validation in understanding aspects of ecology and life history

Reef fishes have been utilized as food fish throughout the U.S. Caribbean and Gulf of Mexico waters for centuries, with increasing fishing effort in recent decades. As a result, many species have experienced declines in landings, including deepwater snappers such as queen snapper Etelis oculatus and blackfin snapper Lutjanus buccanella . However, little to no peer-reviewed published research exists on basic life history parameters for either species. Confirming the accuracy of an age estimation method for a fish species is essential for ensuring sustainable fisheries management. This is because in the assessment of fisheries species population age-based parameters, including longevity, age at sexual maturity, growth rate, mortality, age-specific reproductive output, and lifetime reproductive output, are important in understanding overall life history strategies of managed stocks. The past stock assessment on U.S. Caribbean queen snapper utilized an estimated longevity of 8 y, derived from length frequencies for fish from St. Lucia. Blackfin snapper has an estimated longevity of 27 y based on a relatively small study from offshore waters of the southeastern U.S. The focus of our investigation was to estimate maximum longevity of two data-poor species in the U.S. Caribbean. The accuracy of ageing methods was tested via bomb radiocarbon age estimation validation and effects of depth on Δ 14 C in otolith cores and eye lens core values were examined. Results from our work indicate a maximum validated age of 45 y for queen snapper, and 43 y for blackfin snapper. Our findings indicate queen snapper and blackfin snapper are long-lived (> 40 y). The resulting Δ 14 C comparison between eye lens cores and otolith cores has important implications for the study of age validation, specifically when deepwater species are involved.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Machine Learning Augmented Predictive and Generative Model for Rupture Life in Ferritic and Austenitic Steels

The Larson-Miller parameter (LMP) offers an efficient and fast scheme to estimate the creep rupture life of alloy materials for high temperature applications. However, owing to poor generalizability and dependence on the constant C, which is typically not known a-priori, estimations using the Larson-Miller parameter often result in suboptimal performance for a wide range of materials. At best it is useful in comparing alloys of similar composition. In this work, three machine learning (ML) schemes were developed for rupture life prediction for 9-12% Cr ferritic-martensitic steels and austenitic stainless steels, i.e., a hierarchical model to parameterize LMP using the LMP constant C to compute rupture life, a hierarchical model to parameterize both C and LMP to compute rupture life, and a direct prediction of rupture life. Specifically, we show that the third scheme, using a gradient boosting algorithm, can be used to train ML models for very accurate prediction of rupture life in a variety of alloys (Pear-son Correlation Coefficient > 0.9 for 9-12% Cr and > 0.8 for austenitic stainless steels). In addition, the Shapley value was used to quantify feature importance, making the model interpretable by identifying the effect of various features on the model performance. Furthermore, a variational autoencoder-based generative model was built by conditioning on the experimental dataset to sample hypothetical synthetic candidate alloys from the learnt joint distribution not existing in both 9-12 % Cr ferritic-martensitic steel and austenitic stainless steel datasets. Finally, based on the predictive and generative model, a reinforcement learning strategy has been proposed to guide experimentalists into designing better heat resistant alloys.

Mamun, Md Osman G.↗
DOE OSTI2023

A Machine Learning–Based Tire Life Prediction Framework for Increasing Life of Commercial Vehicle Tires

In the commercial freight industry, tire retreading decisions are often conservative due to limited knowledge of a tire’s remaining service life. This practice leads to increased costs and material waste. This paper proposes a machine learning–based approach for estimating tire casing life and retreadability, focusing on usage data rather than wear information. This approach could extend the tire’s lifespan and reduce landfill waste. Data integration from diverse tire casing measurement sources presents challenges, including imbalanced removal data. Our methodology addresses these challenges by using historical inspection, telematics, and finite element modeling (FEM) datasets. We introduce “Tire Casing Energy” as a comprehensive usage input and apply a Variance-Reduction Synthetic Minority Oversampling Technique (VR-SMOTE) for data imbalance rectification. A random forest model is used to estimate the state of the tire casing and the casing removal probability, with Bayesian optimization applied for hyperparameter tuning, enhancing model accuracy. Here, the proposed prediction framework is able to differentiate different truck fleets and tire locations based on their usage parameters. With the aid of this machine learning model, the importance and sensitivity of different tire usage parameters can be obtained, which is beneficial to maximize tire life.

Data balancing↗
DOE OSTI2026

Tracing U.S. fuel life-cycle greenhouse gas emissions in a multi-sector dynamics model using LC-GCAM

Model-based analysis of fuel pathways is essential for informing energy and environmental policy. Two major model types are typically used: multi-sector dynamics models, which capture the broader energy-economy, such as GCAM (Global Change Analysis Model), and life cycle assessment models, such as GREET (Greenhouse Gases, Regulated Emissions, and Energy Use in Transportation). Each has distinct strengths and limitations, and recent studies increasingly adopt hybrid approaches to harness the advantages of both. However, such integration is often time-consuming and complicated by inconsistencies in system boundaries and technology definitions. We present LC-GCAM, a new tool that enables estimation of life-cycle greenhouse gas emissions and primary energy use for any fuel pathway represented in GCAM. We apply LC-GCAM to 300 scenarios designed to explore key uncertainties affecting the life-cycle performance of future fuel options in the U.S. freight sector. To evaluate LC-GCAM, we compare its results with those from GREET for nine fuel types in a 2030 reference scenario. When input assumptions are modestly aligned, LC-GCAM and GREET estimates typically agree within 10% (absolute sum-based mean absolute percentage error). LC-GCAM offers a flexible and efficient approach to generating life-cycle metrics within an integrated modeling framework, supporting robust policy analysis across a wide range of interacting energy system uncertainties.

Wolfram, Paul↗
DOE OSTI2020

Chapter 13: A Simple Estimation of UV Irradiance Under Clear-Sky Conditions

Accelerated aging tests are designed to estimate the useful life of products in their end-use environment. There is currently no simple way to answer the age-old question: “How long should I run my weathering test to reproduce 1 year of outdoor aging?” At the very least, there is need to (1) evaluate the acceleration rate associated with each stress factor and (2) estimate the intensity of the stress factors that the products under scrutiny are exposed to in natural aging. In this chapter, a model is introduced to calculate the ratio between ultraviolet (UV) irradiance and global horizontal irradiance (GHI). This method was empirically derived from measured or simulated irradiance data and validated against outdoor observations. This ratio provides a simple way to estimate the UV dose that samples are exposed to at any outdoor location.

ENERGY PLANNING, POLICY, AND ECONOMY,OTHER INSTRUM↗
DOE OSTI2020

Life-Cycle Baseline Customization for the Formerly Utilized Sites Remedial Action Program - 20304

One of the responsibilities of the federal government is to estimate sound and defensible life-cycle baseline costs for use in federal budget estimates and to meet federal financial reporting requirements. To accomplish this, the US Department of Energy (DOE) Office of Legacy Management (LM) and the US Army Corps of Engineers (USACE) have partnered together to ensure that the liabilities documented in each Formerly Utilized Sites Remedial Action Program (FUSRAP) site's life-cycle baseline are specifically tailored. FUSRAP was created in the mid-1970's to clean up radiological contamination resulting from the early development of nuclear weapons. DOE was responsible for FUSRAP until October 1997, when Congress transferred the administration and execution of FUSRAP site cleanups to USACE. By 1997, DOE had completed the cleanup of 25 of the 46 sites that were active within the program and had begun cleanup at 13 additional sites. USACE was assigned responsibility for the cleanup of the 21 remaining FUSRAP sites, and at 8 additional sites that had since been referred for cleanup. The LM mission for the FUSRAP sites is to perform long-term surveillance and maintenance (LTS and M). Currently, LM provides long-term stewardship for 34 completed FUSRAP sites. Another 20 sites are under active remediation by USACE. Within the last 5 years, USACE has completed the cleanup at five FUSRAP sites and the LTS and M responsibility has been transferred to LM. By 2029, USACE will compete remediation at eight additional sites and LTS and M for those sites will transfer to LM. Because responsibilities for the FUSRAP sites transfer between USACE and LM upon completion of remedial actions, both agencies maintain life-cycle baselines for different stages of the project and both must have a strong understanding of the needs and requirements for each site. This understanding ensures that the life-cycle baselines form a complete and accurate picture of what is required for the site and for the FUSRAP program. LM focuses on several things when customizing the life-cycle baseline estimates for the FUSRAP sites, including (1) Understanding the unique requirements for each site. By reviewing site-specific documents prepared by USACE, such as Feasibility Studies and Records of Decision, and partnering with USACE to gain additional insight about site conditions and requirements for stewardship, as well as potential risks, LM can better develop the life-cycle baselines. (2) Developing site-specific labor breakdowns. This ensures the required labor mix is baselined for specific activities by comparing the labor mix required to perform activities at (a) other LM-managed FUSRAP sites and (b) non-FUSRAP LM sites and (c) by USACE at active FUSRAP sites. (3) Taking a tiered approach to life-cycle baseline planning. Estimates for sites transferring to LM in the near term (5 years) are more definitive than for sites transferring in the out-year period. Remedial actions at the near-term sites are at or near completion, providing LM a strong understanding of the LTS and M requirements and remaining liabilities. This in turn allows for site-specific customization of the baseline. (4) Using a robust risk management approach to ensure that liabilities specific to each site are identified, evaluated by probability and severity, and documented in relation to the impact to cost or schedule. To ensure the most accuracy within all the baselines, the FUSRAP life-cycle baselines are updated as needed to support program, project, and contract management needs. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Validating Greater Sage-Grouse Individual-based Model (IBM) Tool (Final Report)

The project focused on validating the previously developed Greater Sage-Grouse Individual-based Model (GrSG IBM; LaGory et al. 2012, 2021). The objective was to transform this predictive, spatially and temporally explicit model into a portable resource to assist siting/resource managers in proactively assessing the cumulative impacts of wind energy development on the greater sage-grouse. Utilizing a bottom-up, individual-based approach, the GrSG IBM accounts for landscape context and species behavior, aiming to reduce uncertainty in estimating development impacts and support ecologically mindful land-based wind energy development. The validation effort covered approximately 6,540 km 2 near the Seven Mile Hill Wind Project in Wyoming. The GrSG IBM tool, built on the NetLogo platform (Tisue and Wilensky 2004), was executed over a 50-year period, with the analysis focusing on years following a 10-year initialization phase. Key results demonstrated the tool’s biological soundness across five key biological metrics: non-chick age class distribution (older than 10 weeks), adult sex ratio, life expectancy, population size, and overall population growth. For instance, the tool estimated that 58.6% of the non-chick population was reproductively immature, while the reference ranges from 51.4% to 57.8% (Patterson 1952, Rogers 1964). Experts confirmed the tool’s estimate was within a reasonable range for the species. The tool estimated average life expectancy of 1.43 years, while the reference ranges from 0.9 years to 1.1 years (Ammann 1957, Hamerstrom 1949). Experts also supported the model’s life-expectancy estimate as ecologically sound for the species in the study area. In terms of population change, the model estimated an annual shift between a 0.6% decline and a 1.0% increase over 50 years. While the reference suggests 2.9% annual decline in range-wide populations (Cortes et al. 2023), that includes many at-risk populations in South Dakota and Washington, for example. Our study area—in the northeastern part of Carbon County and western-edge of Albany County, Wyoming—is one of the remaining greater sage-grouse habitats supporting some of the most stable populations. Experts confirmed that the range of the annual population change spanning from a 0.6% decline to a 1.0% increase estimated by the tool was reasonable for our study area for this reason and confirmed that aligned with population estimates from existing studies on the greater sage-grouse and wind energy development in the study area (LeBeau et al. 2017a, Smith et al. 2024). Furthermore, the project showed that temporally explicit biological metrics generated by the GrSG IBM tool can complement the USGS’ Prioritizing Restoration of Sagebrush Ecosystems Tool (PReSET; Duchardt et al. 2021) by incorporating habitat restoration strategies into seasonal habitat suitability models to visualize population responses over time.

17 WIND ENERGY↗
DOE OSTI2025

Searching for a Pulse: Evaluating the Use of Rapid DC Pulses for Diagnosing Battery Health, State-of-Charge, and Safety

Rapid electrochemical diagnostics, like DC pulse sequences or electrochemical impedance spectroscopy, are known to be useful for capacity prediction. However, it is unclear how previous results will map to different cell types and use cases and whether rapid diagnostics are useful for remaining useful life prediction or for detecting potential safety issues. To that end, we have collected a data set with ∼50,000 DC pulse measurements from four types of commercial lithium-ion batteries to enable training of state-of-charge, health, and safety diagnostic models via machine-learning. We demonstrate that 120-second DC pulse sequences can be used to predict capacity with 2%–9% average error, which can separate high- from low-capacity cells with only a 0.3% false positive rate but is not accurate enough to estimate remaining useful life. We also find that no safety related targets can be accurately predicted, highlighting the critical need for other non-invasive methods to diagnose battery safety.

25 ENERGY STORAGE↗
DOE OSTI2021

Biofuel Options for Marine Applications: Technoeconomic and Life-Cycle Analyses

This study performed technoeconomic and life-cycle analyses to assess the economic feasibility and emission benefits and tradeoffs of various biofuel production pathways as an alternative to conventional marine fuels. We analyzed production pathways for (1) Fischer-Tropsch diesel from biomass and cofeeding biomass with natural gas or coal, (2) renewable diesel via hydroprocessed esters and fatty acids from yellow grease and cofeeding yellow grease with heavy oil, and (3) bio-oil via fast pyrolysis of low-ash woody feedstock. We also developed a new version of the Greenhouse gases, Regulated Emissions, and Energy use in Transportation (GREET) marine fuel module for the estimation of life-cycle greenhouse gas (GHG) and criteria air pollutant (CAP) emissions of conventional and biobased marine fuels. The alternative fuels considered have a minimum fuel selling price between 2.36 and 4.58 $/heavy fuel oil gallon equivalent (HFOGE), and all exhibit improved life-cycle GHG emissions compared to heavy fuel oil (HFO), with reductions ranging from 40 to 93%. The alternative fuels also exhibit reductions in sulfur oxides and particulate matter emissions. Additionally, when compared with marine gas oil and liquified natural gas, they perform favorably across most emission categories except for cases where carbon and sulfur emissions are increased by the cofed fossil feedstocks. The pyrolysis bio-oil offers the most promising marginal CO2 abatement cost at less than $100/tonne CO2e for HFO prices >$1.09/HFOGE followed by Fischer-Tropsch diesel from biomass and natural gas pathways, which fall below $100/tonne CO2e for HFO prices >$2.25/HFOGE. Pathways that cofeed fossil feedstocks with biomass do not perform as well for marginal CO2 abatement cost, particularly at low HFO prices. This study indicates that biofuels could be a cost-effective means of reducing GHG, sulfur oxide, and particulate matter emissions from the maritime shipping industry and that cofeeding biomass with natural gas could be a practical approach to smooth a transition to biofuels by reducing alternative fuel costs while still lowering GHG emissions, although marginal CO2 abatement costs are less favorable for the fossil cofeed pathways.

Greenhouse gas, life cycle assessment, techno-econ↗
DOE OSTI2023

Adhesion and tribological characteristics of modified polyurethane coating on composite substrate

In the present study, glass-epoxy composites were used as a substrate to study the performance of modified polyurethane coating. Two-layer coating (180–200 µm) wherein the epoxy primer as the first coat and polyurethane as the top coat was applied using an air-assisted spray gun to increase the service life of the composite. The analysis of coating was performed using gloss, contact angle, FTIR, TGA, tensile test and SEM. The bonding strength between coating and substrate was evaluated by cross-hatch cut, 180 deg peel strength and pull-off adhesion tests. Scratch, Taber abrasion and Pin-on-disc tests were also performed to evaluate the wear resistance. In addition, a rain erosion test was performed to check the stability of the coating. From the above tests, it is concluded that the applied coating well adhered to the composite substrate. The data generated from different tests can be used to estimate the service life of polymer composites and coatings.

Mushtaq, Mohammed↗
DOE OSTI2021

Age and growth of early‐life‐stage Atlantic tarpon ( Megalops atlanticus) from the northcentral Gulf of Mexico

Abstract Age and growth of early‐life‐stage Atlantic tarpon Megalops atlanticus collected from Mississippi coastal waters in the northcentral Gulf of Mexico (GOM) are described using otolith microstructure analysis. Tarpon leptocephali ( n = 95, 16.0—27.8 mm standard length, L S ) collected from June throughOctober 2013—2018, ranged in age from 22 to 43 days (mean = 30.9 ± 0.5 days). Leptocephalus somatic growth rates ranged 0.46—1.24 mm day −1 (mean = 0.76 ± 0.02 mm day −1 ), and leptocephalus otolith growth rates ranged 1.78—3.97 μm day −1 (mean = 2.58 ± 0.04 μm day −1 ). Growth rates were inversely correlated to leptocephalus age, indicating the shrinkage phase associated with leptocephalus metamorphosis. Juvenile tarpon ( n = 358, 50—359 mm fork length, L F ) were collected from August through December 2007—2018. Juveniles exhibited a positive allometric relationship (adjusted R 2 = 0.99, P < 0.001) between length and mass. The age of 100 juveniles (71—277 mm L F ) ranged from 76 to 174 days. Juvenile growth rate was estimated as 1.56 ± 0.11 mm day −1 . Significant ( P < 0.001) linear relationships were found between juvenile age and otolith metrics, including otolith mass ( R 2 = 0.81) and radius ( R 2 = 0.68). Evaluation of the backcalculated hatch dates suggests that specimens in the collection hatched from late May through mid‐September with slight peaks during July and August. A Rao's Spacing Test of Uniformity indicates the presence of significant lunar periodicity in leptocephalus hatch dates ( n = 95, U = 250.1, P < 0.05), with 50% of the leptocephali hatched within 5 days (before or after) of the full moon. This study fills critical gaps in the scientific knowledge of tarpon and provides estimates of early‐life‐history metrics for an iconic game fish at the northernmost extent of its GOM range.

Graham, Patrick M.↗
DOE OSTI2026

Solventless, Ambient-Pressure Production of Bio-Based Lactones Over Earth-Abundant, Mixed Metal Oxide Catalysts for Circular Polyesters

Transitioning to a circular plastics economy will require use of renewable feedstocks, energy-efficient processes, and closed-loop recyclable polymers, such as polyesters. A key challenge lies in sustainably sourcing monomers used to make recyclable polyesters. This work presents a catalytic platform utilizing earth-abundant Cu(x)Ca(1-x)O mixed metal oxides for the oxidative dehydrocyclization of bio-based diols to lactones, which are advantaged for energy-efficient ring-opening polymerization. Operating below 200 degrees C, at ambient pressure, and without solvent, the process uses air as the sole oxidant, achieving high yields of lactones across a broad substrate scope of C4-8 diols in the liquid phase. The oxidative dehydrocyclization reaction is thermodynamically downhill due to water formation and energy-efficient compared to incumbent, non-redox pathways utilized in fossil carbon-based industrial processes for lactone production. Mechanistic studies reveal facile redox cycling of Cu2+-O(Ca2+)-Cu2+ interfacial sites unique to the developed catalyst. Techno-economic analysis and life cycle assessment estimate 40% lower energy demand and 15% lower GHG intensity per mass of butyrolactone produced compared to the fossil carbon-based route. Liquid-phase oxidative dehydrocyclization offers a promising approach for scalable lactone production from renewable, bio-based diols to enable circular polyesters.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Synergy of tensile strength and high cycle fatigue properties in a novel additively manufactured Al-Ni-Ti-Zr alloy with a heterogeneous microstructure

Alloy design strategies in additive manufacturing (AM) to achieve grain refinement and terminal eutectic solidification have been introduced to engineer Al alloys having microstructural hierarchy and heterogeneity. Such alloy design strategies enable crack-free builds with an expanded AM processing window and pushed the strength limit in Al alloys. However, fatigue performance of Al alloys made by AM is restricted by the presence of process induced defects and its stochasticity. In this work, tensile and high cycle fatigue (HCF) behavior of a novel Al-Ni-Ti-Zr alloy with a heterogeneous microstructure is studied in the as-built condition, supplemented by detailed microstructural and mechanical characterization. Excellent strength-ductility synergy of 342 MPa and 16% failure strain achieved in the alloy was associated with the microstructural attributes that pertain to the novel alloy. Additionally, the alloy showed excellent HCF performance with a fatigue endurance limit to ultimate tensile strength ratio of 0.29 in flexural fatigue mode. The study revealed the existence of multiple crack retardation mechanisms and favorable crack propagation pathways through the fine-grained regions which enabled good fatigue performance to the alloy. Further, a probabilistic model has been used to estimate the fatigue life of the alloy as a function of the stochastic microstructure by utilizing the statistical distribution of pores, solid-state inclusions, and grains in the AM Al alloy. Finally, the model parametric trends are consistent with the experimental observations.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development of Predictive Model for Accurate Rupture Time from Multi-Axial Creep in Alloy 709 with Physics-Based Simulations

A physics-based model is developed to predict multiaxial creep behavior in Alloy 709 (A709), an advanced austenitic stainless steel intended for high-temperature applications such as Sodium Fast Reactors (SFRs). Compared to conventional stainless steels like 316H, A709 offers superior high-temperature performance; however, comprehensive data on its multiaxial creep response remain limited. To address this gap, a crystal plasticity finite element (CPFE) framework is used to simulate the deformation and failure mechanisms of A709 under multiaxial loading conditions. The model incorporates an extended Hu-Cocks dislocation creep formulation that accounts for precipitation effects, along with the Sham–Needleman model to capture grain boundary cavitation-driven failure. These advanced constitutive models enable a detailed understanding of the interplay between microstructural evolution and macroscopic creep response. Furthermore, the study evaluates the predictive accuracy of various effective stress measures in estimating creep rupture life, leveraging simulated multiaxial creep data. The findings provide critical insights into the applicability of different stress measures for engineering design and life prediction of A709 components operating under complex loading conditions. This work contributes to improving the reliability of high-temperature structural components by advancing predictive modeling capabilities for advanced austenitic steels.

Alloy 709↗
DOE OSTI2021

Technoeconomic Assessment of a Sequential Step-Leaching Process for Rare Earth Element Extraction from Acid Mine Drainage Precipitates

Herein, Coal waste products have been studied as a new source of Rare Earth Elements (REEs) and other Critical Minerals (CM) essential for the development of renewable energy technologies, but the economic viability of these source materials is not well understood. This paper examines the technoeconomic performance of a novel process for rare earth element extraction from acid mine drainage precipitates (AMDp) in the Appalachian Coal Basin. The three phase extraction process includes excavation and transportation of AMDp, multi-phase pH driven step-leaching of REEs at ambient conditions, and commercial solvent extraction to produce a saleable grade rare earth oxide material that can be reduced to a pure metal. We estimate the life-cycle cost of bench-scale extraction of REEs from two representative Appalachian AMDp feedstock chemistries at between 4000 – 6000 $/kg of mixed REE concentrate produced. Both the AMDp composition and process parameters affect the profitability of REE extraction, with the REE concentration and distribution of REE in the feedstock, extraction and precipitation reagent consumption rates, and the potential for reagent recycling as the key variables. Economically profitable valorization of REE from AMDp will require a combination of continued process innovation and sizable financial incentives to substantially influence domestic supply of REEs.

36 MATERIALS SCIENCE↗