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DOE OSTI2021

High Throughput In-Line Coating Metrology Development for Solid Oxide Fuel Cell Manufacturing

Coatings play key roles in solid oxide fuel cell (SOFC) stack durability. For example, diffusion barrier coatings on Cr-containing interconnect and balance of plant (BOP) components protect electrodes from Cr poisoning over the long operational lifetimes (>10,000 hours) of the fuel cell stack. Common defects in coatings, such as cracks, pinholes, and porosity, result in a failure to protect the electrodes, resulting in shorter operational lifetime and thus higher cost. It is very unlikely, even in the best coating process, that all these defects can be mitigated, hence identifying critical defects in parts, and removing defective parts from production before they can damage the stack, becomes paramount. Furthermore, these quality control techniques must be operational in the production/assembly line (in-line), i.e., high throughput and non-destructive, and cost effective. Redox Power Systems, LLC (Redox) together with the National Renewable Energy Laboratory (NREL) developed much needed high throughput, in-line metrology techniques for protective coatings. The overall goal of the project is to lower cost while increasing robustness, reliability, and endurance of SOFC stacks. To accomplish this, we had several objectives, including: to identify key coating and substrate defects that lead to coating failure through the use of detailed characterization methods (e.g., microscopy, XRD, EDS, electrochemistry); to assess capabilities of in-line metrology techniques, e.g., optical profilometry (Redox) and thermography (NREL), to probe these defects, or evidence thereof; demonstrate long-term performance of “defect-free” protective coatings, as identified by in-line metrology, in solid oxide fuel cell (SOFC) stack operation. In the first part of this project, the ability to identify key defects expected to lead to coating and SOFC degradation using in-line metrology tools were evaluated. Coated interconnect samples with controlled defect types and populations were tested under conditions similar to SOFC operation, followed by detailed post-test analysis to reveal the defects responsible for observed degradation. In the second part of the project, the optimal in-line metrology techniques and methodologies were used to map the defect distribution in full-size interconnects with critical defects intentionally allowed to exist in some cases. These interconnects underwent SOFC testing for extended periods (up to ~3,000 hours) followed by post-test analysis to evaluate the effectiveness of in-line metrology techniques in mitigating MCO coating related degradation. Key accomplishments in this project included the following: Demonstrated ASR of < 0.05 ohm-cm 2 at 650 °C for 1,000 hours with low defect (determined by in-line metrology) interconnect samples (average ASR=37 milliohms-cm 2 after over 1,000 hours). Demonstrated that low defect coatings on interconnects (as screened using in-line metrology) have low volatilization of chromium at ~650 °C for 1,000 hours as detected using Cr-getter material (< 5 at% increase above baseline); 1022 hour duration tests under humidified, elevated temperature (750 °C rather than 650 °C) compared a base case against different coating thicknesses. Demonstrated capability to identify initial key defects of interest with in-line metrology techniques using up to 8 cm by 10 cm having coatings with and without intentional defects of interest using thermal imaging and optical profilometry. Correlated key defects identified using metrology techniques with observed coating performance (e.g., ASR and Cr volatility). Conducted several 4 cm by 4 cm cell tests using MCO-interconnects that were pre-screened using some of the metrology techniques developed in the project (e.g., optical profilometry). An analysis of ASR measurements were able to show that defect-free coatings resulted in the anticipated performance in the cell tests.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Effects of Sodium Exposure on the Tensile Properties of Grade 91 steel

Two heats of G91 steel have been investigated in liquid sodium at 550- 650°C to understand their corrosion behaviour, microstructural evolution, and tensile properties. Sodium exposure experiments of subsized, sheet-type tensile specimens of G91 were performed in Argonne’s forced convection sodium materials testing loops, SMT-1 and SMT-2. Maximum exposure times of ~49,000 h at ~38,000 h, and ~20,000 h have been achieved at 550, 600, and 650°C, respectively. Thermal aging experiments of G91 steel were also conducted in parallel, and the results were compared with those of the sodium-exposed specimens to isolate the effect of thermal aging from the effect of sodium exposure. It was found that the yield stress and ultimate tensile strength of G91 were reduced by more than 50% after sodium exposures at 650°C due to decarburization. The reduction in tensile strength was accompanied by the dissolution of M 23 C 6 carbides and excessive grain growth. The effect of sodium at 550 and 600°C was insignificant for exposure times up to ~49,000 h and ~38,000 h, respectively. The effect of sodium on the microstructural stability and tensile properties of G91 is largely dependent on the carbon mass transfer in the alloy-sodium system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

First Ever Field Pilot on Alaska's North Slope to Validate the Use of Polymer Floods for Heavy Oil EOR a.k.a Alaska North Slope Field Laboratory (ANSFL)

Alaska’s high viscosity oil resources that range between 20–30+ billion barrels represent about a third of known North Slope original oil in place (OOIP). These resources are primarily concentrated in the Schrader Bluff formation (also called West Sak on the Western North Slope) and Ugnu reservoirs and are categorized as “viscous oils” and “heavy oils” owing to their in-situ viscosities between 5–10,000 cP and up to a million+ cP respectively. The viscous oil deposits are relatively deeper (2,000 – 5,000 ft), whereas the heavy oils are somewhat shallower (2,000 – 4,000 ft). The typically shallow depths and the proximity to the continuous permafrost results in relatively lower formation temperatures and pressures, and consequently higher viscosities. The vertical depth vs. viscosity delineated in Paskvan et al. (2016) differentiates the viscous and heavy oils. As depicted in Paskvan et al. (2016), currently the main focus (referred to as “developing”) is on the viscous oils in the Schrader Bluff formation in the Milne Point Unit (MPU). Notwithstanding this Alaska North Slope (ANS) specific categorization, we use the industry adopted, all-inclusive term “heavy oil” for all high viscosity oils. Resource characterization and additional details can be found in topical publications of Paskvan et al. (2016) and Targac et al. (2005). Despite the vast resource base, the development pace, vis-à-vis the production of heavy oils has been very slow and limited due to multiple factors such as cost, logistics, challenging arctic environment, poor waterflood sweep efficiency due to mobility contrasts, and significantly high minimum miscibility pressures (MMP). Most importantly, typical or standard thermal methods that are commonplace elsewhere (Canada, California) are inapplicable due to the continuous permafrost. As a consequence, cumulative production of heavy and viscous oils is a little over 1% of OOIP slope wide and currently, there is hardly any production from Ugnu. However, on a broader level, these unfavorable factors are outweighed by the fact that (1) these resources, within the established infrastructure, are too large to ignore because of their strategic importance to the Nation and the State of Alaska and (2) Prudhoe Bay type diluent crude oil is still available for heavy oil transport through the Trans Alaska Pipeline System (TAPS). Similarly, from a reservoir standpoint, the following factors also are important offsets: (1) favorable rock characteristics of Schrader Bluff; (2) the promise demonstrated by the initial scoping studies (Seright 2010, 2011) suggesting significant increase of heavy oil recovery using polymer flooding; (3) successful field implementation in Canada, China and elsewhere in the world, and (4) availability of the existing pairs of horizontal injector-producer in Schrader Bluff The foregoing was recognized as the best readily available opportunity for significant investment by the US Department of Energy and the field operator Hilcorp Alaska LLC to conduct the first ever field scale experiment to test the polymer flooding technology to unlock the vast heavy oil resources on ANS. With this primary goal in mind, the research team embarked on a ~4.5 years long project that focused on the field polymer pilot complemented by supporting laboratory and simulation studies. As documented in this final report, over the course of the project, many lessons have been learned and valuable field and supporting laboratory data has been collected, which also is complemented by numerical reservoir simulations. We have been able to establish the injectivity of polymer solution, evidence of significant reduction in the water cut of previously waterflooded pattern, effective propagation of a hydrolyzed polyacrylamide (HPAM), benefits of low salinity water, provide practical guidance on handling of produced fluids containing breakthrough polymer, fit-for-purpose forecast-worthy history matched simulation model, polymer EOR benefit of 700-1000 bopd over waterflood, and most importantly a low polymer utilization factor of ~1.7 lb/stb. In summary this project is deemed as a scientific, technical and economic success, having met all objectives, fulfilled deliverables and within budget, providing impetus to apply polymer EOR throughout the Milne Point Field paving the way for even heavier viscosity oils in the Ugnu area, eventually extending the economic life of TAPS.

02 PETROLEUM↗

DOE OSTI2022

Construction of Women’s All-Around Speed Skating Event Performance Prediction Model and Competition Strategy Analysis Based on Machine Learning Algorithms

Introduction Accurately predicting the competitive performance of elite athletes is an essential prerequisite for formulating competitive strategies. Women’s all-around speed skating event consists of four individual subevents, and the competition system is complex and challenging to make accurate predictions on their performance. Objective The present study aims to explore the feasibility and effectiveness of machine learning algorithms for predicting the performance of women’s all-around speed skating event and provide effective training and competition strategies. Methods The data, consisting of 16 seasons of world-class women’s all-around speed skating competition results, used in the present study came from the International Skating Union (ISU). According to the competition rules, distinct features are filtered using lasso regression, and a 5,000 m race model and a medal model are built using a fivefold cross-validation method. Results The results showed that the support vector machine model was the most stable among the 5,000 m race and the medal models, with the highest AUC (0.86, 0.81, respectively). Furthermore, 3,000 m points are the main characteristic factors that decide whether an athlete can qualify for the final. The 11th lap of the 5,000 m, the second lap of the 500 m, and the fourth lap of the 1,500 m are the main characteristic factors that affect the athlete’s ability to win medals. Conclusion Compared with logistic regression, random forest, K-nearest neighbor, naive Bayes, neural network, support vector machine is a more viable algorithm to establish the performance prediction model of women’s all-around speed skating event; excellent performance in the 3,000 m event can facilitate athletes to advance to the final, and athletes with outstanding performance in the 500 m event are more likely competitive for medals.

Liu, Meng↗

DOE OSTI2021

Future Battery Material Demand Analysis Based on U.S. Department of Energy R&D Targets

The U.S. Department of Energy’s Vehicle Technologies Office (VTO) supports research, development, and deployment of efficient, sustainable transportation technologies that will improve energy efficiency and fuel economy, and enable America to use less petroleum. To accelerate the development and adoption of new technologies, VTO has developed specific targets for a wide range of powertrain components, including the energy storage system. In this study, we use Autonomie, Argonne National Laboratory’s (Argonne’s) vehicle system simulation tool to evaluate future energy storage requirements (power, energy, etc.) for different vehicle classes, powertrains, component technologies and timeframes. BatPac, Argonne’s tool dedicated to energy storage pack design and costs, is then used to quantify the materials required for each pack. Market penetrations are then used to estimate the overall material demand worldwide and in the United States, with or without recycling. The results demonstrate that the positive impact of VTO research and development will lead to significant reduction in material compared to business-as-usual due to new anode and cathode designs, along with acceleration in battery cell chemistry penetrations. In terms of material demands, it is observed that lithium demand reaches about 80,000 tons (by a factor of 42–45), nickel demand reaches about 500,000 tons (by a factor of 47–56), manganese demand reaches about 30,000–50,000 tons (by a factor of 20–34), and cobalt demand reaches about 30,000 tons (by a factor of 13–28) in the future by 2050. The individual material demand per unit energy, however, decreases significantly in the future due to advances in VTO research and development activities. The increase in battery material demands is mostly driven by increased electrified vehicle fleet penetration in the markets.

25 ENERGY STORAGE↗

DOE OSTI2021

Extraction of gold, mercury and lead on CL resin in HCl

The uptake behavior of 197 mHg, 194 Au and 212 Pb in HCl on CL resin (Triskem) was studied. The extraction of mercury and gold is high (D w > 5,000) at all concentrations of HCl, with a maximum extraction of gold at 4 M HCl (D w ~ 53,000) and maximum extraction of mercury at 0.01 M HCl (D w ~ 44,000). Lead has moderate uptake on CL resin (D w ~ 100) from lower concentrations of HCl (0.001 to 0.05 M) and no uptake on the resin in concentrations ≥ 0.4 M. The uptake kinetics are similar for all three isotopes with high weight distribution ratios (>1,000 for 197 mHg, 194 Au and > 100 for 212 Pb) in ~ 30 s and equilibrium established at ~ 5 min. A column study was performed to demonstrate that 197m Hg, 194 Au and 212 Pb could be retained on CL resin in dilute HCl and 212 Pb eluted in 1 M HCl with no detectable 197m Hg or 194 Au. Elution of 197 mHg and 194 Au was performed with concentrated HNO 3 , but with significant losses to the column, particularly for 194 Au.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

DOE OSTI2020

Ultrahigh temperature in situ transmission electron microscopy based bicrystal coble creep in zirconia I: Nanowire growth and interfacial diffusivity

This study demonstrates novel in situ transmission electron microscopy-based microscale single grain boundary Coble creep experiments used to grow nanowires through a solid-state process in cubic ZrO 2 between ≈ 1200 °C and ≈ 2100 °C. Experiments indicate Coble creep drives the formation of nanowires from asperity contacts during tensile displacement, which is confirmed by phase field simulations. The experiments also facilitate efficient measurement of grain boundary diffusivity and surface diffusivity. 10 mol% Sc 2 O 3 doped ZrO 2 is found to have a cation grain boundary diffusivity of $D_{gb} = (0.056 ± 0.05)exp (\frac{-380,000±41,000}{RT})m^2 s^{-1}$, and $D_s = (0.10 ± 0.27)exp(\frac{-380,000 ± 28,000}{RT}) m^2 s^{-1}$.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Characterization of γ′/γ″ compact and sandwich type precipitates during long-term high-temperature exposure in Ni-based superalloys

Here, the formation of γ′/γ″ co-precipitates is investigated in Ni-based superalloys with a varying Ti/Al ratio and Ta content and their stability is studied using long-term high-temperature exposure. Transmission electron microscopy and atom probe tomography analyses demonstrate that both higher Ti/Al ratios and increased Ta promote γ″ phase formation, leading to sandwich and compact structures. The compact co-precipitation significantly reduces γ′ precipitate coarsening during 10,000 h exposure at 700°C by restricting elemental diffusion, particularly of aluminum, from the γ matrix to the γ′ phase. For the alloy without a compact structure, and only γʹ precipitates, at the beginning of the exposure, the coarsening rate over 10,000 h was 3.5 times faster than for the alloy with compact γʹ/γʺ precipitates. Evidence of destabilization of the compact morphology was found to occur between 5,000 and 10,000 h exposure and originated from the extensive formation and growth of δ platelets that extended throughout the grains. Thus, the outer layer of the compact, which consists of γʺ, was subjected to the γ″ to δ phase transformation.

gamma double prime↗

DOE OSTI2021

Role of emission controls in reducing the 2050 climate change penalty for PM2.5 in China

Previous studies demonstrated that global warming can lead to deteriorated air quality even when anthropogenic emissions were kept constant, which has been called a climate change penalty on air quality. It is expected that anthropogenic emissions will decrease significantly in the future considering the aggressive emission control actions in China. However, the dependence of climate change penalty on the choice of emission scenario is still uncertain. To fill this gap, we conducted multiple independent model simulations to investigate the response of PM2.5 to future (2050) climate warming (RCP8.5) in China but with different emission scenarios, including the constant 2015 emissions, the 2050 CLE emissions (based on Current Legislation), and the 2050 MTFR emissions (based on Maximum Technically Feasible Reduction). For each set of emissions, we estimate climate change penalty as the difference in PM2.5 between a pair of simulations with either 2015 or 2050 meteorology. Under 2015 emissions, we find a PM2.5 climate change penalty of 1.43 µg m-3 in Eastern China, leading to an additional 35,000 PM2.5-related premature deaths [95% confidence interval (CI), 21,000-40,000] by 2050. However, the PM2.5 climate change penalty weakens to 0.24 µg m-3 with strict anthropogenic emission controls under the 2050 MTFR emissions, which decreases the associated PM2.5-related deaths to 17,000. The smaller MTFR climate change penalty contributes 14% of the total PM2.5 decrease when both emissions and meteorology are changed from 2015 to 2050, and 24% of total health benefits associated with this PM2.5 decrease in Eastern China. This finding suggests that controlling anthropogenic emissions can effectively reduce the climate change penalty on PM2.5 and its associated premature deaths, even though a climate change penalty still occurs even under MTFR. Strengthened controls on anthropogenic emissions is key to attaining air quality targets and protecting human health in the context of future global climate change.

Liu, Song↗

DOE OSTI2024

Material Recovery Facilities (MRFs) in the United States: Operations, revenue, and the impact of scale

An analysis was conducted using nationwide survey data to evaluate how material recovery facilities (MRFs) operations vary regionally and with scale. The survey characterized materials, processes, and energy use involved with operations, and revenue for recyclables. This is the first nationwide analysis of MRFs in the US that accounts for mass processed, energy consumed, and revenue. Of a population of 521 MRFs, 48 responses representing MRFs from five US regions were received and analyzed (9.2 % response rate). Responses were analyzed by size according to yearly mass of inbound materials (small: <1,000 Mg/year, medium: 1,000–10,000 Mg/year, and large: >10,000 Mg/year). Most MRFs identify as single-stream; source from residences; utilize tipping floors, picking lines, baling and warehousing; and are powered by electricity. Most revenue and inbound mass (>50%) came from fiber (cardboard and paper). Glass had little revenue, and plastics were difficult to transition to market. Percent residue ranged from 1-39%, averaged <20%, and increased as the mass of inbound material increased. Large MRFs reported more sources of material, employed advanced sorting technology, had greater plastics revenue (33% versus 5% for small MRFs), and had more market access for plastics compared to small MRFs. Large MRFs had two orders of magnitude less annual electricity consumption per Mg recyclables than small MRFs (5–90 kWh/Mg versus ∼300–550 kWh/Mg). Results demonstrate environmental and economic benefits of larger-scale MRFs, which could be implemented more broadly in the US through regional hub-and-spoke arrangements for collecting and processing recyclables, lowering energy consumption and increasing revenue for recyclables.

Hub-and-Spoke↗

DOE OSTI2020

Identifying Abandoned Well Sites Using Database Records and Aeromagnetic Surveys

Oil and natural gas are primary sources of energy in the United States. Improved drilling and extracting techniques have led to a renewed interest in historic oil and gas fields, but limited records of legacy wells make new drilling efforts more difficult, as abandoned wells may provide conduits for liquids and gases to migrate into groundwater reservoirs or the atmosphere. Well finding using aeromagnetic surveys pinpoints the location of steel-cased wells, detecting both active and abandoned wells, including buried casings lacking aboveground markers. Here, we present six aeromagnetic surveys conducted in Pennsylvania and Wyoming as case studies, comparing the magnetic points to locations known in databases. In all study sites, more magnetic points were detected than recorded in databases. Based on differences between theoretical database well counts and the actual number of wells detected in surveys, we estimated the total number of wells in Pennsylvania to be 395 000–466 000 and 181 000–182 000 in Wyoming. Extrapolating to the national level, in this work, we estimate the average number of wells in the continental United States is 6.04 ± 19.97 million wells with 1.16 ± 3.84 million of those designated as abandoned wells, within the range of previous abandoned well count estimations. Although aeromagnetic surveys are limited to detecting steel-cased wells and do not differentiate sites based on well status, this study nevertheless demonstrates the utility of aeromagnetic surveys in well finding efforts across the country and shows limitations in database records of oil and natural gas wells.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Homomolecular Triplet–Triplet Annihilation in Metalloporphyrin Photosensitizers

Metalloporphyrins are ubiquitous in their applications as triplet photosensitizers, particularly for promoting sensitized photochemical upconversion processes. In this study, bimolecular excited state triplet–triplet quenching kinetics, termed homomolecular triplet–triplet annihilation (HTTA), exhibited by the traditional triplet photosensitizers–zinc(II) tetraphenylporphyrin (ZnTPP), palladium(II) octaethylporphyrin (PdOEP), platinum(II) octaethylporphyrin (PtOEP), and platinum(II) tetraphenyltetrabenzoporphyrin (PtTPBP)–were revealed using conventional transient absorption spectroscopy. Nickel(II) tetraphenylporphyrin was used as a control sample as it is known to be rapidly quenched intramolecularly through ligand-field state deactivation and, therefore, cannot result in triplet–triplet annihilation (TTA). The single wavelength transients associated with the metalloporphyrin triplet excited state decay–measured as a function of incident laser pulse energy in toluene–were well modeled using parallel first- and second-order kinetics, consistent with HTTA being operable. The combined transient kinetic data enabled the determination of the first-order rate constants (k T ) for excited triplet decay in ZnTPP (4.0 × 10 3 s –1 ), PdOEP (3.6 × 10 3 s –1 ), PtOEP (1.2 × 10 4 s –1 ), and PtTPBP (2.1 × 10 4 s –1 ) as well as the second-order rate constant (k TT ) for HTTA in ZnTPP (5.5 × 10 9 M –1 s –1 ), PdOEP (1.1 × 10 10 M –1 s –1 ), PtOEP (7.1 × 10 9 M –1 s –1 ), and PtTPBP (1.6 × 10 10 M –1 s –1 ). In most instances, triplet excited state extinction coefficients are either reported for the first time or have been revised using ultrafast transient absorption spectroscopy and singlet depletion: ZnTPP (78,000 M –1 cm –1 ) at 470 nm, PdOEP (67,000 M –1 cm –1 ) at 430 nm, PtOEP (51,000 M –1 cm –1 ) at 418 nm, and PtTPBP (100,000 M –1 cm –1 ) at 460 nm. Furthermore, the combined experimental results establish competitive time scales for homo- and heteromolecular TTA rate constants, implying the significance of considering HTTA processes in future research endeavors harnessing TTA photochemistry using common metalloporphyrin photosensitizers.

14 SOLAR ENERGY↗

DOE OSTI2024

Observation and Numerical Simulation of Cold Ions Energized by EMIC Waves

This is the first report of significant energization (up to 7,000 eV) of low-energy He + ions, which occurred simultaneously with H-band electromagnetic ion cyclotron (EMIC) wave activity, in a direction mostly perpendicular to the ambient magnetic field. The event was detected by the Arase satellite in the dayside plasmatrough region off the magnetic equator on 15 May 2019. The peak energy of the He + flux enhancements is mostly above 1,000 eV. At some interval, the He + ions are energized up to ~7,000 eV. The H-band waves are excited in a frequency band between the local crossover and helium gyrofrequencies and are close to a linear polarization state with weakly left-handed or right-handed polarization. The normal angle of the waves exhibits significant variation between 0° and 80°, indicating a non-parallel propagation. Here, we run a hybrid code with parameters estimated from the Arase observations to examine the He + energization. The simulations show that cold He + ions are energized up to more than 1,000 eV, similar to the spacecraft observations. From the analysis of the simulated wave fields and cold plasma motions, we found that the ratio of the wave frequency to He + gyrofrequency is a primary factor for transverse energization of cold He + ions. As a consequence of the numerical analysis, we suggest that the significant transverse energization of He + ions observed by Arase is attributed to H-band EMIC waves excited near the local helium gyrofrequency.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2024

A Scale‐Dependent Analysis of the Barotropic Vorticity Budget in a Global Ocean Simulation

Abstract The climatological mean barotropic vorticity budget is analyzed to investigate the relative importance of surface wind stress, topography, planetary vorticity advection, and nonlinear advection in dynamical balances in a global ocean simulation. In addition to a pronounced regional variability in vorticity balances, the relative magnitudes of vorticity budget terms strongly depend on the length‐scale of interest. To carry out a length‐scale dependent vorticity analysis in different ocean basins, vorticity budget terms are spatially coarse‐grained. At length‐scales greater than 1,000 km, the dynamics closely follow the Topographic‐Sverdrup balance in which bottom pressure torque, surface wind stress curl and planetary vorticity advection terms are in balance. In contrast, when including all length‐scales resolved by the model, bottom pressure torque and nonlinear advection terms dominate the vorticity budget (Topographic‐Nonlinear balance), which suggests a prominent role of oceanic eddies, which are of km in size, and the associated bottom pressure anomalies in local vorticity balances at length‐scales smaller than 1,000 km. Overall, there is a transition from the Topographic‐Nonlinear regime at scales smaller than 1,000 km to the Topographic‐Sverdrup regime at length‐scales greater than 1,000 km. These dynamical balances hold across all ocean basins; however, interpretations of the dominant vorticity balances depend on the level of spatial filtering or the effective model resolution. On the other hand, the contribution of bottom and lateral friction terms in the barotropic vorticity budget remains small and is significant only near sea‐land boundaries, where bottom stress and horizontal viscous friction generally peak.

Khatri, Hemant↗

DOE OSTI2025

Material Fracturing and Failure Simulation Datasets

Fracturing is a fundamental physics phenomena with broad relevance across multiple domains, ranging from infrastructure integrity, aerospace durability, reservoir production, and seismic events. We present a diverse dataset of simulated fracture evolution and material failure generated from two numerical solvers: the phase-field method and the combined finite-discrete element method (FDEM). These solvers differ in formulation, physical fidelity, and computational efficiency. The dataset includes five materials: PBX, anisotropic shale, tungsten, aluminum, and steel. For each, phase-field simulations span 400,000 cases: 200,000 under uniaxial tension and 200,000 under biaxial tension. The computationally expensive FDEM simulations include 90,000 split evenly among PBX, shale, and tungsten under uniaxial loading. All simulations begin with randomized initial fracture patterns. Each entry includes temporal data capturing fracture propagation dynamics. This comprehensive dataset is designed to support the development of foundational or surrogate machine learning approaches for predicting material failure. While no such models are introduced here, the dataset lays a robust foundation for advancing future research and innovation in these areas.

36 MATERIALS SCIENCE↗

DOE OSTI2021

An LES study of secondary motion and wall shear stresses in a pipe bend

In this study, large-eddy simulations (LES) of a single-phase, turbulent flow in a 90 ° pipe bend are performed at three Reynolds numbers (5300, 27 000, and 45 000) to investigate the correlation between secondary flow motion and wall shear stresses, which is suspected to be a potential mechanism responsible for material erosion. The isothermal flows are validated against available experimental and numerical data first. The snapshot proper orthogonal decomposition (POD) is applied for the medium and high Reynolds number flows to identify the secondary flow motions and the oscillation of the Dean vortices that are found to cause swirl-switching. Distinguished frequencies of the POD time coefficients at Strouhal numbers of 0.25 and 0.28 are identified for Reynolds numbers at 27 000 and 45 000, respectively. Moreover, shear stress on the pipe wall and the associated power spectral density are obtained and shown to have the same oscillating frequency as the swirl-switching.

42 ENGINEERING↗

DOE OSTI2025

Prediction of carbon nanostructure mechanical properties and the role of defects using machine learning

Graphene-based nanostructures hold immense potential as strong and lightweight materials, however, their mechanical properties such as modulus and strength are difficult to fully exploit due to challenges in atomic-scale engineering. This study presents a database of over 2,000 pristine and defective nanoscale CNT bundles and other graphitic assemblies, inspired by microscopy, with associated stress–strain curves from reactive molecular dynamics (MD) simulations using the reactive INTERFACE force field (IFF-R). These 3D structures, containing up to 80,000 atoms, enable detailed analyses of structure-stiffness-failure relationships. By leveraging the database and physics- and chemistry-informed machine learning (ML), accurate predictions of elastic moduli and tensile strength are demonstrated at speeds 1,000 to 10,000 times faster than efficient MD simulations. Hierarchical Graph Neural Networks with Spatial Information (HS-GNNs) are introduced, which integrate chemistry knowledge. HS-GNNs as well as extreme gradient boosted trees (XGBoost) achieve forecasts of mechanical properties of arbitrary carbon nanostructures with only 3 to 6% mean relative error. The reliability equals experimental accuracy and is up to 20 times higher than other ML methods. Predictions maintain 8 to 18% accuracy for large CNT bundles, CNT junctions, and carbon fiber cross-sections outside the training distribution. The physics- and chemistry-informed HS-GNN works remarkably well for data outside the training range while XGBoost works well with limited training data inside the training range. The carbon nanostructure database is designed for integration with multimodal experimental and simulation data, scalable beyond 100 nm size, and extendable to chemically similar compounds and broader property ranges. The ML approaches have potential for applications in structural materials, nanoelectronics, and carbon-based catalysts.

Winetrout, Jordan J.↗

DOE OSTI2023

Torrefaction of almond shell as a renewable reinforcing agent for plastics: techno-economic analyses and comparison to bioethanol process

Abstract In 2016, the US state of California alone produced nearly 3.5 billion kilograms of almonds, accounting for approximately 84% of the world’s almond production. This generated about 2.58 million metric tons (MTs) of almond residues. Almond shells are currently either burned to generate power or disposed of in landfill. Valorizing almond shells and hulls provides an opportunity to replace petroleum-derived products and divert organic material from landfill. Here we demonstrate a detailed techno-economic analysis (TEA) of an almond shell torrefaction process capable of utilizing the 520 000 MTs of almond shells produced annually in California. Our process also includes preprocessing the torrefied biomass to exploit it as a reinforcing agent for plastics. We further compared the revenue generated from the torrefied biomass and bioethanol derived from the same quantity of almond shells. We considered three different torrefaction facility scales to evaluate trade-offs between economies of scale at the facility and trucking costs to deliver almond shells. A facility that takes in 200 000 MT yr –1 of almond shells results in lower per-unit-output basis capital and operating cost relative to other smaller-scale torrefaction facilities, including 10 000 MT yr –1 and 50 000 MT yr –1 , considered for analysis in this study. The large-sale facility results in a minimum selling price (MSP) of the torrefied biomass of $311.4 MT –1 . An analogous TEA on converting almond residues into bioethanol is also investigated. The MSP of almond shell derived ethanol ($1.71 kg −1 ) is higher than that of corn ($0.48 kg −1 ) or cellulosic biomass ($0.88 kg −1 ) derived ethanol. Compared with the bioethanol route, the torrefied almond shells result in three times more revenue if utilized as a reinforcing agent for plastics.

Liu, Dupeng (ORCID:0000000269514064)↗