Coupons (mini-modules) experimental data
Adhesion testing results on mini-module coupons (cell/encapsulant/glass laminates) that were aged under the different accelerated aging conditions (outlined more in the DataHub URL).
accelerated aging↗
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Results for “laminates”
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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Bowtie Manufacturing Images, Round 1&2
This dataset contains over 3,600 image files of images of a semiconductor manufactured part called 'Bowtie'. The data is grouped into 'accept' and 'reject' but does not contain masks for why the inspector rejected a part. There are further groupings such as different zoom magnifications, types of rejection (e.g. gouge, debris, etc.). Some of the parts have been laminated and are organized as such. For the 2nd round of data also included are Excel spreadsheets which can be used to identify position on the wafer where the images came from. The included PDF has example images and explains this in more detail.
97 MATHEMATICS AND COMPUTING↗
HYBRID COMPOSITES VIA CO-EXTRUSION ADDITIVE MANUFACTURING-COMPRESSION MOLDING FOR PERFORMANCE OPTIMIZATION
The growing demand for hybrid polymer composites with multifunctional properties has led to the development of various hybridization techniques, such as multi-material compounding and controlled laminate stacking sequence. In this study, a novel hybrid manufacturing approach was used by integrating a multiplexing extrusion system (MExS) based on additive manufacturing with subsequent compression molding process. This technique enabled the co-extrusion of different materials during the additive manufacturing process to fabricate composites with tailored performance. The developed hybrid composite featured a skin layer of glass fiberreinforced polycarbonate (PC/GF) encapsulating a carbon fiber-reinforced acrylonitrile butadiene styrene (CF/ABS) core. The structure was engineered to promote improved thermal and impact resistance at the surface, supported by a stiff core for enhanced overall mechanical integrity. Mechanical, thermal and morphological properties of the hybrid composites were investigated to understand trade-offs in performance compared to a single-material system. The results demonstrate that this approach enables the production of multifunctional composites suitable for applications such as automotive body panels and protective housings, where a balance of weight, mechanical strength, and thermal performance is essential.
Wasti, Sanjita [ORNL]↗
Shear Band Formation in Thin-Film Multilayer Columns Under Compressive Loading: A Mechanistic Study
Micro-pillar compression is a popular experimental technique used for characterizing the mechanical behavior of nano- and micro-laminates. The compressive stress–strain response of the column-shaped thin-film composite can be measured, and the deformation and damage features can be revealed by post-test cross-section microscopy. The development of plastic instability in the form of localized strain concentration (shear bands), leading to eventual failure, is frequently observed. In the present study, a computational approach is used to illustrate the commonality of shear band formation from a continuum standpoint. Systematic finite element analyses are conducted, showing that the strain field tends to become localized once plastic yielding commences. Distinct shear offsets of the layered structure can be revealed from the numerical model, which is similar to those observed in experiments. The actual appearance of shear bands depends on the materials’ constitutive behavior and precise geometries. Post-yield strain hardening reduces the propensity of shear band formation, while strain softening enhances it. Imperfections such as the undulated layer geometry, as well as the frictional characteristics between the specimen and test apparatus, can also influence the shear band morphology and overall stress–strain response.
finite element modeling↗
Experiments in 3D Printing Electric Motors
This paper catalogues a series of experiments we conducted to explore how to 3D print a DC electric motor. The individual parts of the electric motor were 3D printed but assembled by hand. First, we focused on a rotor with soft magnetic properties, for which we adopted ProtoPasta TM , which is a commercial off-the-shelf PLA filament incorporating iron particles. Second, we focused on the stator permanent magnets, which were 3D printed through binder jetting. Third, we focused on the wire coils, for which we adopted a form of laminated object manufacture of copper wire. The chief challenge was in 3D printing the coils, because the winding density is crucial to the performance of the motor. We have demonstrated that DC electric motors can be 3D printed and assembled into a functional system. Although the performance was poor due to the wiring problem, we showed that the other 3D printing processes were consistent with high performance. Nevertheless, we demonstrated the principle of 3D printing electric motors.
3D printed motor↗
Testing Protocol Development for the Fracture Toughness of Parts Built with Big Area Additive Manufacturing
The mechanical testing of additively manufactured parts has largely relied on the existing standards developed for traditional manufacturing. While this approach leverages the investment made in current standards development, it inaccurately assumes that the mechanical response of additive manufacturing (AM) parts is identical to that of parts manufactured through traditional processes. When considering thermoplastic, material extrusion AM, the differences in response can be attributed to an AM part’s inherent inhomogeneity caused by porosity, interlayer zones, and surface texture. Additionally, the interlayer bonding of parts printed with large-scale AM is difficult to adequately assess, as much testing is performed such that stress is distributed across many layer interfaces; therefore, the lack of AM-specific standards to assess interlayer bonding is a significant research gap. To quantify interlayer bonding via fracture toughness, double cantilever beam (DCB) testing has been used for some AM materials, and DCB has been generally used for a variety of materials including metal, wood, and laminates. Mode I DCB testing was performed on thermoplastic matrix composites printed with Big Area Additive Manufacturing (BAAM). Of particular interest was the notch shape and deflection speed during testing. The results examine the differences when using two notch types and three deflection speeds. The testing method introduced by the following paper differentiates itself from the ones described in the standards used by modernizing the methodology. This was conducted with the introduction of Digital Image Correlation (DIC) to gather displacement and load data simultaneously without human intervention.
Polymer Science↗
Characterization of the degradation of gamma-irradiated elastomers using Raman spectroscopy
This report presents key findings from Raman spectroscopic analysis of gamma-irradiated rubber samples extracted from a laminated lead-damped rubber (LDR) seismic isolation device. The samples were exposed to gamma radiation from a 60Co source in a Foss Therapy Services gamma irradiator, reaching absorbed doses up to 1600 kGy. A distinct threshold near 400 kGy was identified, beyond which significant spectral changes were observed. Two Raman peaks - at approximately 425 cm-1 and 2440 cm-1 - were tracked as a function of dose using Gaussian fitting. The 425 cm-1 peak, attributed to sulfur–sulfur (S–S) bond stretching (resulting from vulcanization of the rubber), exhibited a dose-dependent upshift, indicating radiation-induced crosslinking within the sulfur-based polymer network. Conversely, the 2440 cm-1 peak, likely associated with vibrational modes of additives or impurities, showed a downward shift with increasing dose, suggesting chain scission and degradation of non-rubber constituents. These results provide first-of-a-kind insights into the microstructural evolution of elastomers under high-dose gamma irradiation and establish a preliminary dose threshold for significant degradation. Future work will incorporate multi-modal characterization—including Fourier Transform Infrared (FTIR) spectroscopy, scanning electrom microscopy (SEM) of the rubber surface morphology, thermogravimetric analysis (TGA) to determine changes in thermal stability, and mechanical testing—to correlate molecular-level changes with macroscopic performance of these elastomers as damping media in seismic isolation devices. These findings are expected to provide regulatory guidance and design criteria for qualifying low-damping rubber seismic isolators in advanced nuclear reactor applications.
36 - MATERIALS SCIENCE↗
Production and installation of wavelength-shifting reflective light enhancers for the Short-Baseline Near Detector
We report on the design, production, and installation of a wavelength-shifting reflective system on the cathode of the Short-Baseline Near Detector (SBND), a liquid argon time projection chamber located along the Fermilab Booster Neutrino Beam. To increase and homogenize scintillation-light collection, 64 double-sided plates were fabricated from FR4, laminated with specular reflector film and coated with 300 $μ$g/cm$^2$ of tetraphenyl butadiene (TPB) wavelength shifter using controlled physical vapor deposition. The coating uniformity was validated through dedicated measurements of deposited mass and profilometry studies. Because exposure to ambient blue/UV light could degrade the TPB, protective filtering and controlled storage conditions were implemented during handling and installation. The coated plates were assembled between conductive meshes for high-voltage compatibility and installed in situ during detector integration. This system constitutes the largest TPB-coated area deployed in a neutrino detector. It operates in conjunction with SBND's photon detection system, which consists of photomultiplier tubes and X-ARAPUCAs. Early light-collection measurements show high uniformity and light response across the detector, supporting improved triggering, calorimetry, and position reconstruction in SBND.
Acciarri, R. [Fermilab]↗
Testing and modeling of CLT-to-CLT joints made using hardwood dowels and screws with varying spacing
With the increasing popularity of mass timber, utilizing large-diameter wood screws and hardwood dowels can offer an easy and cost-efficient way to join structural elements. However, the existing research on hardwood dowels is limited to single fastener joints under monotonic loading. No research is available on the group effects of joints with multiple hardwood dowels. Here, this paper presents the results of 96 monotonic and cyclic single-shear plane CLT-to-CLT joint tests with hardwood dowels (Red Oak and Yellow Birch, 25.4 mm diameter) and self-tapping wood screws (8 mm diameter) in Grand-Fir CLT, where screws were inserted both perpendicular and at a 45-degree angle to the grain for comparison to hardwood dowels. The study evaluated the mechanical properties of the joints by changing fastener spacing. Mechanical properties such as yielding and peak strength, displacement, elastic and yielding stiffness, and ductility were evaluated. The results showed equal strength and stiffness properties for hardwood dowels comparable with large-diameter screws. Additionally, the hardwood dowel joints demonstrated moderate ductility properties. The strength and stiffness of the tested joints were compared with analytical equations found in the literature by considering the group action factor of the fasteners. Lastly, a nonlinear force-displacement model was presented and compared to the experimental results and analytical calculations, which gives the possibility to predict and optimize the mechanical behavior of hardwood dowel and screw joints with varying numbers and spacing between fasteners.
36 MATERIALS SCIENCE↗
Global warming potential estimates of mass timber constructions beyond the first life: A dynamic radiative forcing modeling approach
In the face of a warming planet, steps must be taken to reduce the greenhouse gas emissions (GHG) associated with our building industry, which is a significant contributor to global emissions. Large, prefabricated wood elements such as mass timber panels (MTP) have great potential to achieve these reductions as they help displace high-embodied‑carbon materials like concrete and steel. Furthermore, storing the wood's biogenic carbon in buildings benefits the climate because it delays the eventual release of the carbon into the atmosphere. While these climate impacts have been assessed for the construction phase of mass timber buildings, relatively few life cycle assessment (LCA) studies have evaluated the climate impacts for the buildings' end-of-life (EOL) phase. This research estimates the climate impacts of four EOL scenarios for MTP: reusing as MTP, recycling into particleboard, incinerating, and landfilling. Using dynamic radiative forcing modeling and factoring in temporal GHG emissions and biogenic carbon storage, the global warming potential impacts are calculated for construction, deconstruction, and EOL processing of hybrid mass timber buildings in the U.S. Pacific Northwest for 160 years (GWP 160 ). The 160-year temporal scale used in this paper is an arbitrary scale, with the first 80 years being the assumed life of the building, followed by a series of reuse, recycle, or disposal scenarios over the second 80 years of that temporal scale. Of the four EOL scenarios considered in this paper, the ‘reuse’ scenario has the lowest net GWP 160 impact (calculated by summing the GWP 160 and carbon storage benefits, i.e., GWP$^{bioCS}_{160}$ ), emerging as a climate-preferred scenario, followed by ‘landfill’, ‘incinerate’, and ‘recycle’ scenarios. The lower net GWP 160 impact associated with the reuse scenario is due to the low fossil carbon emissions during EOL processing, as well as the biogenic carbon storage benefits. The results of this study also highlight the importance of efficient reuse and recycling strategies for wood in MTP.
42 ENGINEERING↗
Economic assessment of seismic monitoring for underground hydrogen storage
Underground hydrogen storage (UHS) plays a key role in the energy landscape. However, like other subsurface engineering technologies, UHS may cause leakage into the groundwater or atmosphere and possibly induce local seismicity. To reduce these risks, seismic monitoring could be a viable technique to track the UHS plume, detect leakages, and locate induced seismicity events. Seismic monitoring has been proposed to safely monitor UHS, but research in this area is still new and requires field studies. Lab and theoretical studies have demonstrated the validity of seismic monitoring for UHS. Therefore, it is imperative to analyze the economic feasibility of seismic monitoring for UHS. Hence, we develop a cost model and open-source Python code for seismic monitoring that considers types of seismometers, comprehensive operational scenarios, detection thresholds, and long-term leakage monitoring. A case study is further provided to validate the cost model on reservoir simulations of UHS. We find that the levelized cost for a 10-year operating UHS site will range on the order of ∼0.003 $\$$/kg. The methods developed in this study could also be applied to the monitoring of groundwater, gas, and/or wastewater injection.
08 HYDROGEN↗
Citywide indoor air sampling mirrors wastewater and clinical for environmental surveillance of respiratory viruses
Wastewater surveillance of respiratory pathogens can provide timely estimates of viral activity and disease trends in a population. Indoor air surveillance could be used similarly with some advantages but remains largely unvalidated at the community -scale. Here, an indoor air surveillance program was employed as part of public health environmental surveillance in Chicago, Illinois, USA. Ten air samplers were placed in healthcare and congregate living settings across the city. Weekly air samples were evaluated for influenza A, influenza B, respiratory syncytial virus, and SARS -CoV-2 over two respiratory virus seasons (2023 -2025). Citywide, aggregated air sample positivity and viral load were closely correlated with local clinical case and wastewater surveillance data across all respiratory viruses. Virus trends in air data often preceded clinical and wastewater, although this varied across pathogens and respiratory virus seasons. Further, whole -genome sequencing of SARS -CoV-2 showed close correlation of variant proportions across all datasets. At the building -scale, air samples obtained from a single sampling device provided efficient respiratory virus surveillance, with respiratory pathogen levels mirroring citywide clinical surveillance data. These data demonstrate that air surveillance can provide respiratory virus case and variant trend data at a building or community -scale, serving as an alternative or complementary tool for public health environmental surveillance.
Wilton, Rosemarie↗
Experimental Validation of a Module Cell Cracking Model
The What's Cracking app can predict how changes in crystalline silicon photovoltaic (PV) module materials, design, and mounting affect its susceptibility for cell fracture under uniform loading. This work has experimentally validated the app. A set of commercial crystalline silicon PV modules was obtained for this study. The modules were uniformly loaded at three different mounting points, and their subsequent cell fractures were recorded. A large sample size allowed for the development of an experimental statistical model for cell fracture. Here, the comparison of the experiment to predictions from the app is in excellent agreement. Both experimental and modeling results also elucidate how moving the module mounting points toward the center of the module increases the probability of cell fracture.
14 SOLAR ENERGY↗
Encapsulation Materials Tailored to Perovskite Photovoltaics
The work combines NREL as the world leader in perovskite and polymeric materials, and teams them up with The Dow Chemical Company, the world leader in commercial production of PV encapsulation materials. The team will design and evaluate encapsulation materials that are tailored to perovskite photovoltaics. Demonstration of polyolefin-based encapsulants for perovskite PV will be impactful for a number of reasons: 1) There is no clear-cut choice for encapsulation for perovskite PV to date. 2) There is high synthetic control of the material properties for future perovskite module designs. 3) Among the candidate materials, they have the highest barrier properties, 4) Polyolefins are the most prevalent (>20 million metric tons consumed in the US alone) and inexpensive (<1.5 $USD/kg) polymers used worldwide. 5) They are recyclable and may play a role in future of circular PV materials. 6) They are manufactured domestically. The work also highlights careful design of perovskite transport layer materials for surviving vacuum encapsulation.
14 SOLAR ENERGY↗