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DOE OSTI2024

A hybrid smoothed-particle hydrodynamics model of oxide skins on molten aluminum

A computational model of aluminum melting is proposed which captures both the thermal fluid-solid phase transition and the mechanical effects of oxidation. The model hybridizes ideas from smoothed particle hydrodynamics and bonded particle models to simulate both hydrodynamic flows and solid elasticity. Oxidation is represented by dynamically adding and deleting spring-like bonds between surface fluid particles to represent the formation and rupture of the oxide skin. Various complex systems are simulated to demonstrate the adaptability of the method and to illustrate the significant impact of skin properties on material flow. As a result, initial comparison to experiments of a melting aluminum cantilever highlights that the computational model can reproduce key qualitative features of aluminum relocation.

Clemmer, Joel Thomas↗

DOE OSTI2023

Exploring ice sheet model sensitivity to ocean thermal forcing and basal sliding using the Community Ice Sheet Model (CISM)

Abstract. Multi-meter sea level rise (SLR) is thought to be possible within the next few centuries, with most of the uncertainty originating from the Antarctic land ice contribution. One source of uncertainty relates to the ice sheet model initialization. Since ice sheets have a long response time (compared to other Earth system components such as the atmosphere), ice sheet model initialization methods can have significant impacts on how the ice sheet responds to future forcings. To assess this, we generated 25 different ice sheet spin-ups, using the Community Ice Sheet Model (CISM) at a 4 km resolution. During each spin-up, we varied two key parameters known to impact the sensitivity of the ice sheet to future forcing: one related to the sensitivity of the ice shelf melt rate to ocean thermal forcing (TF) and the other related to the basal friction. The spin-ups all nudge toward observed thickness and enforce a no-advance calving criterion, such that all final spin-up states resemble observations but differ in their melt and friction parameter settings. Each spin-up was then forced with future ocean thermal forcings from 13 different CMIP6 models under the Shared Socioeconomic Pathway (SSP)5-8.5 emissions scenario and modern climatological surface mass balance data. Our results show that the effects of the ice sheet and ocean parameter settings used during the spin-up are capable of impacting multi-century future SLR predictions by as much as 2 m. By the end of this century, the effects of these choices are more modest, but still significant, with differences of up to 0.2 m of SLR. We have identified a combined ocean and ice parameter space that leads to widespread mass loss within 500 years (low friction and high melt rate sensitivity). To explore temperature thresholds, we also ran a synthetically forced CISM ensemble that is focused on the Amundsen region only. Given certain ocean and ice parameter choices, Amundsen mass loss can be triggered with thermal forcing anomalies between 1.5 and 2 ∘C relative to the spin-up. Our results emphasize the critical importance of considering ice sheet and ocean parameter choices during spin-up for SLR predictions and suggest the importance of including glacial isostatic adjustment in ice sheet simulations.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Strong and recyclable bio-derived poly(ester amide) hot-melt adhesive

Bio-based adhesives offer inherent advantages over conventional petrochemical-derived systems, including renewable sourcing, reduced environmental impact and potential degradability. However, most bio-based adhesives suffer from poor adhesion strength, limited substrate compatibility and a lack of chemical recyclability. Here, in this work, we present a bio-derived multiblock poly(ester amide) adhesive that leverages microphase segregation between different segments to reconcile mechanical robustness with strong interfacial bonding. Notably, this multiblock architecture is accessed through a one-pot, selective acceptorless dehydrogenative polymerization, obviating the need for multistep synthesis. The materials exhibit excellent adhesion across a range of substrates including metals, glass and wet wood surpassing commercial benchmarks, while also demonstrating thermal stability, tunable mechanical properties and closed-loop chemical recyclability even in the presence of other commodity plastics. Furthermore, the adhesive strength of these materials could be tuned for various potential applications through control over the chemical composition of the polymer. By integrating renewable feedstocks, high-performance functionality and efficient chemical circularity within a single platform, this work provides a viable pathway toward more sustainable adhesive technologies and contributes to advancing circular materials manufacturing.

09 BIOMASS FUELS↗

DOE OSTI2024

Influence of Antarctic and Greenland Continental Shelf Circulation on High‐Latitude Oceans in E3SM

The science objectives of this project are to simulate and understand the impacts of both deep-basin warm-water intrusions and land-ice melt on the continental shelf circulations and sea-ice distributions around the margins of Greenland and Antarctica. As well, the role of subsurface ocean heat from the Atlantic on declining sea-ice cover in the Arctic is explored. Mesoscale processes and fine bathymetry are implicated in cross-shelf property transports around both Greenland and Antarctica. Therefore, we configured and ran an atmospheric reanalysis-forced global ocean/sea-ice simulation on a grid that reduces from 8 km at the Equator to 2 km at the poles (UH8to2) with 60 vertical levels. It was produced using the Energy Exascale Earth System Model ‘‘HiLAT’’ code (E3SMv0-HiLAT) that uses the Parallel Ocean Program (POP) and CICE5 as its ocean and sea-ice components, respectively. Two main UH8to2 simulations were carried out: one for 1975-2009 and the other for July 2016-2020 after it was initialized from a 1/25° data-assimilative ocean/sea-ice prediction system ocean/sea-ice state. The UH8to2 is not coupled to an active land-ice model. Rather, land-ice melt is represented by observationally informed freshwater fluxes (FWFs). Short (multi-year) UH8to2 simulations were conducted to understand sensitivities when Greenland ice sheet (GrIS) melt is released only at the ocean surface or when it is distributed over the upper water column in accordance with fjord melt plume behavior; these cases were compared with a no GrIS melt case. West Greenland continental shelf currents were fastest in the vertical distribution case and an increase in baroclinic conversion at the shelf break associated with increased eddy kinetic energy was found relative to the surface release case. Further, salinity is lower and meltwater volume greater in the eastern Labrador Sea in the vertical distribution case. For the Arctic, the veracity of the UH8to2 was evaluated for 2017-2020 using available observations. Simulated seasonal sea-ice thickness and concentration are realistic, but the ice is unrealistically thin in the central and eastern Arctic in the fall. Comparisons of vertical sections of ocean temperature, salinity, and buoyancy collected from Ice-Tethered Profilers (ITPs) in the eastern Arctic in the fall and winter of 2019/2020 and co-located/concurrent UH8to2 fields show the stratification over the top 100 m of the water column is too low in the model, the simulated mixed layer too deep, and the simulated subsurface Atlantic Water (AW) too warm; these biases may contribute to the sea-ice biases. A model intercomparison study using the UH8to2 and a forced 1/25° regional Arctic ocean/sea-ice (uses the HYbrid Coordinate Ocean Model and CICE5) simulation further investigates the relationship between AW and sea-ice in the eastern Arctic. The models show a mesoscale-rich pulse of Atlantic Water extending into the eastern basin that reaches maximum intensity in late winter of 2018, after which it decreases in strength. Concurrent and co-located sea-ice melt or the inhibition of sea-ice growth is seen and is attributed to halocline mesoscale eddies doming into the mixed layer with convection bringing this heat into the vicinity of the sea-ice.

58 GEOSCIENCES↗

DOE OSTI2026

Leveraging ARM Data to Improve Models for Predictive Understanding of Energy and Security Challenges

Extreme weather and natural hazards can disrupt the energy sector, affecting demand, generation, transmission, distribution, consumption and operational planning at regional and national scales. These disruptions stem from a broad range of atmospheric phenomena, including winter storms, freezing rain, wet snow loading, severe convection, flooding and landslides, wildfires, prolonged heat, and drought. Many of these same phenomena can also affect national security through impacts to transportation and infrastructure. To support the U.S. Department of Energy (DOE) focus on energy resilience and national security, the Atmospheric Radiation Measurement (ARM) User Facility is uniquely positioned to contribute measurement data, analyses, and modeling frameworks that can significantly improve predictive understanding of these hazards to mitigate their effects. To explore this opportunity, ARM convened a two-part virtual workshop in November 2025. The workshop engaged interdisciplinary experts in atmospheric science, energy systems, modeling, and operations. The goal of the meeting was to engage with these interdisciplinary experts to address three questions: • What are examples of atmospheric processes that represent significant risks to energy security or national security and where are those risks greatest? • What measurements or measurement strategies would improve ARM’s capacity to address these issues? • How can ARM and users of the ARM facility better work with the Energy Exascale Earth System Model (E3SM) and multi-sector modeling communities to apply ARM data to improving E3SM simulations of these phenomena? Participants were asked to submit white papers ahead of the meeting to initiate thinking on these themes and to help organize discussions. Workshop sessions were then organized around themes identified in the white papers. First from the white papers and then through subsequent discussions, workshop participants identified many examples that address the three questions listed above. Participants called out energy system vulnerabilities to weather phenomena such as the impact of freezing rain, strong winds, and excessive heat on power grids. They also noted the effects that weather phenomena could have on energy demand or supply (e.g., through effects of extreme temperatures). They called out security vulnerabilities such as impacts to crops from aerosol-borne pathogens and risks to industry due to melting permafrost in the Arctic. In all, over a dozen meteorological phenomena were linked to energy or security vulnerabilities. For many of the identified phenomena, participants pointed out where ARM was well poised to address issues (e.g., through measurements of cloud microphysics to inform studies of freezing rain) but also noted needs for additional measurements or modified measurement strategies. For example, adaptive scanning of severe weather would be valuable for probing winter storms or severe convection. Participants pointed out the value in integrating external observations with ARM measurements and with applying artificial intelligence (AI) to ARM observation analysis and they advocated for using model simulations to help optimize measurement strategies through Observing System Simulation Experiments (OSSEs). It was clear from the workshop that there are many ways that ARM observations can be used to mitigate energy and security concerns, but meeting participants were also asked to identify what they considered to be the greatest opportunities by ranking issues pertaining to the three workshop questions. This was accomplished through a survey administered to participants between the two virtual sessions. The highest-priority phenomena identified were winter storms, severe convection, and arctic processes. Discussion in the second session, therefore, focused primarily on these three areas, which were most fully developed in exploring ARM opportunities. Nevertheless, it was also clear that ARM has opportunities to contribute to all the identified topics. This report describes the workshop, including input from discussion and white papers (Sections 2 and 3) and a list of priority recommendations (section 4). Many other ideas for ARM contributions are discussed in individual white papers (Appendix D).

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Modelling the complex evaporated gas flow and its impact on particle spattering during laser powder bed fusion

The additive manufacturing (AM) of metals is becoming an increasingly important production process with the potential to replace traditional techniques such as casting. Laser Powder Bed Fusion (LPBF) is used in many applications to print metal parts from powder. The metal powder is heated locally with sufficient laser radiation that the liquid melt easily reaches its boiling temperature, which leads to a metallic vapour jet that can entrain both powder bed particles and molten droplets. The small size of laser-matter interaction site makes a detailed experimental analysis of the process challenging. Synchrotron X-ray imaging experiments are one of the few methods which can capture the dynamic melting and solidification processes. Comparing such experiments with computer simulations of the process is an important approach in order to better understand the manufacturing process and to analyse the influence of process parameters on the evaporated gas jet and the subsequent impact on particle ejection, leading to potentially reduced AM component quality. The melting and solidification of the metal powder is simulated using an Eulerian multiphase approach based on a control volume discretization of powder bed and substrate and a volume of liquid separation from melt and gas phase. The gas phase modelled as an ideal gas reaches velocities up to 100 m/s. Lagrangian particle tracking in the simulation demonstrates that the velocity fields calculated by the Eulerian multi-phase approach in combination with a standard drag-force model lead to particle accelerations in good agreement with those measured experimentally. In order to avoid numerical laborious Lagrangian calculations, a direct method to compare an Eulerian multiphase simulation with synchrotron X-ray experiments was introduced and validated. This approach is used to analyse the influence of process parameters including laser power and laser speed on the maximal acceleration of particles from the melt pool area. While the particle acceleration increases linearly with line energy in the conduction mode, a linear decrease of the acceleration with increasing line energy can be found in the transition mode before the accel-eration increases again with line energy in the keyhole mode.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Effects of Cooling Rates on Self-Reinforced Polyethylene Composites via Multiscale Experimental Characterizations

This study investigates cooling rate effects on self-reinforced polyethylene composites (PE-SRCs), focusing on macroscopic thermal and mechanical properties, and micro- to sub-micron morphologies. Unlike conventional fiber-reinforced composites (e.g., carbon and glass fiber based), cooling rate effects on SRCs remain less studied. PE-SRCs were fabricated from ultrahigh molecular weight polyethylene (UHMWPE) fabric and high-density polyethylene (HDPE) matrix with cooling rates from 0.76°C/min to 425°C/min. Tensile properties, including modulus (~9.5 GPa), strength (~360 MPa), and ultimate elongation (~6%), showed no significant cooling rate dependence. However, thermal analysis revealed melting temperature of HDPE matrix decreased from ~130°C to ~126.5°C with total crystallinity reducing from 84% to 75%. Wide-angle X-ray scattering confirmed decreasing crystallinity but at lower values (67%–59%), as thermal analysis might overestimate crystallinity. Small-angle X-ray scattering showed long period decreased from 24.3 to 17.4 nm, attributed to thinner lamellae and closer packing, suggesting limited crystal growth and faster nucleation. While cooling rates alter melting point and crystalline structures of HDPE matrix, these changes do not translate to substantial impact on macroscale mechanical properties of PE-SRCs. This insensitivity might be related to low interfacial shear strength at PE/PE interfaces, enabling process optimization while maintaining mechanical performance.

Cooling rate↗

DOE OSTI2022

Effect of Macro- and Microstructures on Catalytic Hydrogenolysis of Polyolefins

Here, polyethylenes of varying molecular weight and branch density, as well as polypropylenes of varying molecular weight and tacticity, were catalytically converted to lower-molecular-weight liquid products to showcase how these various properties in a mixed waste plastic stream could affect the final product. A Pt nanoparticle on a strontium titanate nanocuboid (Pt/STO) catalyst was used under solvent-free conditions in the presence of 170 psi of H 2 at 300 °C for hydrogenolysis. The initial molecular weight of polyethylene was found to have a moderate effect on the yield to the final product (ranging from 55 wt% for M n ~ 7600 Da to 67 wt% for M n ~ 50,950 Da). The microstructure, defined as the length and density of branches in a polymer, of higher-molecular-weight polymers was the dominant factor in determining the yield (ranging from 67 wt% for M n ~ 50,950 Da for linear low-density polyethylene (LLDPE) with C 2 branches to 97 wt% for M n ~ 38,850 Da for LLDPE with C 6 branches). The same products (M n = C 29 –C 46 , Ð = 1.1–1.6) and distribution of undesired light gases (C 1 –C 4 ≈ 90 mol%, C 5 –C 8 ≈ 10 mol%) are obtained from conversions of PE of varying molecular weight. The tacticity of polypropylene at a given molecular weight had a significant effect on the molecular weight of the final product, while not strongly affecting conversion. Hydrogenolysis of isotactic polypropylene (iPP) produced ≈C 18 with a wider polydispersity (Ð ~ 1.4) compared to the narrow ≈C 64 (Ð ~ 1.0) and ≈C 54 (Ð ~ 1.0) products from atactic (aPP) and syndiotactic (sPP) polypropylene, respectively. The stereochemistry of the methyl groups dictates the shape and structure of the polymer in the melt, which in turn affects how the hydrocarbon chain interacts with the catalyst surface, thereby impacting the number of C–C scissions. These results show how various characteristics such as the molecular weight and structure of a waste plastic stream could affect the final product.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Optical transparency of LiF (100) shock compressed to ∼360 GPa

High-purity [100] lithium fluoride (LiF) is the most widely used optical window in dynamic compression experiments due to its wide bandgap and well-characterized mechanical response. Recent plate-impact experiments established the [100] LiF Hugoniot to ∼230 GPa and demonstrated shock-induced melting onset at 182 GPa with complete melting by 195 GPa; theoretical models predict LiF optical transparency to nearly 900 GPa. To experimentally examine the optical transparency of [100] LiF at higher pressures and in the liquid state, laser-driven shock experiments were performed at peak stresses ranging from 223 to 363 GPa. Optical response was examined by measuring the particle velocity histories at the Kapton/LiF interface using laser interferometry at 532 and 1550 nm wavelengths; in-material particle velocities were obtained using established refractive-index corrections. Continuous photonic Doppler velocimetry fringes were observed across the entire stress range, demonstrating that LiF remains transparent to 1550 nm light throughout the multi-megabar regime investigated. At 532 nm, fringe visibility depended on the reflector coating: aluminum mirrors provided signals to ∼235 GPa, while gold mirrors extended this limit to 270.5 GPa, indicating that the shorter-wavelength response is likely sensitive to experimental configuration rather than to the loss of LiF transparency. Continued optical transparency to at least 360 GPa indicates that shock-melted LiF does not display bandgap closure over the stress range explored. Furthermore, these results provide direct experimental constraints on the high-pressure optical response and establish LiF (100) as a robust optical window material for laser-driven dynamic compression experiments approaching 400 GPa.

Renganathan, P. [Argonne National Laboratory (ANL)↗

DOE OSTI2024

The Use of High-Density UN Fuel in Heat-Pipe Microreactors

Heat-pipe microreactors (HPMRs) are very small-scale nuclear reactors that employ heat pipes (HPs) for heat removal. HPMRs can be easily integrated with other forms of renewable energies, can be used for emergency responses to disaster relief zones, can be deployed in remote locations not connected to the grid, and can be removed from sites and replaced by new ones. HPMRs can also be used for space missions as HPs do not rely on gravity for heat transfer. Conventional fuel materials, such as uranium oxide (UO 2 ) and uranium oxycarbide (UCO), are currently considered in most existing HPMR designs, but ceramic uranium nitride (UN) fuel that has high uranium density, high thermal conductivity, and high melting point may become a better fuel candidate. Through neutronics calculations, this paper assesses the impact of using UN fuel in HPMRs with two different neutron spectra (fast and thermal) and two different fuel forms [traditional solid fuel pellets and TRi-structural-ISOtropic (TRISO) fuel compacts]. It was concluded that retrofitting HPMRs with UN fuel has the potential to reduce the initial 235 U enrichment requirement by ~3 wt% (to keep the same cycle length) or increase the cycle length (by keeping the same initial 235 U enrichment), which enables more compact and transportable HPMR core designs. However, using UN fuel decreases the control element worth [by up to 20% for the Special Purpose Reactor (SPR) and 5% for HP-MR] and is up to 80% more costly. Increasing 15 N enrichment can further decrease the initial 235 U enrichment requirement and increase the control element worth but is more costly. In conclusion, compared to fast-spectrum HPMRs fueled with solid pellet fuels, retrofitting UN fuel is more suitable for thermal-spectrum HPMRs fueled with TRISO fuel compacts, where the neutron spectrum hardening caused by using UN is less significant.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Simulations of stand-off runaway electron beam termination by tungsten particulates for tokamak disruption mitigation

Abstract Stand-off runaway electron termination by injected tungsten particulates offers a plausible option in the toolbox of disruption mitigation. Tungsten is an attractive material choice for this application due to large electron stopping power and high melting point. To assess the feasibility of this scheme, we simulate runaway collisions with tungsten particulates using the MCNP program for incident runaway energies ranging from 1 to 10 MeV. We assess runaway termination from energetics and collisional kinematics perspectives. Energetically, the simulations show that 99% of runaway beam energy is removed by tungsten particulates on a timescale of 4–9 µ s. Kinematically, the simulations show that 99% of runaways are terminated by absorption or backscattering on a timescale of 3–4 µ s. By either metric, the runaway beam is effectively terminated before the onset of particulate melting. Furthermore, the simulations show that secondary radiation emission by tungsten particulates does not significantly impact the runaway termination efficacy of this scheme. Secondary radiation is emitted at lower particle energies than the incident runaways and with a broad angular distribution such that the majority of secondary electrons emitted will not experience efficient runaway re-acceleration. Overall, the stand-off runaway termination scheme is a promising concept as a last line of defense against runaway damage in ITER, SPARC, and other future burning-plasma tokamaks.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2020

Viscoelastic Response of Dispersed Entangled Polymer Melts

Any polymer synthesis routes result in molecular weight dispersity DAI, depending on the polymerization mechanism. The lowest dispersity polymers are those made by anionic and atom-transfer radical polymerization, which exhibit relatively narrow distributions DM=g,„1A172 — 1.02-1.04. This small divergence from monodispersity results in significant number of molecules that differ in their molecular weight from the average and their impact on the viscoelastic response remains an open question. Here the effects of low dispersity on stress relaxation and shear viscosity of entangled melts are studied using a coarse-grained model for polyethylene. Polymer melts with chain length dispersity set to follow a Schulz-Zimm distribution of Dm = 1.0 — 1.16 for an entangled polyethylene melt using molecular dynamic simulations. The systems were studied to times up to 800 ,us which is beyond the terminal time. These systems are compared to those with binary and ternary distributions. The stress relaxation functions were extracted from the Green-Kubo relation and from stress-strain relaxation following a uniaxial extension. We find on the entanglement time scale, both the mean squared displacement and the stress relaxation are independent of D m . The tube diameter and the rubbery plateau for entangled dynamics do not depend on D m . At longer times, the terminal relaxation time decreases as the faster motion of the shorter chains results in constraint release for the longer chains. Probing this low dispersity regime opens the way to evaluate the degree of dispersity that affects mechanical properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Impact of Cooling Rate and Thermal Mass on Supercooling in a Salt-Hydrogel Complex for Thermal Energy Storage

Glauber’s salt is a promising phase change material for building thermal management because of its high latent heat, acceptable melting temperature of 32.3 °C for indoor air1,2. Despite these advantages, the practical application of Glauber’s salt in thermal energy storage systems is still challenging due to supercooling and phase segregation1–3. Here, we report the impact of temperature ramp rate and thermal mass on the supercooling of Glauber’s salt through the DSC and T-history experiment. The ramp rate effect was studied with a wide range of ramp rates in 1 to 10 °C/min in DSC and 1 to 4 °C/min in the T-history experiment. The thermal mass effect was investigated by comparing DSC and T-history experiment. The latent heat was also analyzed for different ramp rates and thermal mass conditions. The melting temperatures of Glauber’s salt from the two techniques were identical while freezing temperatures were different because of the thermal mass effect. During freezing in the T-history experiment, the latent heat was reduced by around 75% to the latent heat in melting due to supercooling and phase segregation. To overcome this bottleneck, we developed a novel hydrogel complex that reduces the supercooling and prevents phase segregation to maintain volumetric energy density for 100 cycles. Thermodynamic analysis accounting for composition shows that a higher salt composition can further enhance the volumetric energy storage density. For example, a 10% increase in the weight percentage of salt leads to about 50% enhancement in volumetric energy storage density. References: 1. D. R. Biswas, Solar Energy. 19, 99–100 (1977). 2. S. M. Hasnain, Energy Conversion and Management. 39, 1127–1138 (1998). 3. Byung Chul Shin, Sang Done Kim, P. Won-Hoon, Energy. 14, 921–930 (1989).

inorganic, thermodynamics↗

DOE OSTI2023

Antarctic shelf ocean warming and sea ice melt affected by projected El Niño changes

Antarctic shelf ocean warming affects melt of ice shelf/sheets and sea ice but projected changes vary vastly across climate models. A projected increase in El Niño variability has been found to slow future mid-latitude Southern Ocean warming but how this impacts the Antarctic shelf ocean is unknown. Here we show that a projected increase in El Niño variability accelerates Antarctic shelf ocean warming, hastening ice shelf/sheet melt but slowing sea ice reduction.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

The effect of blue and infrared laser melting frequency on oxide morphology in 304L

Continuous Wave Laser Beam (LB) melting offers control over the localised heating and cooling of melt pools for welding, brazing, additive manufacturing and solidification. Research into laserliquid metal interactions has primarily focused on the heat and mass transport under large thermal gradients imposed by the localised melting conditions. Recent commercial availability of blue (450 nm) wavelength lasers has enabled the printing of material with poor IR (1064) nm attenuation like Cu. However, little research has been conducted into varying input laser frequency and scan rate at fixed absorption to understand the effects of laser light on surface oxide formation and the underlying liquid metal thermodynamic response. Here, this article conducts laser melting of 304L under Blue (450 nm) and Infrared (IR, 1064 nm) laser frequencies and examines their impact on laser oxide thickness, chemistry and coloration. We find that laser frequencies induce changes in the oxide layer thickness and chemistry that cannot be explained using conventional thermal absorption shifts and fluid dynamics. We suggest that light coupling may have thermodynamic implications for the chemical potential of the liquid metal, which may drive the observed phase behaviour. Identifying mechanisms for the tuning of the chemical potential via laser frequency control could enable the ability to control solidification microstructure and atomic ordering in laser welding and additive manufacturing processes.

304L↗

DOE OSTI2022

Impact of Nozzle Condition on Powder Catchment Efficiency for Coaxial Powder Direct Energy Deposition

Blown powder directed energy deposition is well-designed for fine resolution additive manufacturing processing. Coaxial powder deposition heads use an outer layer of shielding gas directed by an outer nozzle to prevent oxidation occurring during the powder melting process. Powder blown feedstock catchment efficiency can be as low as 50-80% whereas wire deposition systems are closer to 98% efficient. The present study evaluates the impact of directed energy deposition nozzle condition on catchment efficiency. Changes in the overall outer shielding gas nozzle length has been found to increase material usage efficiency by 10% through convergence of the powder flow. The results of this experiment show that for coaxial powder deposition head design, if the standoff distance can safely be decreased, powder catchment efficiency can be increased as the outer shielding gas nozzle is increased in length, or the standoff distance is decreased.

Heinrich, Lauren↗

DOE OSTI2022

Impact of Nozzle Condition on Powder Catchment Efficiency for Coaxial Powder Direct Energy Deposition

Heinrich, Lauren↗

DOE OSTI2021

Chapter 4: Chemical Recycling of PET

The circular economy of poly(ethylene terephthalate) (PET) today is dominated by collection, sorting, cleaning, melting, and re-processing of transparent bottles via mechanical recycling. This has a better environmental impact as assessed by Life Cycle Assessment (LCA) (e.g. uses less non-renewable energy and produces less greenhouse gases) than production of virgin resin and is the preferred method of recycling wherever possible. However, not all PET products can be recycled this way and there is forecast to be a large shortfall between supply of high quality recycled PET (rPET) and the demands of large users who have made commitments to use more recycled resin over the next 5 - 10 years. Consequently, there is renewed interest, and increased activity, in chemical recycling, where waste PET is depolymerized, and the monomer(s) are purified and repolymerized into resin equivalent to that from petroleum-derived raw materials. The LCA is likely to be not as favorable as traditional mechanical recycling, but will likely be better than virgin PET and the process can be applied to a broader range of lower value wastes and thus promises to dramatically increase the overall recycling rate. In this chapter we will review the processes used in chemical recycling of PET, with the VolCat process from IBM as a detailed case study, followed by descriptions of the alternative technologies and emerging players in the field.

chemical recycling↗