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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Phase Selection During Solidification and Solid-State Phase Transformations in an Al-10Ce-8Mn (wt pct) Alloy

In multicomponent Al-Ce alloys, and especially after additive manufacturing (AM), complex and metastable solidification microstructures are frequently observed. Here, in this research, the relationship between solidification conditions and phase selection are explored for an Al-10Ce-8Mn (wt pct) alloy using a systematic study of laser melting conditions. Three solidification modes were observed: primary Al 10 Mn 2 Ce; primary Al 20 Mn 2 Ce; and eutectic FCC Al + Al 20 Mn 2 Ce. These solidification modes were correlated to specific liquid-solid interface velocities using a simple thermal model, showing the change in primary solidification phase for low (< 6.8 × 10 −4 m/s), moderate (between 8.2 × 10 −4 and 5.9 × 10 −2 m/s) and high solidification velocities (> 6.2 x 10 −2 m/s) for the above three solidification microstructures, respectively. These results were rationalized by using interface response function (IRF) theory to describe the solidification undercooling for the possible primary intermetallic phases. The implication of the local phase selection from differing solidification conditions is summarized by a comparison of hardness which demonstrates the potential variance of Vickers hardness from 101 to 242 (VHV) by changing the laser velocity from 1 to 83 mm/s. Interestingly, on heat treatment at 400°C, the decomposition pathways of the solidification microstructure and hardness were also found to be different, thereby opening multiple pathways for spatial microstructure and property control within AM components.

Sisco, Kevin↗
DOE OSTI2024

Effect of Si impurities on microstructure and tensile properties of a cast Al-Mg-Fe alloy

Al-Mg alloys are attractive for structural castings owing to their superior strength and ductility in the as-cast state. However, given the tight tolerance for impurities, Al-Mg alloys produced from secondary sources still face multiple challenges. Here, we report the effect of increased Si impurity (0.05–1.6 wt%), which is commonly found in secondary Al sources, on microstructure and tensile properties of a cast Al-4.3Mg-1.6Fe (wt%) alloy, commercially referred to as Castaduct-42 alloy. Microstructural characterization revealed that Si addition increased the volume fraction, size, and aspect ratio of primary Al13Fe4 intermetallic particles as well as the volume fraction of other binary and ternary eutectic phases. Tensile testing results demonstrated that increasing Si impurities from 0.05 to 1.6 wt% reduced ductility from 14.3 ± 1.4 % to 2.2 ± 1.0 %. A particle cracking damage accumulation model coupled with failure analysis indicated primary Al13Fe4 intermetallic particles to be the major contributing factor to the deterioration in ductility with increasing Si content. Additionally, the stabilizing effect of Si on primary Al 13 Fe 4 was inconsistent with the CALPHAD calculation results based on existing CALPHAD databases which predict a slightly decreasing primary Al13Fe4 phase fraction with increasing Si concentration. This work provides new insights into the phase stability and mechanical behavior of the lesser studied Al-Mg-Fe-Si alloy system that will contribute to the development of sustainable cast Al-Mg based alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Heat Loss Effects on Emissions in an NH 3 RRQL Combustor

Ammonia (NH 3 ) is a carbon-free energy carrier with an infrastructure for production, storage, and distribution. There is interest in direct NH 3 combustion, but managing pollutant emissions is a key challenge, particularly nitric oxides (NO x ) due to the fuel-bound nitrogen atom, nitrous oxide (N 2 O), which is a potent greenhouse gas, and unburned NH 3 , which is harmful to humans and the environment. Rich staged combustor concepts with extended primary residence times (τ res,primary ), like Rich-Relax- Quick-mix-Lean (RRQL), offer a viable pathway for direct NH 3 combustion with low levels of NO x formation. However, minimizing secondary emissions such as N 2 O and unburned NH 3 and hydrogen (H 2 ) remains a critical challenge. Prior atmospheric-pressure studies have demonstrated that RRQL operation with sufficiently long τ res,primary enables substantial NO x relaxation and promotes NH 3 cracking to H 2 , if heat losses from the relaxation stage are limited. However, the combined influence of elevated pressure and long residence time on RRQL performance has not been explored. The present work examines RRQL operation at pressures up to 5 bar and elevated τ res,primary . Exhaust measurements of NO x , NH 3 , and N 2 O are used to quantify the extent of NO x relaxation and NH 3 cracking under nonadiabatic conditions. To contextualize and quantify the effects of heat losses in the experimental data, chemical reactor networks (CRNs) incorporating prescribed heat loss rates are employed to assess the sensitivity of emissions to thermal losses in the relaxation stage. Collectively, the results demonstrate that management and quantification of heat losses are essential to preserve NO x relaxation and limit NH 3 and N 2 O emissions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

ALD with Alternative Coreactants: Which Work, Which Do Not, and Why

In this paper, we present a combined experimental and theoretical study that systematically evaluates a series of alcohols (i.e., primary, secondary, and tertiary) as coreactants for trimethylaluminum (TMA)-based atomic layer deposition (ALD) of Al 2 O 3 . We employed in situ quartz crystal microbalance techniques and ex situ X-ray photoelectron spectroscopy to probe growth across a range of temperatures from T = 120 to 285 °C. Dispersion-inclusive hybrid density functional theory was employed to identify potential reaction pathways and compute corresponding Gibbs free-energy barriers and rate coefficients. Experimentally on an Al 2 O 3 surface, sustained thin-film growth, where the rate is constant over many cycles, was only observed with tertiary alcohols (tert-butanol and 2-methyl-2-butanol) at elevated temperatures (e.g., T = 285 °C); for tert-butanol specifically, sustained growth also occurred at T = 240 °C, with no sustained growth at or below T = 210 °C. Growth using primary and secondary alcohols decayed to a negligible value after only 2–3 cycles on an Al 2 O 3 surface at all tested temperatures. Intentional trace additions of H 2 O to anhydrous alcohols restored sustained growth but at reduced deposition rates relative to pure H 2 O. Theoretical analysis supports a bimolecular alkoxy β-H elimination mechanism as the primary reaction pathway: initiated by the formation of a bound alkoxy species, the subsequent β-H elimination step is rate-determining, with a barrier that systematically decreases as the degree of the alcohol coreactant is increased from primary to secondary to tertiary. Computed rate coefficients (k) also indicate a strong temperature dependence (with k increasing by ∼4–5 orders of magnitude from T = 120 to 285 °C) and are consistent with the experimental observation that only tertiary alcohols lead to steady thin-film growth at elevated temperatures. This integrated approach establishes why only certain alcohols can sustain Al 2 O 3 ALD and delivers a predictive framework for identifying effective alcohol coreactants.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Violent mergers revisited: The origin of the fastest stars in the Galaxy

Binary systems of two carbon-oxygen white dwarfs are one of the most promising candidates for the progenitor systems of Type Ia supernovae. Violent mergers, where the primary white dwarf ignites when the secondary white dwarf smashes into it while being disrupted on its last orbit, were the first double degenerate merger scenario proposed that ignites dynamically. However, violent mergers likely contribute only a few percent to the total Type Ia supernova rate and do not yield normal Type Ia supernova light curves. Here we revisit the scenario, simulating a violent merger with better methods and, in particular, a more accurate treatment of the detonation. We find good agreement with previous simulations but with one critical difference: The secondary white dwarf being disrupted and accelerated towards the primary white dwarf and impacted by its explosion does not fully burn, and its core survives as a bound object. The explosion leaves behind a 0.16 M ⊙ star travelling 2800 km/s, making it an excellent (and so far the only) candidate to explain the origin of the fastest observed hypervelocity stars. We also show that before the explosion, 5 × 10 −3 M ⊙ of material predominantly consisting of helium, carbon, and oxygen had already been ejected at velocities above 1000 km/s. Finally, we argue that if a violent merger made the hypervelocity stars D6-1 and D6-3 and violent mergers require the most massive primary white dwarfs in binaries of two carbon-oxygen white dwarfs, there has to be a much larger population of white dwarf mergers with slightly lower mass primary white dwarfs. Because this population likely represents ≫10% of the Type Ia supernovae rate, it can essentially only give rise to normal Type Ia supernovae.

Astronomy and AstroPhysics↗
DOE OSTI2025

The scintillator surface detector of the Pierre Auger observatory

Data collected so far by the Pierre Auger Observatory have enabled major advances in ultra-high energy cosmic ray physics and demonstrated that improved determination of masses of primary cosmic-ray particles, preferably on an event-by-event basis, is necessary for understanding their origin and nature. Improvement in primary mass measurements was the main motivation for the upgrade of the Pierre Auger Observatory, called AugerPrime. As part of this upgrade, scintillator detectors are added to the existing water-Cherenkov surface detector stations. By making use of the differences in detector response to the electromagnetic particles and muons between scintillator and water-Cherenkov detectors, the electromagnetic and muonic components of cosmic-ray air showers can be disentangled. Since the muonic component is sensitive to the primary mass, such combination of detectors provides a powerful way to improve primary mass composition measurements over the original Auger surface detector design. In this paper, the so-called Scintillator Surface Detectors are discussed, including their design characteristics, production process, testing procedure and deployment in the field.

Detector design and construction technologies and ↗
DOE OSTI2025

Spatially structured bacterial interactions alter algal carbon flow to bacteria

Phytoplankton account for nearly half of global photosynthetic carbon fixation, and the fate of that carbon is regulated in large part by microbial food web processing. We currently lack a mechanistic understanding of how interactions among heterotrophic bacteria impact the fate of photosynthetically fixed carbon. Here, we used a set of bacterial isolates capable of growing on exudates from the diatom Phaeodactylum tricornutum to investigate how bacteria-bacteria interactions affect the balance between exudate remineralization and incorporation into biomass. With exometabolomics and genome-scale metabolic modeling, we estimated the degree of resource competition between bacterial pairs. In a sequential spent media experiment, we found that pairwise interactions were more beneficial than predicted based on resource competition alone, and 30% exhibited facilitative interactions. To link this to carbon fate, we used single-cell isotope tracing in a custom cultivation system to compare the impact of different "primary" bacterial strains in close proximity to live P. tricornutum on a distal "secondary" strain. We found that a primary strain with a high degree of competition decreased secondary strain carbon drawdown by 51% at the single-cell level, providing a quantitative metric for the "cost" of competition on algal carbon fate. Additionally, a primary strain classified as facilitative based on sequential interactions increased total algal-derived carbon assimilation by 7.6 times, integrated over all members, compared to the competitive primary strain. Our findings suggest that the degree of interaction between bacteria along a spectrum from competitive to facilitative is directly linked to algal carbon drawdown.

genome-scale metabolic model↗
DOE OSTI2026

Software Control Program For Transportable Microgrid State-of-charge Balancing And Frequency Stability Controls

A deterministic state-of-charge (SOC) balancing approach software control code is introduced as an integral secondary management to primary control layer of an islanded small microgrid or nanogrid system made up of multiple grid-forming inverter/battery/solar combination systems, where each set of batteries with each inverter are on independent DC buses (i.e. non-paralleled on the DC sides). A DERMS-level control approach, algorithm and automation controller program was developed to improve coordination and enable microgrid asset compliance and SOC balancing, enabling provision of a system-level power stability support architecture, load support, and asset scalability. The architecture is configured to treat each unit or micro/nano-grid as a node in a microgrid network, allowing for autonomous DERMS control regarding load and SOC balancing and power stability. As the network grows with the addition of units, greater coordination efforts may be required. The ideal small network microgrid ranges from 2-10 inverter/battery units before additional control parameters must be considered in the existing architecture. The control approach focuses on a deterministic state-of-charge analysis as the primary level control process followed by a secondary control loop using a forced frequency-watt droop strategy to conform off-the-shelf components into behaving under a leader-follower configuration. Adopting this control scheme has been shown to allow for a balanced, unit-coordinated microgrid network, enabling stable power flow. The deterministic state-of-charge approach is introduced as an integral primary control layer of an islanded small network microgrid. A standard strategy for SOC balancing is implementing a battery management system (BMS) to control SOC on the DC side. An alternative approach is to determine how to coordinate sending and receiving power on the AC side with multiple units. The latter approach assesses all the integrated units in the microgrid network. Once the individual units are identified, further system data is required to calculate each unit's total kWh, provided information about its capability to supply or consume kWh and availability. The secondary control layer in the multi-layered small network microgrid methodology uses the primary layer’s decision to initiate frequency setpoint changes, initializing the SOC balancing. The secondary control layer considers numerous system-dependent variables to enable a charging and discharging profile based on adjustable frequency setpoints. The combined architecture will result in stable, coordinated power flow enhancing an AC microgrid's functionalities.

Myers, KurtS [Idaho National Laboratory (INL), Ida↗
DOE OSTI2024

Prospects of hydrogen cogeneration and carbon dioxide utilization in electrochemical refineries for ethylene production via oxidative coupling of methane: A techno-economic assessment

Ethylene is recognized as one of the most significant chemicals globally. The projected ethylene production for 2023 stands at 227.6 million tonnes, with expectations of continued demand growth. The primary use of ethylene, accounting for over 76%, lies in the production of plastics such as polyethylene, polyvinyl chloride, and polystyrene. Despite the enduring carbon retention potential of plastics themselves, traditional ethylene feedstock production from fossil resources contributes substantially to greenhouse gas emissions, ranging from 0.29 to 2.29 kg CO2 /kg Ethylene depending on various factors like feedstock and process design. Various decarbonization strategies, including the utilization of hydrogen as a primary heat source, have been proposed to reduce the carbon footprint of ethylene production, but their efficacy remains limited, offering at best a 0–30% reduction in on-site CO 2 emissions.

09 BIOMASS FUELS↗
DOE OSTI2026

Dual-loop Solvent-based CCS for Net Negative CO 2 Emissions with Lower Cost

This final technical report details the successful design, construction, and operational validation of an innovative dual-loop CO 2 capture technology designed to achieve deep decarbonization (>99%) from Natural Gas Combined Cycle (NGCC) power plants that results in the electricity with carbon intensity of approximate 42 kg CO 2 -eq/MWh, less than the electricity produced by solar PV. The integrated process couples a primary aqueous solvent (in this project, a water lean solvent – WLS) absorption loop for bulk CO 2 removal with a secondary potassium hydroxide (KOH) polishing loop featuring electrochemical regeneration. This architecture leverages the higher exergy efficiency of the primary loop while utilizing the fastest kinetic of the secondary loop to capture dilute residual CO 2 , achieving an overall capture rate of 99.9% and co-producing pure hydrogen after moisture being condensed and dehydrated. Technical feasibility was established through a comprehensive 2,000-hour experimental campaign on a bench-scale fully-integrated unit (using 4” absorber and 4” stripper) with the feeding flue gas flowrate in the range of 8-20 cfm, confirming the attainment of Technology Readiness Level (TRL) 4. The project executed extensive parametric testing followed by 1,000 hours of continuous steady-state testing, demonstrating exceptional process stability with the electrochemical regenerator exhibiting less than a 10% reduction in electrical conductivity over the duration of the campaign. Operational characterization gathering on the bench unit revealed distinct energy profiles for the hybrid system: the primary loop required approximately 280 kJ mol -1 for bulk removal, while the polishing loop required approximately 1,600 kJ mol -1 specifically when reducing dilute CO 2 concentrations from ~740 ppm down to <50 ppm. (Please note those energy values/numbers can only be viewed as relative relationship and should not be extrapolated as absolute values required for CO 2 capture). Furthermore, dynamic testing validated the system’s flexibility for utility applications, demonstrating a rapid process response time of <30 minutes to changes in flue gas flowrate. Emission monitoring confirmed that the dual-loop architecture effectively mitigates solvent losses, utilizing a water wash to remove entrained aerosols to <1 ppm. The Techno-Economic Analysis (TEA) indicates a cost of capture of $\$$59.3/tonne and a Levelized Cost of Electricity (LCOE) of 71.7 $\$$/MWh at the overall capture efficiency of 99.8% of total carbon in the flue gas stream, with sensitivity analysis identifying an economic optimum when the primary loop captures 97% of the total CO 2 . A Life Cycle Assessment (LCA) confirms the technology’s potential for net-negative emissions, determining a Global Warming Potential (GWP) of 52 kg CO 2 -eq/MWh—significantly lower than the baseline—which further decreases to 42 kg CO 2 -eq/MWh when crediting the displacement of conventional hydrogen production.

03 NATURAL GAS↗
DOE OSTI2026

Qualitative Risk Assessment of Legacy Wells within the Estimated Prairie State Generating Company Area of Review

This report details the digitization of a legacy wellbore database, including data processing assumptions, parameter estimation, and risk assessment methodology. The database, comprising 6,454 documents, was provided by ISGS. It includes valuable data from the Prairie State Generating Company (PSGC) and One Earth Energy (OEE) sites of the CarbonSAFE Phase III – Illinois Storage Corridor project. The report focuses on wells within a 15-mile radius from the Lively Grove #1 (LG#1) well at PSGC site, evaluating subsurface conditions and potential risks. A total of 4,386 wellbores within 15 miles of the LG#1 well were filtered based on depth and formation codes. LG#1 is the stratigraphic well at the PSGC site drilled in 2021. Ninety-four (94) wells penetrating the Maquoketa Shale Group (the primary confining unit) within the estimated area-of-review (AoR) for the PSGC site were evaluated using a qualitative risk assessment (QRA) methodology. The QRA developed by Arbad et al. 2022 focuses on legacy wells within the AoR and categorizes them based on well construction details. The QRA identifies wells that need immediate attention by categorizing them based on penetration depth and protection. Wells within the AoR were categorized into nine groups based on penetrations and protections. These categories range from Type 1 wells, with no documentation, to Type 9 wells, which do not penetrate the primary confining unit or storage reservoir (unit). Well accessibility within the AoR varies based on well status, including Dry & Abandoned (DA), Plugged & Abandoned (PA), Injection (INJ), Oil/Gas Producing (PROD), and Observation (Obs) wells. Accessibility levels were determined by well construction, with DA wells being the least accessible and Observation wells the most accessible, impacting gas leakage detection possibilities. Remedial action priority of wells decreases from Type 1 to Type 9 wells. Type 1 to Type 6 wells with status DA and PA require immediate attention, while Type 7 and Type 8 wells are low priority. A risk matrix used to prioritize corrective actions for legacy wells is proposed to categorize wells within an AoR based on penetrations, protections, and accessibility. The methodology involves data acquisition, well categorization into nine types, and determining CO 2 leakage pathways using well schematics and geospatial mapping. This approach is particularly useful for managing the integrity of legacy wells throughout the lifecycle of a Carbon Capture and Storage (CCS) project. A qualitative risk assessment of 94 wells within the AoR of the PSGC site identified 54 wells with high priority for corrective action due to penetration of the primary containment seal. The assessment utilizes color-coded maps to categorize well types and prioritize corrective actions, providing a comprehensive analysis. Schematics of wells penetrating the primary confining unit were drawn, and leakage pathways were identified. Details of all wells penetrating the confining zone are provided in the appendix, including information on well types, plugging, and casing status.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Microchannel-based Membrane-less Extraction of Li from Unconventional Lithium Sources & the Separation of REE

This final report provides an overview of the Project's entire duration, covering July 1, 2021 to December 31, 2023. It primarily focuses on the achievements, technological developments, and unique challenges the team faced while working on separating and extracting Lithium from produced waters. The project's primary aim was to create an integrated, high-throughput, membrane-less, and modular microfluidic platform that could extract Lithium from unconventional sources. We have successfully met all goals and milestones envisioned in the SOPO document. The most critical primary milestones, including the Go-No-Go milestone (refer to the Gantt chart in the Appendices), were successfully accomplished. We demonstrated phase separation (>90%) and extraction (>85%) performance in the MPSE using synthetic, and representative produced water composition feed at 50 ml/min total flow through MPSE 36. We have also performed a parametric study of the MPSE operations, beyond the scope of SOPO, exploring operating conditions of current and broader interest. The extended investigation of operational parameters is concurrent with our efforts to seek further development of the MPSE technology beyond the scope of the Project. Along these lines of development, we have made efforts to be responsive to DOE calls for technological developments of other types of resources (beyond PW) for the recovery of Critical Materials and higher TRL development (beyond TRL 4). During the work on this Project, we developed and implemented three innovative technical approaches that emerged from our efforts to successfully meet the Project milestones. The innovative & original technical approaches developed and implemented in this Project are now the contributions to process engineering that could be clearly credited to the Project. First, Convergent Design Approach is a comprehensive feedforward & feedback loop of four design phases: i) design for functionality, ii) design for manufacturing, iii) design for sustainability, and iv) design for market. Next was Process Intensification. A major aim of this Project was to create an innovative phase separation & extraction microscale-based technology for Li separation – thus the words microchannel-based in the Project title. A microscale-based technology is intrinsically in the center of the Process Intensification domain as defined by its unique principles. Therefore, Process Intensification was implicitly envisioned in the Project’s SOPO. Lastly, Time Scale Analysis is a novel tool for discovering the needs and directions of Process Intensification implementations in any process technology. This Project is fully credited for developing and implementing the three novel technical approaches mentioned above. These are general contributions to process engineering that emerged from this Project. Beyond the original SOPO scope, the OSU-U.Pitt research group utilized a Convergent Design methodology, integrating first-principles mathematical modeling with experimental validation on the Minimum Development Vehicle. By creating these Digital Twins, the team rapidly assessed manufacturing iterations to support TEA analysis. This framework further enabled the development of advanced Surface Modification Techniques, where hydrophobic and oleophobic coating strategies were optimized via Digital Twin tools and validated through rigorous 100-hour longevity testing. TEA Analysis: The closing efforts of this Project were focused on the TEA analysis. TEA analysis had two primary functions: i) enabling critical assessments of design variations withing 10 the Concurrent Design Approach, thus enabling evolution of the MPSE design to reach faster- better-cheaper alternatives; and ii) to create a bridge between the accomplishments of this Project and future projects of higher TRL, beyond TRL 6 level. It is important to note that the TEA model created in the Project stirred the technological solutions for the recovery of critical materials toward a vision of a very profitable modular plant that has unique zero-waste water discharge signature. More importantly, thanks to our experimental performance data and conservative assumptions, the TEA model predicts minimal technological and investment risks. Low cost of a modular unit of a nominal capacity of [1000 tons of Li 2 CO 3 /year] positions the MPSE based technology within the reach of community investors, thus offering a paradigm shift in the development of critical technologies. The project successfully navigated two primary challenges: solvent selection and manufacturing adaptation. Restricted by the SOPO to existing literature for lithium recovery, the team identified a critical need for a "material excellence program" to develop next-generation solvents, eventually concluding with a preliminary investigation into promising Ionic Liquids (ILs). Simultaneously, COVID-19 supply chain disruptions forced a pivot from traditional manufacturing to advanced additive methods at ATAMI-OSU. By transitioning from stainless steel to 3D-printed polymer substrates, the team achieved a transformative three-order-of- magnitude reduction in manufacturing costs and compressed prototyping timelines from several months to just two days. The MPSE technology offers significant energy, environmental, and economic advantages by overcoming the traditional bottlenecks of phase-separation hardware and contactor size. Unlike conventional mixer-settlers or membrane-based systems, MPSE operates without moving parts or fouling-prone membranes, achieving robust performance even with challenging, viscous, or particulate-heavy feeds. Key performance metrics include an energy intensity reduction of 5–50x (3–40 kJ/m 3 ) compared to incumbent technologies and a dramatic reduction of processing time to under 60 seconds, which drastically reduces the physical plant footprint. These technical efficiencies translate into superior economic outcomes; for a 100 t/year Li 2 CO 3 facility, implementing MPSE is projected to nearly halve contactor CAPEX (from $\$$6.08M to $\$$3.01M) and significantly increase the project's Net Present Value (NPV), derisking new investment and enabling distributed critical-mineral processing configurations. The commercialization of MPSE technology is being spearheaded by Vigsur Dynamics Inc., which has adopted a structured, parallel approach to technical and business development since its formation in January 2026. Following extensive customer discovery and engagement with the Oregon State University accelerator, Vigsur Dynamics is working to establish a business model that transitions from pilot demonstrations to modular hardware sales, ultimately aiming for a "build-own-operate" service strategy. Current technical milestones—including 100 hours of continuous operation, superior energy efficiency, and successful 6-unit modular scale-up— provide a foundation for this transition. Backed by ongoing IP licensing and a growing network of industrial and venture advisors, the company is actively de-risking the platform to replace conventional mixer-settler systems in the critical minerals market.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Existing Hydropower Assets (EHA) Annual Gross Generation Plant Database, 2003-2024

Existing Hydropower Asset (EHA) Annual Gross Generation is a geospatial point-level dataset containing annual gross generation over time (2003-2024) and key characteristics of operational U.S. pumped storage and hybrid plants with 1 megawatt or greater of nameplate capacity. EIA 923 and EHA are the primary sources of the derived data. Hydropower units are excluded.

Johnson, Megan [ORNL] (ORCID:0000000290141741)↗
DOE OSTI2025

Existing Hydropower Assets (EHA) Annual Net Generation Plant Database, 2003-2024

Existing Hydropower Asset (EHA) Annual Net Generation is a geospatial point-level dataset containing annual net generation over time (2003-2024) and key characteristics of operational U.S. hydropower plants with 1 megawatt or greater of nameplate capacity. EIA 923 and EHA are the primary sources of the derived data. Pumped storage and hybrid plants are excluded.

Johnson, Megan [ORNL] (ORCID:0000000290141741)↗
DOE OSTI2026

Additively Reinforced Thermoformable PETG Composite Sheets for Improved Structural Efficiency

Thermoforming of short-fiber reinforced thermoplastic sheets offers a viable pathway for producing lightweight composite components; however, inherent anisotropy in fiber-reinforced sheets can limit structural performance under multidirectional loading. In this work, short carbon fiber, glass fiber, and hybrid fiber–reinforced PETG sheets were evaluated as candidate feedstock materials for thermoforming, with flexural and tensile testing performed both along the primary fiber direction and in the off-axis orientation to establish baseline stiffness, strength, and anisotropy. As expected, short carbon fiber PETG exhibited the highest stiffness and strength in the primary fiber direction, while all systems showed reduced performance in the off-axis direction. This off-axis performance reduction provides clear justification for the use of additive reinforcement when such thermoformed sheets are intended for structural applications. The intended manufacturing sequence involves thermoforming the reinforced sheet first, followed by the application of additively manufactured lattice reinforcement; therefore, the reinforcement strategy does not impose limitations on sheet formability during thermoforming. Post-forming lattice reinforcement significantly reduced load-normalized displacement by approximately 95–99% relative to non-reinforced sheets and improved weight-normalized stiffness by ~70%. These findings demonstrate that geometry-driven additive reinforcement can effectively compensate for off-axis property reductions in thermoformed PETG composites, enabling enhanced multidirectional structural performance without compromising manufacturability.

Talabi, Isaac [ORNL] (ORCID:0000000340215594)↗
DOE OSTI2024

EPCAPE-PT-LANL Measurements: Single Particle Soot Photometer

Coastal cities offer a unique environment for studying aerosol-cloud interactions and the effects of urban emissions on cloud properties. As part of the Eastern Pacific Cloud Aerosol Precipitation Experiment (EPCAPE), the Partitioning Thrust by Los Alamos National Laboratory (EPCAPE-PT-LANL) was conducted. Our campaign focused on measuring the optical and chemical properties of aerosols and their interactions within marine stratocumulus clouds in La Jolla, California. EPCAPE-PT-LANL enhances the primary goals of EPCAPE through innovative observations of vapor-phase transitions between aerosols and cloud droplets, the impact of black carbon on aerosol-cloud dynamics, and the effects of cloud processing on aerosol optical properties. Instrument: Single Particle Soot Photometer (Droplet Measurements Technology) Data Notes: Contact us if you want additional data products from this instrument. Reported data is the black carbon (rBC) number and mass concentration with diagnostic flags. The SP2 measures incandescence from particles that is induced with a 1064 Nd-YAG laser. Particles that absorb the laser energy and then emit radiation is assumed to contain black carbon. The amount of intensity of radiation is related to the mass of absorbing material in the particle. Here, we calibrate the incandescence intensity to size selected Regal Black (Cabot) nebulized from solution. Data provided for the EPCAPE campaign used the combined broadband high-gain + low-gain channels (BHBL). Each channel has a lower threshold of detection equivalent to 2-s of the respective channel noise. Thresholding has been applied to select between the high-gain and low-gain channels. The detection limit is 80-540 nm (Deq) or 0.36- 55 fg. It is assumed that rBC is the only aerosol type that is in significant concentration in the sampled atmosphere that absorbs the laser energy. Particle data are integrated over 10 second windows to calculate a rBC number and mass concentration. QC/QA: • Diagnostic flags that impacted measured concentration: - Sample, Sheath, and Purge Flow Rates: Despite observing fluctuations in all flows, the rBC detection and mass quantification are generally observed to be stable, although large changes in sample flow rate did impact detection efficiency. A flag was implemented for sample flow deviations >12 cm3/min from the set point averaged over 30 seconds - Laser Power: Detection efficiency decreases with laser power and deviations in laser power also affect mass quantification. Flag for laser power is set for deviations in laser current from the set value >5 mA. - Primary Detector Threshold: Primary thresholding is the signal value which determines whether a “particle” is recorded. Thresholding errors occur when the threshold value is too HIGH and real particles are ignored. • Several periods without data: - 16-18 Nov: Ultra Zero Air generator failure, flows deviated significantly from set points. rBC # conc recovered but questionable. - 20-21 Nov: Offline for calibrations for several hours each day. - 25-27 Nov: Data is missing. - 30 Nov: Power outage 3 Dec: SP2 hard-drive full. - 3 Dec: Power Outage Header: - BHBL_NumbConc[#/cc]: Refers to the number concentration of refractory black carbon (rBC) measured from combined broadband high-gain and low-gain channels, expressed in particles per cubic centimeter. - BHBL_BCMass_Conc[ug/m3]: Refers to the mass concentration of refractory black carbon (rBC) measured from combined broadband high-gain and low-gain channels, expressed in micrograms per cubic meter. - NoData_Flag[bool]: A boolean flag that indicates whether no data was recorded during a measurement. - NoBC_Flag[bool]: A boolean flag indicating whether no black carbon particles were recorded during the measurement. - Laser_Flag[bool]: A boolean flag indicating deviations in laser current during the measurement. - SampleFlow_Flag[bool]: A boolean flag indicating deviations from the set sample flow rate during the measurement. - PrimThresh_Flag[bool]: A boolean flag indicating deviations from the set primary threshold during the measurement, potentially ignoring real particles. - Manual_Flag[bool]: A boolean flag indicating manual intervention or adjustments during the measurement. - CVI_Flag[bool]: A boolean flag indicating whether the Counterflow Virtual Impactor (CVI) was active or inactive during the measurement.

54 ENVIRONMENTAL SCIENCES↗