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At least 1,405 records · Page 78

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

Additive Manufacturing↗

Comprehensive Digital Twin of a Macro-fluidic Electrochemical Reactor to Optimize the Electrochemical-based Recovery of O2 from Metabolic CO2

Future long-duration missions will require a sustainable and efficient system capable of yielding a minimum of 75% O 2 recovery from metabolic CO 2 to achieve self-sufficiency for long space missions beyond Earth's low orbit. A Macro-fluidic Electrochemical Reactor (MFECR) development effort to electrochemically recover O 2 from CO 2 is underway at NASA Marshall Space Flight Center (MSFC) to increase current O 2 recovery efficiency and reduce air revitalization (AR) system complexity at the International Space Station (ISS) habitat and future long missions. The authors have developed and deployed a digital twin of an actual single cell of the MFECR via a comprehensive 3D multiphysics model that thoroughly replicates the exact configuration and fluid/material domains of the MFECR. This model's electrochemical physics consists of multicomponent-multiphase electrochemical-driven reactions leading to CO 2 conversion to C 2 H 4 and CO along with the formation of H 2 on the cathode in parallel with the generation of O 2 and H 2 O on the anode. This electrochemical model is coupled with all the physics phenomena involved in the process, including but not limited to fluid and non-ideal mass transfer of reactant and product species in free and porous media, convective/conduction/radiative heat transfer, and conduction of DC electrical current with Joule heating generation. The digital twin has proved to be an essential tool for performing different qualitative studies, including the effect of reducing the height (increasing the respect ratio) of the serpentine walls, leading to a further redesign of the EDU (the newly redesigned MFECR EDU has been fabricated and is expected to be used in future tests), the evaluation of setting different MFECRs connected in series, and the assessment of feeding air directly to the MFECR skipping the preceding metabolic CO 2 separation from air. The MFECR's test stand is fully automated and equipped with several inline measurements (flow, pressure, temperature, pH, component concentration) systems on all six MFECR's IO streams, allowing reliable experimental validation of the model, parametric determination of all electrochemical reactions, and process optimization.

Jesus A Dominguez↗

A Dynamic Testing Approach for Particulate Erosion–Corrosion for Gas Turbine Coatings

Particle interactions in gas turbine engines can be multicomponent, complex phenomena leading to the degradation of thermal (TBCs) and environmental barrier coatings (EBCs) meant to protect engine components. Ingestion of particles into the engine can lead to recession of coatings due to particle erosion. Similarly, these same particles can become molten, adhere to coatings and result in thermochemical corrosion of coating materials. Particle erosion testing is often carried out where the particles are injected into a gas stream, accelerated within a nozzle, and impinge on sample. Conversely, most molten particle corrosion testing is often done in static laboratory furnaces, which does not capture the dynamic nature of deposition in application. Nevertheless, these damage mechanisms are often tested separately and no single standard exists to test both erosive and corrosive particle interactions with coating materials under relevant operating conditions for gas turbine engines. Understanding the synergies of particle interactions in engines is crucial in determining operating lifetimes of potential coating materials. Such considerations emphasize the need for realistic approaches in standardizing particle interaction testing in combustion environments. The current study outlines initial efforts at NASA Glenn’s Erosion Burner Rig Facility in improving dynamic erosion/corrosion testing methods by assessing the durability of state-of-the-art (SOA) TBC material 7 wt.% yttria stabilized zirconia (7YSZ) as a function of particle deposition rate, burner temperature, and particle size. Calibration data to determine particle deposition rate will be presented, and mass and optical profilometry measurements were utilized to estimate mass/volume loss versus deposition per increment of particulate used over time. Electron microscopy analyses were then carried out to assess coating damage after testing.

TBC↗

A Dynamic Testing Approach for Particulate Erosion–Corrosion for Gas Turbine Coatings

Particle interactions in gas turbine engines can be multicomponent, complex phenomena leading to the degradation of thermal (TBCs) and environmental barrier coatings (EBCs) meant to protect engine components. Ingestion of particles into the engine can lead to recession of coatings due to particle erosion. Similarly, these same particles can become molten, adhere to coatings and result in thermochemical corrosion of coating materials. Particle erosion testing is often carried out where the particles are injected into a gas stream, accelerated within a nozzle, and impinge on sample. Conversely, most molten particle corrosion testing is often done in static laboratory furnaces, which does not capture the dynamic nature of deposition in application. Nevertheless, these damage mechanisms are often tested separately and no single standard exists to test both erosive and corrosive particle interactions with coating materials under relevant operating conditions for gas turbine engines. Understanding the synergies of particle interactions in engines is crucial in determining operating lifetimes of potential coating materials. Such considerations emphasize the need for realistic approaches in standardizing particle interaction testing in combustion environments. The current study outlines initial efforts at NASA Glenn’s Erosion Burner Rig Facility in improving dynamic erosion/corrosion testing methods by assessing the durability of state-of-the-art (SOA) TBC material 7 wt.% yttria stabilized zirconia (7YSZ) as a function of particle deposition rate, burner temperature, and particle size. Calibration data to determine particle deposition rate will be presented, and mass and optical profilometry measurements were utilized to estimate mass/volume loss versus deposition per increment of particulate used over time. Electron microscopy analyses were then carried out to assess coating damage after testing.

TBC↗

Semi-Empirical Interatomic Potential for Large-Scale Molecular Dynamics Simulation of Metal-Oxide Systems

Classical molecular dynamics (MD) simulation can be applied to systems containing billions of atoms during times up to microseconds. However, utilization of a large-scale MD simulation requires reliable but computationally cheap interatomic potentials. In the case of metallic systems, embedded atom method (EAM) and Finnis-Sinclair (FS) potentials are the reasonable choices, but their development for multicomponent alloys is a challenge. Addition of oxygen atoms makes the problem of developing semi-empirical potentials even more difficult because the long-range Coulomb interaction cannot be neglected, and different atoms have different charges which vary during MD relaxation such that a charge equilibration procedure should be applied every MD step. As results researchers tend to avoid simulating metal-oxide systems. In this talk, a new Finnis-Sinclair (FS) Ni-Co-Cr potential will be presented. Special attention will be paid to reproducing of the element melting temperatures and clustering. Next, a charge transfer ionic potential (CTIP) developed to simulate the NiO properties will be presented. This potential utilizes the Ni FS potential and accounts for the Coulomb interaction in the vicinity of oxygen atoms. Fitting of the CTIP parameters and FS potential functions describing the interaction with oxygen atoms to the available experimental and ab initio data will be discussed. Results of MD simulation of interaction of NiO particles with dislocations in Ni will be shown.

molecular dynamics simulation↗

A Dynamic Testing Approach for Particulate Erosion–Corrosion for Gas Turbine Coatings

Particle interactions in gas turbine engines can be multicomponent, complex phenomena leading to the degradation of thermal (TBCs) and environmental barrier coatings (EBCs) meant to protect engine components. Ingestion of particles into the engine can lead to recession of coatings due to particle erosion. Similarly, these same particles can become molten, adhere to coatings and result in thermochemical corrosion of coating materials. Particle erosion testing is often carried out where the particles are injected into a gas stream, accelerated within a nozzle, and impinge on sample. Conversely, most molten particle corrosion testing is often done in static laboratory furnaces, which does not capture the dynamic nature of deposition in application. Nevertheless, these damage mechanisms are often tested separately and no single standard exists to test both erosive and corrosive particle interactions with coating materials under relevant operating conditions for gas turbine engines. Understanding the synergies of particle interactions in engines is crucial in determining operating lifetimes of potential coating materials. Such considerations emphasize the need for realistic approaches in standardizing particle interaction testing in combustion environments. The current study outlines initial efforts at NASA Glenn’s Erosion Burner Rig Facility in improving dynamic erosion/corrosion testing methods by assessing the durability of state-of-the-art (SOA) TBC material 7 wt.% yttria stabilized zirconia (7YSZ) as a function of particle deposition rate, burner temperature, and particle size. Calibration data to determine particle deposition rate will be presented, and mass and optical profilometry measurements were utilized to estimate mass/volume loss versus deposition per increment of particulate used over time. Electron microscopy analyses were then carried out to assess coating damage after testing.

burner rig↗

Development of a One-Domain Volume-Averaged Navier–Stokes Solver

The interaction between a high-enthalpy flow and a thermal protection material is inherently multiscale and multiphysics. In conventional aerothermal analyses, the external flow and material response are generally modeled using separate computational domains coupled through boundary conditions at the material surface. Although this approach has supported many practical applications, it requires assumptions about the location and behavior of the interface and may become difficult to apply when material decomposition, internal reactions, and surface recession substantially alter the porous structure. This report presents the development of a one-domain formulation in which the free-fluid and porous-material regions are represented within a single computational domain. The formulation is based on the volume-averaged Navier–Stokes (VANS) equations, derived from the governing equations for reacting, compressible flow and condensed material. Volume averaging transfers the influence of the unresolved material microstructure to the macroscale equations through effective transport properties, interfacial source terms, and dispersion fluxes. Particular attention is given to regions in which porosity and permeability vary rapidly, including the diffuse transition between a porous material and the surrounding fluid. The resulting equations are implemented in the Porous-material Analysis Toolbox based on OpenFOAM (PATO). The report describes the pressure–velocity coupling strategy used by the solver, examines spatial filtering techniques for deriving effective properties, and evaluates the influence of a smoothly varying interface permeability. Numerical demonstrations include canonical porous-flow configurations, a flow-tube configuration representative of FiberForm® permeability experiments, and the oxidation of a porous carbon material. The purpose of this work is to establish a mathematical and computational foundation for a unified treatment of flow and thermal protection material response. The present formulation is intended to support the progressive inclusion of additional physical processes, including multicomponent transport, finite-rate gas–surface chemistry, pyrolysis, internal oxidation, and material recession. It also provides a framework for connecting pore-scale simulations and microstructural characterization with macroscale aerothermal-response calculations. This report is intended for researchers and engineers working in computational fluid dynamics, porous-media transport, material response, and thermal protection system modeling. It documents both the theoretical development and the initial numerical assessment of the one-domain approach, while identifying the closure of effective and dispersion terms as an important subject for continued investigation.

Ablation↗

EMHOLE v. 2.1

Program EMHOLE is an electromagnetic (EM) forward modeling algorithm that calculates time-domain electric vector e (with SI unit V/m) and magnetic vector h (in A/m) responses generated by a variety of point body sources situated within a homogeneous and isotropic wholespace. A mathematically exact (i.e., without low-frequency or far-field approximation) numerical evaluation procedure is utilized to simulate EM responses (alternately, Green functions) observed at a set of multicomponent receivers distributed throughout the wholespace.

Aldridge, David F.↗

iGeoT v1.0

iGeoT v1.0 automates into a stand-alone computer program the multicomponent chemical geothermometry code GeoT v2.1 and the numerical optimization engine of iTOUGH2. iGeoT allows for optimizations of GeoT runs using multiple water chemical analyses. The underlying geothermometry method is that previously developed by Reed and Spycher (1984) using the computed saturation indices of multiple minerals. GeoT automatically reconstitutes deep fluid compositions and estimates reservoir temperature from statistical evaluation of computed mineral saturation indices. The output include estimated temperatures following various statistical methods and their range of uncertainty. The computer program also outputs temperatures predicted using classical geothermometers. Input parameters include water composition and, optionally, gas composition, fraction of gas discharge, dilution/evaporation factor (in case of boiling or mixing with dilute waters), and end-member water composition (in case of mixing with other non-dilute waters). The dilution/evaporation factor, fraction of gas discharge, and concentration of various aqueous and gas species can be automatically estimated by numerical optimization. This program was designed for geothermal applications.

Spycher, Nicolas↗

Idea Paper: The Lifecycle of Software for Scientific Simulations

The software lifecycle is a well researched topic that has produced many models to meet the needs of different types of software projects. However, one class of projects, software development for scientific computing, has received relatively little attention from lifecycle researchers. In particular, software for end-to-end computations for obtaining scientific results has received few lifecycle proposals and no formalization of a development model. An examination of development approaches employed by the teams implementing large multicomponent codes reveals a great deal of similarity in their strategies. This idea paper formalizes these related approaches into a lifecycle model for end-to-end scientific application software, featuring loose coupling between submodels for development of infrastructure and scientific capability. We also invite input from stakeholders to converge on a model that captures the complexity of this development processes and provides needed lifecycle guidance to the scientific software community.

Dubey, Anshu↗

eSTOMP-WR

The eSTOMP-WR mode is designed to efficiently simulate isothermal variably saturated flow (Richards Equation) and multicomponent reactions in porous media on the most powerful computers available.

Source record↗

Mixing effects on geothermometric calculations of the Newdale geothermal area in the Eastern Snake River Plain, Idaho

The Newdale geothermal area in Madison and Fremont Counties in Idaho is a known geothermal resource area whose thermal anomaly is expressed by high thermal gradients and numerous wells producing warm water (up to 51 °C). Geologically, the Newdale geothermal area is located within the Eastern Snake River Plain (ESRP) that has a time-transgressive history of sustained volcanic activities associated with the passage of Yellowstone Hotspot from the southwestern part of Idaho to its current position underneath Yellowstone National Park in Wyoming. Locally, the Newdale geothermal area is located within an area that was subjected to several overlapping and nested caldera complexes. The Tertiary caldera forming volcanic activities and associated rocks have been buried underneath Quaternary flood basalts and felsic volcanic rocks. Two southeast dipping young faults (Teton dam fault and an unnamed fault) in the area provide the structural control for this localized thermal anomaly zone. Geochemically, water samples from numerous wells in the area can be divided into two broad groups – Na-HCO3 and Ca-(Mg)-HCO3 type waters and are considered to be the product of water-rhyolite and water-basalt interactions, respectively. Each type of water can further be subdivided into two groups depending on their degree of mixing with other water types or interaction with other rocks. For example, some bivariate plots indicate that some Ca-(Mg)-HCO3 water samples have interacted only with basalts whereas some samples of this water type also show limited interaction with rhyolite or mixing with Na-HCO3 type water. Traditional geothermometers [e.g., silica variants, Na-K-Ca (Mg-corrected)] indicate lower temperatures for this area; however, a traditional silica-enthalpy mixing model results in higher reservoir temperatures. We applied a new multicomponent equilibrium geothermometry tool (e.g., Reservoir Temperature Estimator, RTEst) that is based on inverse geochemical modeling which explicitly accounts for boiling, mixing, and CO2 degassing. RTEst modeling results indicate that the well water samples are mixed with up to 75% of the near surface groundwater. Relatively, Ca-(Mg)-HCO3 type water samples are more diluted than the Na-HCO3 type water samples. However, both water types result in similar reservoir temperatures, up to 150 °C. Samples in the vicinity of faults produced higher reservoir temperatures than samples away from the faults. Although both the silica-enthalpy mixing and RTEst models indicated promising geothermal reservoir temperatures, evaluation of the subsurface permeability and extent of the thermal anomaly is needed to define the hydrothermal potential of the Newdale geothermal resource.

Eastern Snake River Plain, Newdale, RTEst, geother↗

Potential hydrothermal resource temperatures in the Eastern Snake River Plain, Idaho

The Eastern Snake River Plain (ESRP) in southern Idaho is a region of high heat flow. Sustained volcanic activities in the wake of the passage of the Yellowstone Hotspot have turned this region into an area with great potential for geothermal resources as evidenced by numerous hot springs scattered along the margins of the plain and several hot-water producing wells and hot springs within the plain. Despite these thermal expressions, it is hypothesized that the pervasive presence of an overlying groundwater aquifer in the region effectively masks thermal signatures of deep-seated geothermal resources. The dilution of deeper thermal water and re-equilibration at lower temperature are significant challenges for the evaluation of potential resource areas in the ESRP. Over the past several years, we collected approximately 100 water samples from springs/wells for chemical analysis as well as assembled existing water chemistry data from literature. We applied several geothermometric and geochemical modeling tools to these chemical compositions of ESRP water samples. Geothermometric calculations based on principles of multicomponent equilibrium geothermometry with inverse geochemical modeling capability (e.g., Reservoir Temperature Estimator, RTEst) have been useful for the evaluation of reservoir temperatures. RTEst geothermometric calculations of ESRP thermal water samples indicated numerous potential geothermal areas with elevated reservoir temperatures. Specifically, areas around southern/southwestern side of the Bennett Hills and within the Camas Prairies in the western-northwestern regions of the ESRP and its margins suggest temperatures in the range of 140-200°C. In the northeastern portions of the ESRP, Lidy Hot Springs, Ashton, Newdale, and areas east of Idaho Falls have expected reservoir temperature =140 °C. In the southern ERSP, areas near Buhl and Twin Falls are found to have elevated temperatures as high as 160 °C. These areas are likely to host potentially economic geothermal resources; however, further detailed study is warranted to each site to evaluate hydrothermal suitability for economic use.

Eastern Snake River Plain, ESRP, RTEst, geothermal↗

Geothermometric Temperature Comparison of Hot Springs and Wells in Southern Idaho

Conventional geothermal resource prospecting often begins with geochemical analysis of geothermal fluids sampled from surface expressions (hot springs and fumaroles). Similarly, water samples from hot wells located near the surface expressions are also routinely collected and analyzed as a part of regional exploration efforts. The chemical compositions of these water samples can be used to assess the likely reservoir temperatures of the geothermal sites as well as to understand other reservoir characteristics. In this paper, we present comparative results of geothermometric reservoir temperatures based on water compositions measured from pairs of hot springs and nearby wells of 10 potential geothermal sites in southern Idaho using both traditional and multicomponent equilibrium geothermometric approaches. Our results show that the reservoir temperatures estimated using water compositions measured surface thermal features and wells produce similar results. However, for two of the 10 sites, Durfee Hot Spring and Fairchild Hot Spring, the estimated reservoir temperatures based on water compositions measured from hot springs were significantly higher than the estimated reservoir temperatures using the well water sample. In the case of the Durfee system, the well water may have chemically re-equilibrated within the aquifer resulting in a lower estimated temperature than that calculated using the hot spring. Similarly, in the case of the Fairchild system, the hot spring and well water chemistry are chemically distinct and had the greatest distance between the hot spring and well pairs of the examined geothermal sites. The difference in fluid chemistry suggests that the Fairchild Hot Spring reservoir is compartmentalized and the two expressions are issuing waters migrated from two separate portions of the reservoir. Although the majority of the hot spring/well pairs in southern Idaho provided concordant reservoir temperatures, it is imperative to consider the consistency of the water types and distance between the sources when estimating reservoir temperatures.

15 GEOTHERMAL ENERGY↗

Corrosion Evaluation of CoCrFeMnNi High-Entropy Alloys (HEAs) for Corrosion Protection of Natural Gas Transmission Pipelines

High-entropy alloys (HEAs), are multicomponent alloys composed of at least five elements with compositions of 5-35 atomic % for each element. These alloys are being investigated for corrosion protection of natural gas transmission pipelines by studying their behavior under aqueous acidic conditions. Electrochemical and immersion experiments were carried out in 3.5 weight % NaCl solution at pH 4 and 40°C. Oxygen was purged out from the solution by using CO2 as stripping gas. The electrochemical experiments included potentiodynamic and electrochemical impedance spectroscopy tests, used to calculate corrosion rates. Potentiodynamic polarization curves, including cyclic voltammograms, were used to explain active, active-passive, and passive regions of these alloys and susceptibility to localized corrosion. Surface characterization of the corroded samples were performed using scanning electron microscopy (SEM) and x-ray diffraction (XRD). The results of the immersion and electrochemical testing indicate that some of the HEAs have better corrosion performance than commercial alloys UNS N10276, UNS K03014, and UNS 31600.

03 NATURAL GAS↗

Provisional Conceptual Model of the Camas Prairie (ID) Geothermal System from Play Fairway Analysis

Camas Prairie, Idaho, is an EW-trending structural graben that lies north of the Snake River Plain hotspot track. It is bounded on the north by the Idaho Batholith, and on the south by the Mount Bennett Hills. This region was investigated by the SRP Geothermal Play Fairway Analysis team, which included focused geologic, geochemical, and geophysical studies. The Camas Prairie geothermal system resource is indicated by warm springs and wells, geophysical analysis of buried faults and basins, mapped faults, structural analysis of all faults and lineaments, high 3He/4He, cation and multicomponent geothermometry, and the occurrence of young basalt vents and lava flows along the range front. Our provisional conceptual model includes the following components: (1) High permeability is indicated by the confluence of intersecting faults, including the major range front system and The Pothole fault system, with releasing bends as deduced from detailed field studies, and the presence of springs along mapped structural features; (2) High heat is inferred to result from mid- to shallow crustal sills, as evidenced by the location of vents along the range front; the youngest dated vent is 692 ka, but 2 ka vents lie to NW; (3) an effective seal is indicated by magnetotelluric studies, which suggest a clay seal over the prospective target area that is likely a result of hydrothermal alteration. This model is similar to that proposed for the western SRP but is less energetic due to the smaller volume of magma inferred. It is also similar to Basin-and-Range geothermal systems, but differs by including a distinct magmatic heat component.

15 GEOTHERMAL ENERGY↗

Experimental and modeling study of the autoignition behavior of a standard oxygenated gasoline fuel

Gasoline surrogate models can be conveniently used to simulate the combustion behavior of fuels in internal combustion engines. Because of limitations in the number of robust models available and the high computational cost of running them, simple surrogates with only 2 or 3 components (namely n-heptane, iso-octane and toluene) have been long preferred to simulate the ignition behavior of gasoline in engine calculations. More recently, thanks to the development of new, well-validated kinetic models and the access to cheap high-performance computing, the scientific and engineering community is utilizing the higher fidelity provided by more complex mixture models. The added detail in composition can in fact better reproduce variation in the fuel reactivity with pressure (an important feature for downsized, boosted conditions) and blending behavior of real fuels. In this study, the ignition behavior of a research grade full blend oxygenated fuel matching the typical specification of US standard grade gasoline has been investigated by means of rapid compression experiments and detailed kinetic calculations. A multicomponent fuel surrogate model has been developed using compositional information and a surrogate optimization tool. Based on the experimental and computational results presented in this study, general considerations about guidelines in the formulation of gasoline fuel surrogates are provided.

autoignition↗

Phase Formation in Nuclear Fallout

An understanding of the physical and chemical process occurring in a nuclear explosion enables predictions of the effects of nuclear weapons, including characteristics of radioactive fallout resulting from the explosion. Near-surface nuclear explosions are of particular interest due to the potential for significant amounts of environmental material to interact with and alter the physical and chemical behavior of the fireball. Such interactions have the potential to affect the distribution of radioactive species in the fireball and subsequently become incorporated into fallout through a process known as radiochemical fractionation. Studying variations in fallout formed in different historical testing environments allows us to understand the influence of local environments on fallout formation processes. In particular, constraining variations in thermal evolution and redox conditions during the evolution of the fireball can be useful to understanding how sensitive fallout radiochemical fractionation may be to the local explosion environment. However, untangling these conditions in complex, multicomponent fallout is a challenge. Here we present one method of constraining and interpreting fallout formation conditions by relating computationally derived phase stability predictions to observations in historic fallout. Development of such approaches will help improve physics-based models of fallout formation and radiochemical fractionation in complex, near surface nuclear detonations.

36 MATERIALS SCIENCE↗