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DOE OSTI2021

Joining Light Metals with Polymer Composites Through Metal Overcasting

This work investigates a unique technique to join aluminum (Al) and magnesium (Mg) alloys to carbon fiber reinforced polymer (CFRP) composites without the use of adhesives or mechanical fasteners. The joints were made using an overcasting technique where the molten alloys were cast around the polymer composites using high pressure die casting method. Rapid cooling during casting allowed the composite to be embedded inside the cast metal without causing any gross damage to the former even though the molten metal temperature exceeded the melting point of the composite matrix by several 100’s of deg. C. The metal/composite interface was examined using optical microscopy and x-ray imaging and the joint strength was examined through tensile testing. Although evidence of polymer melting was evident in the x-ray images, the embedded section of the composite coupons retained their overall shape and integrity. Preliminary tension tests on Al/CFRP composites showed strength degradation of the CFRP and it failed near the metal/CFRP interface (outside the joint). Strength degradation in the CFRP suggests that the overcasting process needs further optimization to minimize thermal excursion in the CFRP. Nevertheless, the overcasting process shows great promise as a unique joining technique with application in fabricating light-weight structures for automotive and transportation industries.

overcasting, Casting, Mg Castings, Al Casting, Joi↗

DOE OSTI2026

Review of SiC material development for nuclear fusion applications: Cross-cutting research and emerging opportunities

The SiC-based materials, particularly SiC-fiber-reinforced SiC matrix (SiC/SiC) composites, show strong potential for structural and functional applications in future fusion power plants because they can operate at high temperatures with a range of coolants and breeders, thereby enabling higher energy conversion efficiency. Here, this paper presents recent advancements in the development of SiC-based materials, focusing on processing techniques and material performance and resistance under fusion-relevant environments. The processing activities have emphasized near-net-shape fabrication and the joining of SiC subcomponents, with processing methods and material compositions informed by previous irradiation experiments on various grades of SiC. Research on irradiation effects has remained focused on degradation mechanisms and the microstructural optimization of SiC/SiC composites irradiated to high neutron damage levels. Analysis of irradiation defects in SiC has advanced via the application of cutting-edge characterization methods, among which Raman spectroscopy is becoming a common tool to assess atomic-scale chemical disorder. Fusion–fission crosscutting irradiation research has explored combined effects in SiC/SiC composites with application-relevant geometries, including bowing of SiC/SiC composite channels under neutron flux gradients, stress evolution in SiC/SiC composite tubes under through-thickness temperature gradients, and irradiation-enhanced corrosion in SiC. Finally, research opportunities for component testing and assessment under fusion-relevant conditions, in support of emerging concepts from the private fusion sector, are discussed.

Advanced manufacturing↗

DOE OSTI2024

Biopolymer-supramolecular polymer hybrids for photocatalytic hydrogen production

Solar generation of H 2 is a promising strategy for dense energy storage. Supramolecular polymers composed of chromophore amphiphile monomers containing perylene monoimide (PMI) have been reported as crystalline light-harvesting assemblies for aqueous H 2 -evolving catalysts. Gelation of these supramolecular polymers with multivalent ions creates hydrogels with high diffusivity but insufficient mechanical stability and catalyst retention for reusability. We report here on using sodium alginate (SA) biopolymer to both induce supramolecular polymerization of PMI and co-immobilize them with catalysts in a robust hydrogel with high diffusivity that can also be 3D-printed. Faster mass transfer was achieved by controlling the material macrostructure by reducing gel diameter and microstructure by reducing biopolymer loading. Optimized gels produce H 2 at rates rivaling solution-based PMI and generate H 2 for up to 6 days. The PMI assemblies in the SA matrix create a percolation network capable of bulk-electron transfer under illumination. These PMI–SA materials were then 3D-printed on conductive substrates to create 3D hydrogel photoelectrodes with optimized porosity. The design of these versatile hybrid materials was bioinspired by the soft matter environment of natural photosynthetic systems and opens the opportunity to carry out light-to-fuel conversion within soft matter with arbitrary shapes and particular local environments.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Retrieval of high time resolution growth factor probability density function from a humidity-controlled fast integrated mobility spectrometer

Hygroscopicity describes the tendency of aerosol particle to uptake water and is among the key parameters in determining the impact of atmospheric aerosols on global radiation and climate. A hygroscopicity tandem differential mobility analyzer (HTDMA) system is the most widely utilized instrument for determining the aerosol hygroscopic growth. Because of the time needed to scan the classifying voltage of the DMA, HTDMA measurement normally requires a minimum of 30 min to characterize the particle hygroscopic growth at a single relative humidity for five to six different sizes. This slow speed is often inadequate for measurements onboard mobile platforms or when aerosols evolve rapidly. Recently, a humidity-controlled fast integrated mobility spectrometer (HFIMS) was developed for measuring the hygroscopic growth of particles. The measurement speed of the HFIMS is about one order of magnitude faster than that of the conventional HTDMA. Here, a data inversion routine is developed to retrieve the growth factor probability density function (GF-PDF) of particles measured by the HFIMS. The inversion routine considers the transfer functions of the upstream DMA and the downstream water-based fast integrated mobility spectrometer (FIMS), and derives the GF-PDF that reproduces the measured responses of the HFIMS. The performance of the inversion routine is examined using ambient measurements with different assumptions for the spectral shape of the particle GF-PDF (multimodal lognormal or piecewise linear). The influences of the data inversion parameters and counting statistics on the inverted GF-PDFs were further investigated, and an approach to determine the optimized inversion parameters is presented.

47 OTHER INSTRUMENTATION↗

DOE OSTI2026

Strong-field QED limitations on TeV-class plasma wakefield accelerators

We demonstrate that quantum and classical radiation effects can become non-negligible for TeV-class beams propagating through plasma channels typical of staged plasma accelerators. Although the quantum nonlinearity parameter χ e remains small under currently envisioned experimental conditions, the cumulative influence of radiation over long acceleration distances can lead to significant modifications to the beam’s energy spread, emittance, and polarization. Our analytic models, validated by particle-in-cell simulations, highlight that for standard Gaussian beams, the orbit-induced energy spread dominates over quantum stochastic effects but can be mitigated by tailoring the beam profile, for example, through ring-shaped transverse distributions. In regimes where the radiation reaction approaches the accelerating force, the emittance may be cooled, forming distinctive ring-shaped phase-space structures. Finally, we analyze the influence of the radiation effect on spin transport inside the wakefield. These findings underscore the importance of considering both classical and quantum radiation dynamics in the design and optimization of future high-intensity plasma accelerators.

accelerator↗

DOE OSTI2019

Predicting the Longitudinally and Radially Varying Gut Microbiota Composition Using Multi-Scale Microbial Metabolic Modeling

Background: The gut microbiota is a heterogeneous group of microbes that is spatially distributed along various sections of the intestines and across the mucosa and lumen in each section. Understanding the dynamics between the spatially differential microbial populations and the driving forces for the observed spatial organization will provide valuable insights into important questions such as the nature of colonization of the infant gut and different types of inflammatory bowel disease localized in different regions of the intestines. However, in most studies, the microbiota is sampled only at a single site (often feces) or from a particular anatomical site of the intestines. Differential oxygen availability is putatively a key factor shaping the spatial organization. Results: To test this hypothesis, we constructed a community genome-scale metabolic model consisting of representative organisms for the major phyla present in the human gut microbiome. By solving step-wise optimization problems embedded in a dynamic framework to predict community metabolism and integrate the mucosally-adherent with the luminal microbiome between consecutive sections along the intestines, we were able to capture (i) the essential features of the spatially differential composition of obligate anaerobes vs. facultative anaerobes and aerobes determined experimentally, and (ii) the accumulation of microbial biomass in the lumen. Sensitivity analysis suggests that the spatial organization depends primarily on the oxygen-per-microbe availability in each region. Oxygen availability is reduced relative to the ~100-fold increase in mucosal microbial density along the intestines, causing the switch between aerobes and anaerobes. Conclusion: The proposed integrated dynamic framework is able to predict spatially differential gut microbiota composition using microbial genome-scale metabolic models and test hypotheses regarding the dynamics of the gut microbiota. It can potentially become a valuable tool for exploring therapeutic strategies for site-specific perturbation of the gut microbiota and the associated metabolic activities.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1981

Fundamental procedures of geographic information analysis

Analytical procedures common to most computer-oriented geographic information systems are composed of fundamental map processing operations. A conceptual framework for such procedures is developed and basic operations common to a broad range of applications are described. Among the major classes of primitive operations identified are those associated with: reclassifying map categories as a function of the initial classification, the shape, the position, or the size of the spatial configuration associated with each category; overlaying maps on a point-by-point, a category-wide, or a map-wide basis; measuring distance; establishing visual or optimal path connectivity; and characterizing cartographic neighborhoods based on the thematic or spatial attributes of the data values within each neighborhood. By organizing such operations in a coherent manner, the basis for a generalized cartographic modeling structure can be developed which accommodates a variety of needs in a common, flexible and intuitive manner. The use of each is limited only by the general thematic and spatial nature of the data to which it is applied.

Berry, J. K.↗

NASA NTRS1984

Study of high performance alloy electroforming

Using the two nickel-manganese alloy electroforming baths of near identical compositions, panels were electroformed under the same deposition parameters of current density, bath temperature, pH, and pulse plating conditions of duty cycle and frequency. By changing the electrolyte agitation conditions, significant effects on mechanical properties were noted. Since electrolyte agitation conditions on the typical flat panels studied to date will not be identical to those existing on a complex curved shape such as the SSME combustion chamber simulation, it is most important that these effects be evaluated prior to Phase B studies. The subscale chamber has been fabricated and shield support tooling is being made. Electroforming of optimized alloy test bars is being deferred until the electrolyte agitation effects are more fully appraised.

Malone, G. A.↗

NASA NTRS1986

Numerical study of combustion processes in afterburners

Mathematical models and numerical methods are presented for computer modeling of aeroengine afterburners. A computer code GEMCHIP is described briefly. The algorithms SIMPLER, for gas flow predictions, and DROPLET, for droplet flow calculations, are incorporated in this code. The block correction technique is adopted to facilitate convergence. The method of handling irregular shapes of combustors and flameholders is described. The predicted results for a low-bypass-ratio turbofan afterburner in the cases of gaseous combustion and multiphase spray combustion are provided and analyzed, and engineering guides for afterburner optimization are presented.

Zhou, Xiaoqing↗

NASA NTRS1990

Assignment Of Finite Elements To Parallel Processors

Elements assigned approximately optimally to subdomains. Mapping algorithm based on simulated-annealing concept used to minimize approximate time required to perform finite-element computation on hypercube computer or other network of parallel data processors. Mapping algorithm needed when shape of domain complicated or otherwise not obvious what allocation of elements to subdomains minimizes cost of computation.

Salama, Moktar A.↗

NASA NTRS2008

Electron Beam Freeform Fabrication: A Fabrication Process that Revolutionizes Aircraft Structural Designs and Spacecraft Supportability

The technological inception and challenges, as well as current applications of the electron beam freeform fabrication (EBF3) process are outlined. The process was motivated by the need for a new metals technology that would be cost-effective, enable the production of new alloys and that would could be used for efficient, lightweight structures. EBF3 is a rapid metal fabrication, layer-additive process that uses no molds or tools and which yields properties equivalent to wrought. The benefits of EBF3 include it near-net shape which minimizes scrap and reduces part count; efficiency in design which allows for lighter weight and enhanced performance; and, its "green" manufacturing process which yields minimal waste products. EBF3 also has a high tensile strength, while a structural test comparison found that EBF3 panels performed 5% lower than machined panels. Technical challenges in the EBF3 process include a need for process control monitoring and an improvement in localized heat response. Currently, the EBF3 process can be used to add details onto forgings and to construct and form complex shapes. However, it has potential uses in a variety of industries including aerospace, automotive, sporting goods and medical implant devices. The novel structural design capabilities of EBF3 have the ability to yield curved stiffeners which may be optimized for performance, low weight, low noise and damage tolerance applications. EBF3 has also demonstrated its usefulness in 0-gravity environments for supportability in space applications.

Taminger, Karen M.↗

NASA NTRS2020

Structural Model Tuning Tool: User's Reference Manual

This report presents an efficient approach for tuning finite element models to match the measured ground vibration test and static test data. Frequencies, mode shapes, total weight, location of the center of gravity, and static deformation computed from the finite element model are matched to the measured data. The model tuning procedure used in this work is based on solving an optimization problem in which the errors for the considered metrics, between the finite element prediction and the measured data, are minimized. Analytical sensitivity values of performance indices are computed using the NASTRAN-generated sensitivity values together with the in-house computer codes, which allow for faster computational time and the use of gradient-based optimizers. The method is applied to the Aerostructures Test Wing IV model. The study shows that the military standard and the National Aeronautics and Space Administration standard for comparing analytical and experimental modal data are all satisfied. The final finite element model correlates well with the test data. The flutter speed decreases by 8.91 percent after model tuning compared with the original Aerostructures Test Wing IV design.

Chan-gi Pak↗

DOE OSTI2025

Integrated operation scenarios: Chapter 6 of the special issue: on the path to tokamak burning plasma operation

Here we report the progress of the development and optimization of operational scenarios for ITER and beyond, focusing upon baseline, hybrid, and steady-state scenarios since 2007. This includes advancements made by the integrated operation scenarios (IOS) topical group of the international tokamak physical activity as well as contributions from the broader tokamak community. The key area of research involves developing IOSs that encompass tokamak physics, operation, and technology by utilizing integrated modeling and control strategies. This requires leveraging available actuators to simultaneously control plasma position and shape, MHD activities that could lead to disruptions, transport, plasma-wall interaction and power exhaust, fuel cycle, fusion burn, and tritium breeding. The control extends from the plasma initiation phase, through the current ramp-up, flattop, start and end of the fusion burn, and current ramp-down, to the plasma termination phase. A review of the currently developed scenarios and modeling is provided in terms of (i) optimizing plasma initiation in ITER, (ii) preparing for the low activation phase to fully commission all tokamak systems and establish and validate physics and scenario conditions in preparation for deuterim-tritium (DT) operation, (iii) developing and preparing baseline and hybrid scenarios to demonstrate the feasibility of achieving these regimes within device constraints, (iv) exploring steady-state scenarios to meet ITER’s steady-state goals, (v) evaluating and preparing actuators for ITER, (vi) developing integrated control solutions using shared actuators. The most notable achievements include; (i) the development of ITER demonstration discharges by matching various dimensionless parameters, (ii) the development of scenarios in an ITER-like tungsten environment and DT operation, and (iii) the development of scenarios in superconducting tokamaks, enabling long-pulse operations with similar coil constraints to ITER. Along with these significant achievements, outstanding issues and recommendations for further research and development are provided. Importantly, this study goes beyond simply updating the ITER Physics Basis; it carries profound implications for the broader field of burning plasma research, offering valuable insights and guidance for the next generation of fusion experiments and devices.

ITER↗

NASA NTRS2008

Object Recognition using Feature- and Color-Based Methods

An improved adaptive method of processing image data in an artificial neural network has been developed to enable automated, real-time recognition of possibly moving objects under changing (including suddenly changing) conditions of illumination and perspective. The method involves a combination of two prior object-recognition methods one based on adaptive detection of shape features and one based on adaptive color segmentation to enable recognition in situations in which either prior method by itself may be inadequate. The chosen prior feature-based method is known as adaptive principal-component analysis (APCA); the chosen prior color-based method is known as adaptive color segmentation (ACOSE). These methods are made to interact with each other in a closed-loop system to obtain an optimal solution of the object-recognition problem in a dynamic environment. One of the results of the interaction is to increase, beyond what would otherwise be possible, the accuracy of the determination of a region of interest (containing an object that one seeks to recognize) within an image. Another result is to provide a minimized adaptive step that can be used to update the results obtained by the two component methods when changes of color and apparent shape occur. The net effect is to enable the neural network to update its recognition output and improve its recognition capability via an adaptive learning sequence. In principle, the improved method could readily be implemented in integrated circuitry to make a compact, low-power, real-time object-recognition system. It has been proposed to demonstrate the feasibility of such a system by integrating a 256-by-256 active-pixel sensor with APCA, ACOSE, and neural processing circuitry on a single chip. It has been estimated that such a system on a chip would have a volume no larger than a few cubic centimeters, could operate at a rate as high as 1,000 frames per second, and would consume in the order of milliwatts of power.

Duong, Tuan↗

DOE OSTI2022

Uncovering translation roadblocks during the development of a synthetic tRNA

Ribosomes are remarkable in their malleability to accept diverse aminoacyl-tRNA substrates from both the same organism and other organisms or domains of life. This is a critical feature of the ribosome that allows the use of orthogonal translation systems for genetic code expansion. Optimization of these orthogonal translation systems generally involves focusing on the compatibility of the tRNA, aminoacyl-tRNA synthetase, and a non-canonical amino acid with each other. As we expand the diversity of tRNAs used to include non-canonical structures, the question arises as to the tRNA suitability on the ribosome. Specifically, we investigated the ribosomal translation of allo-tRNA UTu1 , a uniquely shaped (9/3) tRNA exploited for site-specific selenocysteine insertion, using single-molecule fluorescence. With this technique we identified ribosomal disassembly occurring from translocation of allo-tRNA UTu1 from the A to the P site. Using cryo-EM to capture the tRNA on the ribosome, we pinpointed a distinct tertiary interaction preventing fluid translocation. Through a single nucleotide mutation, we disrupted this tertiary interaction and relieved the translation roadblock. With the continued diversification of genetic code expansion, our work highlights a targeted approach to optimize translation by distinct tRNAs as they move through the ribosome.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2021

Impacts of turbine and plant upsizing on the levelized cost of energy for offshore wind

Turbine and plant upsizing are major trends in offshore wind deployment, although the quantitative impact on project costs has not been well-characterized. The uncertain value of continued wind turbine and project growth limits the ability of the supply chain to prepare for future technology trends, leading to challenges in the realization of larger projects. This analysis explores the levelized cost of energy impacts of turbine ratings between 6 and 20 MW and plant capacities between 250 and 2,500 MW for fixed-bottom offshore wind using techno-economic cost models for foundation, electrical, installation, and operation and maintenance costs, along with annual energy production. We consider a nominal set of technology assumptions for all scenarios to isolate economies of size and scale without additional benefits from decreasing turbine capital costs, quantity discounts for larger projects, or optimized technology solutions. These results indicate that using a 20-MW wind turbine in a 2,500-MW power plant array can reduce the levelized cost of energy by over 23% relative to the global average turbine and plant size installed in 2019; primarily because of reductions in the balance-of-system and operation and maintenance costs. We also identify improved installation vessels, optimized export systems, and novel operation and maintenance strategies as additional cost reduction opportunities. These results suggest that upsizing represents a significant cost reduction opportunity for offshore wind energy and will continue to be a main factor in shaping the future of the sector.

17 WIND ENERGY↗

DOE OSTI2025

In-Situ Atomic-Scale Revelation of Amorphous Metallic Iron Formation during Hydrogen-Driven Reduction of Iron Oxides

The transition to hydrogen as a green reductant in metal production is critical for decarbonizing the metallurgical industry, yet atomic-scale mechanisms governing reduction pathways and phase evolution remain unresolved. Using in-situ environmental transmission electron microscopy, we identify a hidden pathway that reveals dynamic formation of amorphous metallic iron (Fe) during the hydrogen-driven reduction of ferrous oxides of Fe 3 O 4 and FeO. Real-time imaging uncovers three coexisting transformation routes: (i) Fe 3 O 4 → FeO, (ii) Fe 3 O 4 → amorphous Fe, and (iii) FeO → amorphous Fe. The resulting amorphous Fe exhibits fluid-like mobility, enabling its rapid aggregation and crystallization into core-shell nanostructures, with a crystalline core enveloped by an amorphous shell. Complementary ab initio molecular dynamics simulations trace the amorphous Fe formation to interfacial strain at the metal/oxide interfaces, where large lattice mismatches destabilize the metal lattice during initial metallization. This interplay between thermodynamics and kinetics governs phase evolution: thermodynamics favors a self-limiting amorphous Fe overlayer, while rapid oxide reduction kinetics drives amorphous overgrowth. Our findings demonstrate that amorphous intermediates bypass rate-limiting crystalline steps, providing mechanistic insights to optimize H 2 -based processes for sustainable steelmaking. In conclusion, these insights bridge the gap between macroscopic process engineering and atomic-scale dynamics, with broader implications for catalysis and nanostructured material synthesis, where oxide reduction pathways critically shape functional phases and microstructures.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Multi-Electron Transfer at H-Terminated p-Si Electrolyte Interfaces: Large Photovoltages under Inversion Conditions

Here, photovoltages for hydrogen terminated p-Si(111) in an acetonitrile electrolyte were quantified with methyl viologen [1,1'-(CH 3 ) 2 -4,4'-bipyridinium](PF 6 ) 2 , abbreviated MV 2+ , and [Ru(bpy) 3 ](PF 6 ) 2 , where bpy is 2,2'-bipyridine, that respectively undergo two and three one-electron transfer reductions. The reduction potentials, E°, of the two MV 2+ reductions occurred at energies within the forbidden bandgap, while the three [Ru(bpy) 3 ] 2+ reductions occurred within the continuum of conduction band states. Bandgap illumination resulted in reduction that were more positive than that measured with a degenerately doped n + -Si demonstrative of a photovoltage, Vph, that increased in the order: MV 2+/+ (260 mV) < MV +/0 (400 mV) < Ru 2+/+ (530 mV) ~ Ru +/0 (540 mV) ~ Ru 0/– (550 mV). Pulsed 532 nm excitation generated electron-hole pairs whose dynamics were nearly constant under depletion conditions and increased markedly as the potential was raised or lowered. A long wavelength absorption feature assigned to conduction band electrons provided additional evidence for the presence of an inversion layer. Collectively, the data reveal that the most optimal photovoltage, as well at the longest electron-hole pair lifetime and the highest surface electron concentration, occur when E° lies energetically within the unfilled conduction band states where an inversion layer is present. The bell-shaped dependence for electron-hole pair recombination with the surface potential was predicted by the time-honored SRH model providing a clear indication that this interface provides access to all four bias conditions, i.e., accumulation, flat band, depletion, and inversion. The implications of these findings for photocatalysis applications and solar energy conversion are discussed.

14 SOLAR ENERGY↗